Gyratory crusher, control device thereof, and method of controlling gyratory crusher

Abstract

This gyratory crusher comprises: a setting sensor for detecting the setting of a gap between a mantle and a concave; a hydraulic circuit for generating cylinder hydraulic pressure for changing the setting in a hydraulic chamber that includes an accumulator; and a crushing load detector for detecting a crushing load. A control device of this gyratory crusher comprises: a load stabilization control unit for generating a setting target value for controlling the crushing load at a prescribed crushing load target value; a setting control unit that operates the hydraulic circuit and controls the setting at the setting target value; and a load abnormality sensing unit that determines a setting fluctuation index that indicates a degree of sudden increase in the setting, and senses an abnormal rise in the crushing load on the basis of the setting fluctuation index exceeding a prescribed setting threshold value.

Description

Title of Invention: GYRATORY CRUSHER, CONTROL DEVICE THEREOF, AND METHOD OF CONTROLLING GYRATORY CRUSHER Technical Field

[0001] The present disclosure relates to a gyratory crusher, a control device of the gyratory crusher, and a method of controlling the gyratory crusher. Background Art

[0002] Conventionally known are gyratory crushers configured such that: a crushing chamber is located between a conical tubular concave and a truncated conical mantle located inside the concave; and raw materials supplied from a raw material hopper to the crushing chamber are sandwiched between the concave and the mantle and are crushed. The mantle is driven by an electric motor so as to perform eccentric gyratory motion. A gap between a crushing surface of the concave and a crushing surface of the mantle periodically changes. The particle size of a crushed object is determined by a value of a set (i.e., an opening) of the gap. The gyratory crushers are classified into hydraulic gyratory crushers and mechanical gyratory crushers according to a method of changing the set. The hydraulic gyratory crusher includes a hydraulic cylinder that lifts or lowers the mantle relative to the concave that is positioned and fixed. The mechanical gyratory crusher includes an electric motor that lifts or lowers the concave relative to the mantle.

[0003] PTL 1 (Published Japanese Translation of PCT Application No. 2009-511254) discloses the hydraulic gyratory crusher. In this gyratory crusher, a main shaft coupled to the mantle is supported by a ram of the hydraulic cylinder. When the ram is lifted or lowered by hydraulic pressure, the set changes. When an overload occurs since, for example, uncrushable foreign matters have gotten into a crushing cavity between the concave and the mantle, or the amount of raw materials put into the crushing cavity has temporarily increased, the hydraulic cylinder and an accumulator are automatically connected to each other, and operating oil of the cylinder is discharged to the accumulator. Then, the mantle lowers, and this expands the set of the crushing cavity. Thus, the overload is reduced. 2023360381   13 Aug 2026

[0004] As above, when a crushing load suddenly changes, the accumulator automatically operates to keep pressure balance. Therefore, when an operator continues the operation of the crusher without recognizing the change in the crushing load, a poppet valve located at an inlet of the accumulator frequently and repeatedly opens and closes, i.e., a so-called tapping phenomenon occurs. The tapping phenomenon accelerates abrasion of the poppet valve, promotes the fatigue of a bag that repeatedly expands and contracts at the accumulator, and also promotes abrasion of machine parts of the crusher. When it is possible to detect a steep increase of the sudden crushing load, the continuation of the tapping phenomenon may be avoided by taking a measure to eliminate the overload in addition to the operation of the accumulator.

[0005] It is an object of the invention to address at least one shortcoming of the prior art and / or provide a useful alternative. Summary of Invention

