BrainWave crushing
  • Automation products
  • Advanced process control
  • BrainWave crushing

BrainWave crushing

The solution for stabilizing and improving crushing operations

Control stabilization with BrainWave 

BrainWave is a patented advanced controller that outperforms traditional Proportional-Integral-Derivative (PID) control. BrainWave outperforms PID systems because of its two main components: an adaptive model and a predictive controller.

BrainWave builds its own live models during normal plant operations, a powerful feature not offered by traditional Model Predictive Control (MPC) systems.

BrainWave’s predictive controller accurately forecasts process responses and accounts for multiple objectives. It adapts to process conditions, such as changes in production rate, keeping the process on target. BrainWave can also accept measured disturbance inputs, like raw materials properties, and takes corrective action before the process is pushed off target (PID, by comparison, must wait for the error to occur, and then react).

BrainWave easily integrates with existing control systems and its patented Laguerre technology means an average implementation time of just a few weeks. Best of all, the plant’s own staff can support and deploy BrainWave.


Raw materials conveyor at a mine site in Peru

Control stabilization for crushing operations 

BrainWave crushing stabilizes the operation of primary, secondary, and tertiary crushers, resulting in improved crusher capacity. This unique control package, using patented model-based predictive adaptive control technology, is widely used by many primary processing industries.

BrainWave crushing is able to stabilize the level of ore in the crusher by using its patented integrating control algorithm to make direct adjustments to the ore feed rate. BrainWave crushing is also able to take into account the transportation time present in the crushing process due to the various feed and conveyor systems, and still maintain a stable level in the crusher.

Maintaining the crusher in a choked condition allows ore to be crushed more efficiently, since there will be more rock-on-rock crushing. This also results in less wear on the crusher itself.

Owing to this improved crushing performance, BrainWave crushing has the added benefits of increasing crusher capacity and stabilizing the production of fines.

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