[0006] In one aspect of the invention there is provided a control device of a gyratory crusher, the gyratory crusher including: a main shaft; a mantle fixed to the main shaft; a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle; a set sensor configured to detect a set between the mantle and the concave; a hydraulic cylinder supporting the main shaft; a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder, and the hydraulic circuit is configured to generate cylinder hydraulic pressure, which changes the set, in the hydraulic chamber; and a crushing load detector configured to detect a crushing load, the control device including: a load stabilization controller configured to generate a set target value by which the crushing load is controlled to become a predetermined crushing load target value; a set controller configured to operate the hydraulic circuit to control the set such that the set becomes the set target value; an overload detector configured to: calculate a set variation index indicating a degree of sudden increase of the set, and 2023360381   13 Aug 2026 detect an abnormal increase of the crushing load on the basis that the set variation index has exceeded a predetermined set threshold; and an overload elimination controller temporarily configured to generate the set target value instead of the load stabilization controller when the abnormal increase of the crushing load is detected. wherein: the overload elimination controller configured to set as the set target value a predetermined set reference value smaller than a detected set value detected by the set sensor; and until the set target value becomes the detected set value or more, the overload elimination controller is repeatedly and newly configured to generate the set target value by adding a predetermined set addition value to the set target value. [0006a] In another aspect of the invention, there is provided a control device of a gyratory crusher, the gyratory crusher including: a main shaft; a mantle fixed to the main shaft; a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle; a set sensor configured to detect a set between the mantle and the concave; a hydraulic cylinder supporting the main shaft; a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder, and the hydraulic circuit is configured to generate cylinder hydraulic pressure, which changes the set, in the hydraulic chamber; a crushing load detector configured to detect a crushing load, the control device including: a load stabilization controller configured to generate a set target value by which the crushing load is controlled to become a predetermined crushing load target value; a set controller configured to operate the hydraulic circuit to control the set such that the set becomes the set target value; an overload detector configured to: calculate a set variation index indicating a degree of sudden increase of the set, and detect an abnormal increase of the crushing load on the basis that the set variation index has exceeded a predetermined set threshold; and 2023360381   13 Aug 2026 an overload elimination controller temporarily configured to generate the set target value instead of the load stabilization controller when the abnormal increase of the crushing load is detected, wherein: the overload elimination controller is configured to set as the set target value a maximum value of a detected set value detected by the set sensor after the abnormal increase is detected; and then, until the set variation index becomes the set threshold or less, the overload elimination controller is repeatedly and newly configured to set as the set target value a larger one of the present set target value and the detected set value before a predetermined period of time. [0006b] In a further aspect of the invention there is provided a method of controlling a gyratory crusher, the gyratory crusher including: a main shaft; a mantle fixed to the main shaft; a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle; a set sensor configured to detect a set between the mantle and the concave; a hydraulic cylinder supporting the main shaft; a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder, and the hydraulic circuit is configured to generate cylinder hydraulic pressure, which changes the set, in the hydraulic chamber; and a crushing load detector configured to detect a crushing load, the method including: acquiring a detected value of the crushing load and generating a set target value by which the crushing load is controlled to become a predetermined crushing load target value; operating the hydraulic circuit to control the set such that the set becomes the set target value; acquiring a detected value of the set, calculating a set variation index indicating a degree of sudden increase of the set, and detecting an abnormal increase of the crushing load on the basis that the set variation index has exceeded a predetermined set threshold; and 2023360381   13 Aug 2026 .           when the abnormal increase of the crushing load is detected, setting as the set target value a predetermined set reference value smaller than the detected set value detected by the set sensor, and repeatedly and newly generating the set target value by adding a predetermined set addition value to the set target value until the set target value becomes the detected set value or more. [0006c] In still another aspect of the invention, there is provided a method of controlling a gyratory crusher, the gyratory crusher including: a main shaft; a mantle fixed to the main shaft; a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle; a set sensor configured to detect a set between the mantle and the concave; a hydraulic cylinder supporting the main shaft; a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder, and the hydraulic circuit is configured to generate cylinder hydraulic pressure, which changes the set, in the hydraulic chamber; and a crushing load detector configured to detect a crushing load, the method including: acquiring a detected value of the crushing load and generating a set target value by which the crushing load is controlled to become a predetermined crushing load target value; operating the hydraulic circuit to control the set such that the set becomes the set target value; acquiring a detected value of the set, calculating a set variation index indicating a degree of sudden increase of the set, and detecting an abnormal increase of the crushing load on the basis that the set variation index has exceeded a predetermined set threshold; and when the abnormal increase of the crushing load is detected, setting as the set target value a maximum value of the detected set value detected by the set sensor after the abnormal increase is detected, and then repeatedly and newly setting as the set target value a larger one of the present set target value and the detected set value before a predetermined period of time until the set variation index becomes the set threshold or less. 2023360381   13 Aug 2026

[0007] A control device of a gyratory crusher according to one aspect of the present disclosure is a control device of a gyratory crusher, the gyratory crusher including: a main shaft; a mantle fixed to the main shaft; a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle; a set sensor that detects a set between the mantle and the concave; a hydraulic cylinder supporting the main shaft; a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder and generates cylinder hydraulic pressure, which changes the set, in the hydraulic chamber; and a crushing load detector that detects a crushing load, the control device including: a load stabilization controller that generates a set target value by which the crushing load is controlled to become a predetermined crushing load target value; a set controller that operates the hydraulic circuit to control the set such that the set becomes the set target value; and an overload detector that calculates a set variation index indicating a degree of sudden increase of the set and detects an abnormal increase of the crushing load on the basis that the set variation index has exceeded a predetermined set threshold.

[0008] A gyratory crusher according to one aspect of the present disclosure includes: a main shaft; a mantle fixed to the main shaft; a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle; a set sensor that detects a set between the mantle and the concave; a hydraulic cylinder supporting a lower portion of the main shaft; a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder and generates cylinder hydraulic pressure, which changes the set, in the hydraulic chamber; a crushing load detector that detects a crushing load; and the control device.

[0009] A method of controlling a gyratory crusher according to one aspect of the present disclosure is a method of controlling a gyratory crusher, the gyratory crusher including: a main shaft; a mantle fixed to the main shaft; a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle; a set sensor that detects a set between the mantle and the concave; a hydraulic cylinder supporting the main shaft; a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder and generates cylinder hydraulic pressure, which changes the set, in the hydraulic chamber; and a crushing load detector that detects a crushing load, the method including: acquiring a detected value of the crushing load and generating a set target value by which the crushing load is controlled to become a predetermined crushing load target value; operating the hydraulic circuit to control the set such that the set becomes the set target value; and acquiring a detected value of the set, calculating a set variation index indicating a 2023360381   13 Aug 2026 degree of sudden increase of the set, and detecting an abnormal increase of the crushing load on the basis that the set variation index has exceeded a predetermined set threshold.

[0010] According to the present disclosure, the steep increase of the sudden crushing load in the hydraulic gyratory crusher can be detected without the addition of the new equipment. Brief Description of Drawings

[0011] FIG. 1 is a diagram showing the schematic configuration of a gyratory crusher according to one embodiment of the present disclosure. FIG. 2 is a block diagram showing the configuration of a control system of the crusher. FIG. 3 is a diagram for explaining functional components of a control device of the crusher. FIG. 4 is a diagram showing the configuration of a hydraulic system of a hydraulic cylinder. FIG. 5 is a timing chart of control of a crushing load. Description of Embodiments

[0012] Next, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a diagram showing the schematic configuration of a gyratory crusher 100 according to one embodiment of the present disclosure. The gyratory crusher 100 shown in FIG. 1 is a gyratory crusher or a cone crusher, and the configuration of the crusher 100 itself except for a control device 50 is publicly known.

[0013] The gyratory crusher 100 includes a shell 30, and the shell 30 includes a top shell 31 and a bottom shell 32 coupled to the top shell 31. A machine central axis line A extending in a vertical direction is defined at a middle portion of an internal space of the shell 30. A hopper 3 is continuously located at an upper portion of the shell 30. Raw materials that are objects to be crushed are supplied from a feeder 9 (conveyor, for example) to the hopper 3.

[0014] A main shaft 5 is located at a substantially middle portion of the shell 30. A central axis of the main shaft 5 is inclined relative to the machine central axis line A. An upper end of the main shaft 5 is supported by the top shell 31 through an upper bearing 17. The upper bearing 17 is located at a spider 18 projecting inward from an upper end portion of the top shell 31. A lower end of the main shaft 5 is supported by a ram 61 of a hydraulic cylinder 6 through a main shaft thrust bearing 2. The hydraulic cylinder 6 is a bearing cylinder including a cylinder tube 62 and the ram 61 that slides inside the cylinder tube 62.

[0015] A lower portion of the main shaft 5 is in an eccentric sleeve 4 such that the main shaft 5 is rotatable. The eccentric sleeve 4 is in a boss 7, located at the bottom shell 32, so as to be rotatable. A lower portion of the eccentric sleeve 4 is supported by the bottom shell 32 through a thrust sliding bearing 23.

[0016] A mantle core 12 is fixed to an upper portion of the main shaft 5. An outer surface of the mantle core 12 is a truncated conical surface. A mantle 13 is attached to the outer surface of the mantle core 12.  An outer surface of the mantle 13 is a truncated conical surface. The outer surface of the mantle 13 is opposed to an inner surface of a concave 14 located on an inner surface of the top shell 31. A crushing chamber 16 having a wedge-shaped vertical section is defined by the inner surface of the concave 14 and the outer surface of the mantle 13. The raw materials which have been supplied to the hopper 3 flow into the crushing chamber 16 by their own weight.

[0017] A collar 24 having a cylindrical shape is located at an upper side of the boss 7. A hydraulic chamber 27 is defined by the collar 24 so as to be located above the eccentric sleeve 4 and the boss 7 and under the mantle core 12. Lubricant is supplied from the hydraulic chamber 27 to between an outer peripheral surface of the main shaft 5 and an inner peripheral surface of the eccentric sleeve 4 and between an outer peripheral surface of the eccentric sleeve 4 and an inner peripheral surface of the boss 7. A journal sliding bearing located between the outer peripheral surface of the main shaft 5 and the inner peripheral surface of the eccentric sleeve 4 is referred to as an “eccentric bush 10,” and a journal sliding bearing located between the outer peripheral surface of the eccentric sleeve 4 and the inner peripheral surface of the boss 7 is referred to as a “bottom shell bush11.” Then, a multiple bearing including the eccentric bush 10 and the bottom shell bush 11 is referred to as a “lower bearing 15.”

[0018] A drive motor 8 is located outside the shell 30. Power is transmitted from an output shaft 8a of the drive motor 8 to the eccentric sleeve 4 through a power transmitting structure 20. The power transmitting structure 20 includes: a pulley 22a located at the output shaft 8a; a horizontal shaft 21; a pulley 22b located at the horizontal shaft 21: a power transmitting belt 22c wound around the pulleys 22a and 22b; a bevel pinion 19a located at the horizontal shaft 21; and a bevel gear 19b located at the eccentric sleeve 4. The horizontal shaft 21 is supported by the bottom shell 32 through a horizontal shaft bearing 25. When the eccentric sleeve 4 rotates, the main shaft 5 performs turning motion that is eccentric to the machine central axis line A, i.e., the main shaft 5 performs so-called precession. Thus, a distance between the outer surface of the mantle 13 and the inner surface of the concave 14 changes in accordance with a turning position of the main shaft 5. The raw materials which have fallen into the crushing chamber 16 are crushed between the concave 14 and the mantle 13 and are collected as crushed products from a lower side of the bottom shell 32.

[0019] Control Device 50 The crusher 100 configured as above includes the control device 50. The control device 50 does not necessarily have to be located close to the components of the crusher 100 except for the control device 50 and may be located away from the components of the crusher 100 except for the control device 50. For example, the control device 50 may be configured on a network server and control the components of the crusher 100 through a network.

[0020] FIG. 2 is a block diagram showing the configuration of a control system of the crusher 100. As shown in FIG. 2, a display 58, a setter 59, various instruments 52, 55, and 56, and control targets 8, 9a, and 90 are connected to the control device 50. The functionality of the control device 50 disclosed herein may be implemented using circuitry or processing circuitry which includes general purpose processors, special purpose processors, integrated circuits, ASICs (“Application Specific Integrated Circuits”), conventional circuitry and / or combinations thereof which are configured or programmed to perform the disclosed functionality. Processors are considered processing circuitry or circuitry as they include transistors and other circuitry therein. In the disclosure, the circuitry, units, or means are hardware that carry out the recited functionality. The hardware may be any hardware disclosed herein or otherwise known which is programmed or configured to carry out the recited functionality. When the hardware is a processor which may be considered a type of circuitry, the circuitry, means, or units are a combination of hardware and software, the software being used to configure the hardware and / or processor.

[0021] FIG. 3 is a diagram for explaining functional components of the control device 50. As shown in FIG. 3, the control device 50 includes functional components that are a feed controller 81, a rotation controller 82, a set controller 83, a load stabilization controller 84, an overload detector 85, and an overload elimination controller 86.

[0022] The feed controller 81 of the control device 50 controls the amount of raw materials supplied by the feeder 9. The control device 50 is connected to a drive motor 9a of the feeder 9 through wireless communication or wired communication. The control device 50 transmits a command signal corresponding to a target supply amount to the drive motor 9a of the feeder 9. When the drive motor 9a operates in response to the command signal from the control device 50, the target supply amount of raw materials is supplied from the feeder 9 to the hopper 3.

[0023] The rotation controller 82 of the control device 50 controls the rotational frequency of the eccentric sleeve 4. The rotational frequency of the eccentric sleeve 4 has a correspondence relationship with the rotational frequency of the horizontal shaft 21 rotated by the drive motor 8 and the rotational frequency of the main shaft 5. The control device 50 is connected to the drive motor 8 through wireless communication or wired communication. Moreover, a current sensor 56 that detects a driving current of the drive motor 8 is connected to the control device 50. The control device 50 transmits a command signal corresponding to a target rotational frequency to the drive motor 8. When the drive motor 8 operates in response to the command signal from the control device 50, the rotational frequency of the eccentric sleeve 4 becomes the target rotational frequency.

[0024] The set controller 83 of the control device 50 controls a “set” such that the set becomes a set target value. The set denotes the dimension of a crushing gap between a crushing surface of the concave 14 and a crushing surface of the mantle 13. The set in the present embodiment denotes the size of a gap at a position where the crushing gap is the narrowest, i.e., a CSS (Closed Side Setting). In the crusher 100 according to the present embodiment, the hydraulic cylinder 6 serves as a set adjuster. When the main shaft thrust bearing 2 is lifted or lowered together with the ram 61, the mantle 13 is lifted or lowered relative to the concave 14, and this changes the dimension of the set. The particle size of a crushed object is determined by the dimension of the set. The control device 50 is connected to a set sensor 52 through wireless communication or wired communication. The set sensor 52 detects the set. The set sensor 52 is, for example, a displacement sensor that detects the displacement of the ram 61.

[0025] FIG. 4 is a diagram showing the configuration of a hydraulic system of the hydraulic cylinder 6. As shown in FIG. 4, a hydraulic chamber 63 is located in the cylinder tube 62 of the hydraulic cylinder 6. The volume of the hydraulic chamber 63 is changed by the displacement of the ram 61. A hydraulic circuit 90 is connected to the hydraulic chamber 63. When operating oil of an oil tank 71 is supplied to the hydraulic chamber 63 through the hydraulic circuit 90, the ram 61 is lifted.  Moreover, when the operating oil of the hydraulic chamber 63 is discharged to the oil tank 71 through the hydraulic circuit 90, the ram 61 is lowered.

[0026] Although the configuration of the hydraulic circuit 90 is not limited, one example is as below.  The hydraulic circuit 90 includes: a communication pipe 91 communicating with a lower portion of the hydraulic chamber 63; an accumulator 92 connected to the communication pipe 91; an oil supply pipe 93 connected to the communication pipe 91; and an oil discharge pipe 94 connected to the oil supply pipe 93. A poppet valve 92a is located at a port of the accumulator 92. When the poppet valve 92a opens or closes, the inflow or outflow of the operating oil to or from the accumulator 92 is switched to be allowed or inhibited. A hydraulic sensor 55 is located at the communication pipe 91. The hydraulic sensor 55 detects the pressure of the operating oil of the hydraulic chamber 63. A gear pump 76 is located at the oil supply pipe 93. The gear pump 76 supplies by pressure the operating oil of the oil tank 71 to the hydraulic chamber 63. The gear pump 76 is driven by a pump motor 77. A normally closed on-off valve 98 is located at the oil supply pipe 93. A normally closed on-off valve 99 is located at the oil discharge pipe 94.

[0027] The load stabilization controller 84 of the control device 50 performs load stabilization control of stabilizing the crushing load such that the crushing load is maintained at a given crushing load target value. The load stabilization controller 84 acquires the crushing load detected by a crushing load detector. The crushing load denotes a load applied to a movable part of the crusher 100 by crushing. In the present embodiment, as an index indicating the crushing load, “cylinder hydraulic pressure” that is the pressure of the operating oil of the hydraulic cylinder 6 which is detected by the hydraulic sensor 55 or the “driving current” of the drive motor 8 which is detected by the current sensor 56 is used. When the cylinder hydraulic pressure is adopted as the index indicating the crushing load, the hydraulic sensor 55 serves as the crushing load detector, and the load stabilization controller 84 acquires the cylinder hydraulic pressure from the hydraulic sensor 55. Moreover, when the driving current of the drive motor 8 is adopted as the index indicating the crushing load, the current sensor 56 serves as the crushing load detector, and the load stabilization controller 84 acquires the current value from the current sensor 56.

[0028] The load stabilization controller 84 generates the set target value by which the crushing load is controlled to become a predetermined crushing load target value. Specifically, the load stabilization controller 84 generates a crushing load command value which changes the set such that: the set is expanded when the detected crushing load is higher than the crushing load target value; and the set is contracted when the detected crushing load is lower than the crushing load target value. The crushing load command value generated by the load stabilization controller 84 is limited so as not to steeply change the present crushing load. The set target value is adjusted step by step in order that the crushing load is controlled to become the predetermined crushing load target value. For example, until the crushing load becomes the crushing load target value, adding or subtracting a predetermined set adjustment amount to or from the present set target value to newly generate the set target value is repeatedly performed.

[0029] The set controller 83 makes the hydraulic circuit 90 of the hydraulic cylinder 6 operate to control the set such that the set becomes the set target value. The set controller 83 acquires an actual measurement value of the set (hereinafter referred to as a “detected set value”) which is detected by the set sensor 52, determines the operation amount of the ram 61 based on a difference between the detected set value and the set target value, and generates an operation command of the hydraulic circuit 90 based on the operation amount. More specifically, the set controller 83 generates operation commands with respect to control elements of the hydraulic circuit 90, such as the pump motor 77, the on-off valve 98, and the on-off valve 99. When the hydraulic circuit 90 operates in accordance with this operation command, the cylinder hydraulic pressure that displaces the ram 61 by the operation amount such that the set becomes the set target value is generated in the hydraulic chamber 63 of the hydraulic cylinder 6.

[0030] During the above load stabilization control, the crushing load may suddenly increase when uncrushable foreign matters are put into the crushing chamber 16, when a packing phenomenon occurs, or when a momentary overload occurs. Such steep increase of the sudden crushing load is referred to as an “abnormal increase of the crushing load” herein. The overload detector 85 detects the abnormal increase of the crushing load.

[0031] The overload detector 85 uses a “set variation index” to detect the abnormal increase of the crushing load. The set variation index is an index indicating the degree of increase of the set when the set suddenly increases. In the present embodiment, a difference d between the detected set value and a moving average value of the detected set value is used as the set variation index. The difference d indicates the degree of increase of the set. Moreover, whether or not the increase of the set is sudden can be estimated by using the difference d.

[0032] The overload detector 85 calculates the moving average value of the detected set value based on the detected set value acquired from the set sensor 52 and a predetermined moving average time. A moving average filter may be used to calculate the moving average value. The overload detector 85 calculates the difference d between the detected set value and the moving average value of the detected set value and monitors the difference d during the operation of the crusher 100. The overload detector 85 compares the difference d with a predetermined set threshold. When the difference d exceeds the set threshold, the overload detector 85 detects the abnormal increase of the crushing load. The set threshold and the moving average time are prestored in the control device 50, and the detected set value detected by the set sensor 52 is associated with a detection time and stored in the control device 50. The set threshold is set to a value larger than the difference d that changes when the set target value is changed by the set adjustment amount in the load stabilization control.

[0033] When the overload detector 85 detects the abnormal increase of the crushing load, the overload elimination controller 86 performs overload elimination control. The overload elimination controller 86 generates the set target value such that the tapping phenomenon that has occurred is eliminated, or the tapping phenomenon is prevented from occurring. During the overload elimination control, the set controller 83 controls the set based on the set target value generated by the overload elimination controller 86.

[0034] Method of Controlling Crusher 100 Herein, a method of controlling the crusher 100 by the control device 50 will be described, and the control of the crushing load will be mainly described. FIG. 5 is a timing chart of the control of the crushing load. In FIG. 5, (A) shows the detected set value detected by the set sensor 52, (B) shows the moving average value of the detected set value, (C) shows the difference d between the detected set value and the moving average value of the detected set value, (D) shows ON and OFF of the overload elimination control, and (E) shows the set target value.

[0035] As shown in the timing chart of FIG. 5, when the crushing load is steady, the overload elimination control is in an off state, and the crushing load is controlled by the load stabilization control performed by the load stabilization controller 84. When the crushing load is steady, nitrogen gas pressure of the accumulator 92 is higher than the cylinder hydraulic pressure of the hydraulic cylinder 6, and therefore, the operating oil does not flow into the accumulator 92. However, when the abnormal increase of the crushing load occurs as described above, the mantle 13 is pushed down, and the ram 61 of the hydraulic cylinder 6 which supports the main shaft 5 is pushed downward. As a result, the cylinder hydraulic pressure becomes higher than the nitrogen gas pressure, and thus, the operating oil flows into the accumulator 92 through the hydraulic circuit 90. The set is quickly expanded by such operation of the accumulator 92, and the discharge of the foreign matters in the crushing chamber 16 is promoted. The set starts increasing at a time point T1 in the timing chart since the accumulator 92 operates in accordance with the abnormal increase of the crushing load. The difference d starts increasing due to such sudden and steep increase of the set.

[0036] The overload detector 85 of the control device 50 monitors the difference d during the operation of the crusher 100. When the difference d exceeds the set threshold at a time point T2, the overload detector 85 detects the abnormal increase of the crushing load. When the set gently increases, the value of the difference d does not reach the set threshold.

[0037] When the abnormal increase of the crushing load is detected, the overload elimination control becomes an on state. The overload elimination controller 86 of the control device 50 starts the overload elimination control, and the load stabilization control performed by the load stabilization controller 84 is temporarily stopped.

[0038] When the overload elimination controller 86 starts the overload elimination control, first, the overload elimination controller 86 compares the set target value with a predetermined set reference value. When the present set target value is the set reference value or more, the overload elimination controller 86 performs first control of the overload elimination. When the present set target value is less than the set reference value, the overload elimination controller 86 performs second control of the overload elimination. The set reference value is prestored in the control device 50.

[0039] First Control of Overload Elimination The overload elimination controller 86 resets the set target value to the predetermined set reference value. The set reference value is prestored in the control device 50. Next, the overload elimination controller 86 adds a predetermined set addition value to the present set target value to newly generate the set target value. The set controller 83 controls the set by using the newly generated set target value. The set addition value is prestored in the control device 50. The set target value is adjusted step by step, and the set target value is repeatedly and newly generated until the set target value becomes the detected set value or less. The difference d gradually decreases by such overload elimination control. At a time point T3 at which the difference d becomes a predetermined threshold, an off-delay timer starts measuring time. At a time point T4 after a predetermined off-delay time has elapsed, the overload elimination control becomes the off state. Then, the load stabilization control performed by the load stabilization controller 84 is restarted.

[0040] The set addition value in the above overload elimination control is larger than the set adjustment amount in the load stabilization control. As a result, a change amount of the set target value per step in the overload elimination control is larger than that in the load stabilization control. Thus, the overload is quickly eliminated, and the operation can quickly return to a steady operation.

[0041] Second Control of Overload Elimination First, the overload elimination controller 86 sets a predetermined overload elimination target value to the set target value. The overload elimination target value is a maximum value of the detected set value after the occurrence of the tapping phenomenon by the overload. However, the overload elimination target value is not limited to this and may be a value prestored in the control device 50. Next, the overload elimination controller 86 compares the present set target value (i.e., the maximum value of the detected set value after the occurrence of the tapping phenomenon) with the detected set value before a predetermined period of time (for example, 0.5 second), and newly sets a larger one of them as the set target value. The difference d gradually decreases by such overload elimination control. The set target value is repeatedly and newly set until the difference d becomes the set threshold. At the time point T3 at which the difference d becomes the set threshold, the off-delay timer starts measuring time. At the time point T4 after the predetermined off-delay time has elapsed, the overload elimination control becomes the off state. Then, the load stabilization control performed by the load stabilization controller 84 is restarted.

[0042] According to the above overload elimination control (the first control and second control of the overload elimination), the overload is quickly eliminated. Therefore, the frequency of repetition of the operation and stop of the accumulator 92 is suppressed. Thus, the tapping phenomenon does not occur, or even when the tapping phenomenon occurs, the tapping phenomenon is quickly eliminated. Since the continuation of the tapping phenomenon is avoided as compared to conventional cases, the lives of hydraulic parts, such as the accumulator 92 and the poppet valve 92a, and the lives of machine parts of the power transmitting structure 20 can be extended.

[0043] In the above method of controlling the crusher 100, the overload detector 85 uses as the set variation index the difference d between the detected set value and the moving average value of the detected set value. However, the set variation index is not limited to this and may be an index indicating the degree of increase of the set when the set suddenly increases. For example, the set variation index may be the amount of increase per unit time of the difference between the set (i.e., the detected set value) detected by the set sensor 52 and the set target value. The amount of increase per unit time of the difference between the detected set value and the set target value indicates the degree of increase of the set. Moreover, by using the difference between the detected set value and the set target value, sudden separation of the set from the set target value can be estimated. Even when this set variation index is used, the load abnormality can be detected in the same manner as the above embodiment. To be specific, the overload detector 85 acquires the detected set value detected by the set sensor 52 during the operation of the crusher 100 and the set target value generated by the load stabilization controller 84 and calculates the amount of increase per unit time of the difference between the detected set value and the set target value. When this amount of increase exceeds the predetermined set threshold, the overload detector 85 detects the abnormal increase of the crushing load.

[0044] Moreover, in the above method of controlling the crusher 100, the overload detector 85 detects the abnormal increase of the crushing load based on the set variation index. However, the overload detector 85 may detect the abnormal increase of the crushing load based on the set variation index and the cylinder hydraulic pressure. In this case, during the operation of the crusher 100, the overload detector 85 detects the abnormal increase of the crushing load on the basis that: the set variation index calculated from the detected set value detected by the set sensor 52 has exceeded the set threshold; and the cylinder hydraulic pressure detected by the hydraulic sensor 55 has exceeded a predetermined hydraulic pressure threshold.

[0045] Conclusion The control device 50 of the gyratory crusher 100 according to a first aspect of the present disclosure is the control device 50 of the gyratory crusher 100, the gyratory crusher 100 including: the main shaft 5; the mantle 13 fixed to the main shaft 5; the concave 14 located so as to be opposed to the mantle 13, the crushing chamber 16 being located between the concave 14 and the mantle 13; the set sensor 52 that detects the set between the mantle 13 and the concave 14; the hydraulic cylinder 6 supporting the main shaft 5; the hydraulic circuit 90 that includes the accumulator 92 connected to the hydraulic chamber 63 of the hydraulic cylinder 6 and generates the cylinder hydraulic pressure, which changes the set, in the hydraulic chamber 63; and the crushing load detector 55, 56 that detects the crushing load, the control device 50 including: the load stabilization controller 84 that generates the set target value by which the crushing load is controlled to become the predetermined crushing load target value; the set controller 83 that operates the hydraulic circuit 90 to control the set such that the set becomes the set target value; and the overload detector 85 that calculates the set variation index indicating the degree of sudden increase of the set and detects the abnormal increase of the crushing load on the basis that the set variation index has exceeded the predetermined set threshold.

[0046] The control device 50 of the gyratory crusher 100 according to the first aspect can also be described as below. To be specific, the control device 50 includes a processor and a memory that stores a program executable by the processor and is accessible from the processor, and the processor which has executed the program (i) generates the set target value by which the crushing load is controlled to become the predetermined crushing load target value, (ii) operates the hydraulic circuit 90 to control the set such that the set becomes the set target value, and (iii) calculates the set variation index indicating the degree of sudden increase of the set and detects the abnormal increase of the crushing load on the basis that the set variation index has exceeded the predetermined set threshold.

[0047] The control device 50 of the gyratory crusher 100 according to a second aspect of the present disclosure is configured such that in the control device 50 of the gyratory crusher 100 according to the first aspect, the set variation index is the difference d between the detected set value detected by the set sensor 52 and the moving average value of the detected set value.

[0048] The control device 50 of the crusher 100 according to a third aspect of the present disclosure is configured such that in the control device 50 of the gyratory crusher 100 according to the first aspect, the set variation index is the amount of increase per unit time of the difference between the detected set value detected by the set sensor 52 and the set target value.

[0049] In the control device 50 according to the first to third aspects, the steep increase of the crushing load which is caused since, for example, foreign matters are put into the crushing chamber 16 can be detected by the set sensor 52 that is a sensor included in a conventional crusher. Then, since the steep increase of the crushing load can be detected as above, the overload can be quickly eliminated by a measure to eliminate the overload in addition to the operation of the accumulator 92. Thus, the tapping phenomenon may be avoided.

[0050] The control device 50 of the crusher 100 according to a fourth aspect of the present disclosure is configured such that in the control device 50 of the gyratory crusher 100 according to any one of the first to third aspects, the overload detector 85 detects the abnormal increase of the crushing load on the basis that the set variation index has exceeded the set threshold, and the cylinder hydraulic pressure has exceeded the predetermined hydraulic pressure threshold.

[0051] According to the control device 50 of the crusher 100 configured as above, in addition to the set variation index, the cylinder hydraulic pressure is also used as information for determination. Therefore, the steep increase of the crushing load can be more accurately detected.

[0052] The control device 50 of the crusher 100 according to a fifth aspect of the present disclosure is configured such that: the control device 50 of the gyratory crusher 100 according to any one of the first to fourth aspects further includes the overload elimination controller 86 that temporarily generates the set target value instead of the load stabilization controller 84 when the abnormal increase of the crushing load is detected; the overload elimination controller 86 sets as the set target value the predetermined set reference value smaller than the detected set value detected by the set sensor 52; and until the set target value becomes the detected set value or more, the overload elimination controller 86 repeatedly and newly generates the set target value by adding the predetermined set addition value to the set target value.

[0053] The control device 50 of the crusher 100 according to a sixth aspect of the present disclosure is configured such that: the control device 50 of the gyratory crusher 100 according to any one of the first to fourth aspects includes the overload elimination controller 86 that temporarily generates the set target value instead of the load stabilization controller 84 when the abnormal increase of the crushing load is detected; the overload elimination controller 86 sets as the set target value the maximum value of the detected set value detected by the set sensor 52 after the abnormal increase is detected; and then, until the set variation index becomes the set threshold or less, the overload elimination controller 86 repeatedly and newly sets as the set target value a larger one of the present set target value and the detected set value before a predetermined period of time.

[0054] In the control device 50 of the crusher 100 according to the fifth and sixth aspects, the control of stabilizing the crushing load is stopped once, and the processing of eliminating the overload is actively performed. Thus, the overload state can be quickly eliminated.

[0055] The control device 50 of the crusher 100 according to a seventh aspect of the present disclosure is configured such that: in the control device 50 of the gyratory crusher 100 according to the fifth or sixth aspect, after the overload elimination controller 86 generates the set target value, the set variation index becomes the set threshold or less; and after a predetermined off-delay time has elapsed, the load stabilization controller 84 generates the set target value instead of the overload elimination controller 86.

[0056] Thus, after the overload state is eliminated, the control of stabilizing the crushing load is automatically restarted.

[0057] The crusher 100 according to an eighth aspect of the present disclosure includes: the main shaft 5; the mantle 13 fixed to the main shaft 5; the concave 14 located so as to be opposed to the mantle 13, the crushing chamber 16 being located between the concave 14 and the mantle 13; the set sensor 52 that detects the set between the mantle 13 and the concave 14; the hydraulic cylinder 6 supporting the lower portion of the main shaft 5; the hydraulic circuit 90 that includes the accumulator 92 connected to the hydraulic chamber 63 of the hydraulic cylinder 6 and generates the cylinder hydraulic pressure, which changes the set, in the hydraulic chamber 63; the crushing load detector 55, 56 that detects the crushing load; and the control device 50 of the gyratory crusher 100 according to any one of the first to seventh aspects.

[0058] The method of controlling the crusher 100 according to a ninth aspect of the present disclosure is a method of controlling the gyratory crusher 100, the gyratory crusher 100 including: the main shaft 5; the mantle 13 fixed to the main shaft 5; the concave 14 located so as to be opposed to the mantle 13, the crushing chamber 16 being located between the concave 14 and the mantle 13; the set sensor 52 that detects the set between the mantle 13 and the concave 14; the hydraulic cylinder 6 supporting the main shaft 5; the hydraulic circuit 90 that includes the accumulator 92 connected to the hydraulic chamber 63 of the hydraulic cylinder 6 and generates the cylinder hydraulic pressure, which changes the set, in the hydraulic chamber 63; and the crushing load detector that detects the crushing load, the method including: acquiring the detected value of the crushing load and generating the set target value by which the crushing load is controlled to become the predetermined crushing load target value; operating the hydraulic circuit 90 to control the set such that the set becomes the set target value; and acquiring the detected value of the set, calculating the set variation index indicating the degree of sudden increase of the set, and detecting the abnormal increase of the crushing load on the basis that the set variation index has exceeded the predetermined set threshold.

[0059] According to the above method of controlling the crusher 100, the steep increase of the crushing load which is caused since, for example, foreign matters are put into the crushing chamber 16 can be detected by the set sensor 52 that is a sensor included in a conventional crusher. Then, since the steep increase of the crushing load can be detected as above, the overload can be quickly eliminated by a measure to eliminate the overload in addition to the operation of the accumulator 92. Thus, the tapping phenomenon may be avoided.

[0060] The foregoing discussion of the present disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the present disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the present disclosure are grouped together in one embodiment for the purpose of streamlining the disclosure. However, some of the features may be combined with each other. The features of the present disclosure may be combined in alternate embodiments, configurations, or aspects other than those discussed above.

Claims

1. A control device of a gyratory crusher,the gyratory crusher including:a main shaft;a mantle fixed to the main shaft;a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle;a set sensor configured to detect a set between the mantle and the concave;a hydraulic cylinder supporting the main shaft;a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder, and the hydraulic circuit is configured to generate cylinder hydraulic pressure, which changes the set, in the hydraulic chamber; anda crushing load detector configured to detect a crushing load,the control device including:a load stabilization controller configured to generate a set target value by which the crushing load is controlled to become a predetermined crushing load target value;a set controller configured to operate the hydraulic circuit to control the set such that the set becomes the set target value;an overload detector configured to:calculate a set variation index indicating a degree of sudden increase of the set, anddetect an abnormal increase of the crushing load on the basis that the set variation index has exceeded a predetermined set threshold; andan overload elimination controller temporarily configured to generate the set target value instead of the load stabilization controller when the abnormal increase of the crushing load is detected.wherein:the overload elimination controller is configured to set as the set target value a predetermined set reference value smaller than a detected set value detected by the set sensor; anduntil the set target value becomes the detected set value or more, the overload elimination controller is repeatedly and newly configured to generate the set target value by adding a predetermined set addition value to the set target value.2023360381   13 Aug 2026

2. The control device according to claim 1, wherein the set variation index is a difference between a detected set value detected by the set sensor and a moving average value of the detected set value.

3. The control device according to claim 1, wherein the set variation index is an amount of increase per unit time of a difference between a detected set value detected by the set sensor and the set target value.

4. The control device according to any one of claims 1 to 3, wherein the overload detector is configured to detect the abnormal increase of the crushing load on the basis that the set variation index has exceeded the set threshold, and the cylinder hydraulic pressure has exceeded a predetermined hydraulic pressure threshold.

5. A control device of a gyratory crusher, the gyratory crusher including:a main shaft;a mantle fixed to the main shaft;a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle;a set sensor configured to detect a set between the mantle and the concave;a hydraulic cylinder supporting the main shaft;a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder, and the hydraulic circuit is configured to generate cylinder hydraulic pressure, which changes the set, in the hydraulic chamber;2023360381   13 Aug 2026a crushing load detector configured to detect a crushing load, the control device including:a load stabilization controller configured to generate a set target value by which the crushing load is controlled to become a predetermined crushing load target value;a set controller configured to operate the hydraulic circuit to control the set such that the set becomes the set target value;an overload detector configured to:calculate a set variation index indicating a degree of sudden increase of the set, and detect an abnormal increase of the crushing load on the basis that the set variation index has exceeded a predetermined set threshold; andan overload elimination controller temporarily configured to generate the set target value instead of the load stabilization controller when the abnormal increase of the crushing load is detected,wherein:the overload elimination controller is configured to set as the set target value a maximum value of a detected set value detected by the set sensor after the abnormal increase is detected; andthen, until the set variation index becomes the set threshold or less, the overload elimination controller is repeatedly and newly configured to set as the set target value a larger one of the present set target value and the detected set value before a predetermined period of time.

6. The control device according to claim 1 or 5, wherein the load stabilization controller is configured to generate the set target value instead of the overload elimination controller after the overload elimination controller generates the set target value, the set variation index becomes the set threshold or less, and a predetermined off-delay time has elapsed.

7. A gyratory crusher including:a main shaft;a mantle fixed to the main shaft;a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle;a set sensor configured to detect a set between the mantle and the concave;2023360381   13 Aug 2026a hydraulic cylinder supporting a lower portion of the main shaft;a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder and the hydraulic cylinder is configured to generate cylinder hydraulic pressure, which changes the set, in the hydraulic chamber;a crushing load detector configured to detect a crushing load; andthe control device according to any one of claims 1 to 6.

8. A method of controlling a gyratory crusher,the gyratory crusher including:a main shaft;a mantle fixed to the main shaft;a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle;a set sensor configured to detect a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder, and the hydraulic circuit is configured to generate cylinder hydraulic pressure, which changes the set, in the hydraulic chamber; anda crushing load detector configured to detect a crushing load,the method including:acquiring a detected value of the crushing load and generating a set target value by which the crushing load is controlled to become a predetermined crushing load target value;operating the hydraulic circuit to control the set such that the set becomes the set target value;acquiring a detected value of the set, calculating a set variation index indicating a degree of sudden increase of the set, and detecting an abnormal increase of the crushing load on the basis that the set variation index has exceeded a predetermined set threshold; and.           when the abnormal increase of the crushing load is detected, setting as the set targetvalue a predetermined set reference value smaller than the detected set value detected by the set sensor, and repeatedly and newly generating the set target value by adding a predetermined set addition value to the set target value until the set target value becomes the detected set value ormore.2023360381   13 Aug 2026

9. A method of controlling a gyratory crusher,the gyratory crusher including:a main shaft;a mantle fixed to the main shaft;a concave located so as to be opposed to the mantle, a crushing chamber being located between the concave and the mantle;a set sensor configured to detect a set between the mantle and the concave;a hydraulic cylinder supporting the main shaft;a hydraulic circuit that includes an accumulator connected to a hydraulic chamber of the hydraulic cylinder, and the hydraulic circuit is configured to generate cylinder hydraulic pressure, which changes the set, in the hydraulic chamber; anda crushing load detector configured to detect a crushing load,the method including:acquiring a detected value of the crushing load and generating a set target value by which the crushing load is controlled to become a predetermined crushing load target value;operating the hydraulic circuit to control the set such that the set becomes the set target value;acquiring a detected value of the set, calculating a set variation index indicating a degree of sudden increase of the set, and detecting an abnormal increase of the crushing load on the basis that the set variation index has exceeded a predetermined set threshold; andwhen the abnormal increase of the crushing load is detected, setting as the set target value a maximum value of the detected set value detected by the set sensor after the abnormal increase is detected, and then repeatedly and newly setting as the set target value a larger one of the present set target value and the detected set value before a predetermined period of time until the set variation index becomes the set threshold or less.

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