System and method for monitoring the movement of a crusher head

Abstract

A system for monitoring at least one motion parameter of a main shaft of a gyratory or cone crusher. The system includes a sensor, such as a magnetometer, positioned adjacent to a magnetic element, such as a lifting lug, formed at the top end of the main shaft. When the main shaft rotates or moves vertically, this movement produces a change in magnetic flux, which is sensed by the magnetometer. The change in magnetic flux is sensed by the magnetometer and an output signal is generated. A controller receives the output signal and determines at least one motion parameter based on the detected change in magnetic flux. In one embodiment, a permanent magnet can be the magnetic element or can be inserted into the lifting lug to enhance the change in magnetic flux caused by the rotational or vertical movement of the main shaft.

Description

Technical Field

[0001] The present disclosure generally relates to a system and method for monitoring spindle rotation, also referred to as "head spin," and the vertical position of the spindle within a crusher. More specifically, the present disclosure relates to a method and system for monitoring head spin and the vertical position of the spindle to assess the operating health of the crusher while the crusher is idling and / or crushing material. Background Art

[0002] In a crusher, more specifically a primary gyratory crusher, the main shaft rotates when the crusher is idling and when the crusher is crushing incoming feed material. The main shaft / head rotation can be used to assess the operating health of the machine while the crusher is idling and / or crushing.

[0003] During idle, the typical observed head rotation is approximately 5 to 20 RPM, but this value can be affected by various factors. One major factor affecting head rotation is the fit between the spider bushing and the spindle's upper journal. If the spider bushing begins to lose its friction fit with the spindle's upper journal, the friction between these components decreases, and spindle / head rotation can increase above the observed "baseline."

[0004] If head rotation is monitored and compared to a baseline value measured during normal operation of the crusher under ideal conditions, it is possible to determine when the spider bushing is worn. Furthermore, by monitoring head rotation relative to the baseline value, other components that contribute to changes in head rotation, such as the dust seal and the fit between the lower spindle journal and the eccentric bushing, can be analyzed to determine wear. Furthermore, head rotation can also be potentially affected by the weight of the mantle. Since the weight of the mantle changes over time as it wears, small changes in head rotation can also indicate and potentially allow monitoring of the mantle's wear life. Summary of the Invention

[0005] By monitoring head rotation, the present disclosure will allow greater visibility into the operational health of the gyratory crusher, which will help prevent unplanned downtime and minimize production losses.

[0006] In addition to monitoring head rotation, the systems and methods of the present disclosure will allow for monitoring the vertical displacement of the main shaft relative to the crusher. By monitoring the vertical displacement of the main shaft, the present disclosure will allow for the detection of main shaft runout, which can negatively impact the overall operational health of the crusher. By monitoring vertical position, the present disclosure will allow for the potential elimination of existing sensors used to monitor main shaft position, which can be achieved by monitoring the MPS piston.

[0007] The disclosed method and system utilizes magnetic flux deviations caused by the moving crusher head to identify the rotation and position of the moving crusher head. A magnetic sensor, such as a magnetometer, is used to detect changes in magnetic flux. The data generated by the magnetic sensor can be interpreted by a controller to provide analysis of the spindle head's rotation and vertical displacement.

[0008] According to an exemplary embodiment of the present disclosure, a magnetic element is mounted to the top of a spindle that can be sensed by a magnetic sensor. In one exemplary embodiment, the magnetic element is a lifting lug located on the top of the spindle. The lifting lug is formed from a ferromagnetic metal material. The lifting lug is typically used to lift the spindle during assembly of the crusher. The lifting lug has a rectangular shape that is sufficient to interfere with the magnetic flux in a manner that enables a magnetometer to identify the rotation and position of the lifting lug and the associated spindle. In an exemplary embodiment of the present disclosure, the lifting lug is located within a spider bushing cavity during crusher operation. The spider bushing cavity is surrounded by metal so that the spider bushing cavity acts as a "Faraday cage" and prevents magnetic / electrical interference from affecting the magnetometer readings. Although the lifting lug is a type of magnetic element, ferromagnetic materials of varying masses can be attached to the top of the spindle. The mass of such material can also be sensed by the magnetometer in the same manner as the lifting lug.

[0009] In another contemplated exemplary embodiment of the present disclosure, if a stronger magnetic field is desired for improved sensing, the magnetic element may comprise a permanent magnet mounted on the top end of the spindle, either alone or in combination with a lifting lug. In embodiments where the magnetic element comprises both a lifting lug and a permanent magnet, the permanent magnet may fit into an existing hole formed in the lifting lug. Currently, when lifting the spindle, the hole in the lifting lug is utilized to mount a shackle. If a permanent magnet is used, the permanent magnet would be mounted within the lifting lug after the spindle is installed in the crusher.

[0010] The magnetometer used in this disclosure is capable of sensing changes in the magnetic field generated by a rotating spindle. The spindle's rotation causes a magnetic element to create a disturbance in the magnetic flux. This change in magnetic flux is converted into an output signal generated by the magnetometer. The output signal from the magnetometer can then be interpreted to provide an indication of spindle head rotation and / or vertical displacement of the spindle.

[0011] According to the present disclosure, magnetic flux caused by variations in the magnetic field is used to monitor the position and rotation of the crusher's "head." The disclosed method and system can be retrofitted to existing crushers and will withstand the harsh environments to which these crushers are subjected. The ability to monitor spindle / head rotation has been desirable for many years, and the present disclosure addresses this challenge in addition to allowing for monitoring spindle runout.

[0012] Various other features, objects and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The accompanying drawings illustrate the best mode presently contemplated for carrying out the present disclosure. In the drawings:

[0014] Figure 1 is a perspective assembly diagram of a gyratory crusher including a star-shaped bracket and a monitoring system of the present disclosure;

[0015] Figure 2 It is a partial cross-sectional view of the gyratory crusher;

[0016] Figure 3 is an enlarged view showing the crusher head monitoring system of the present disclosure;

[0017] Figure 4 is a cross-sectional view through the spider and illustrates the positions of the magnetic sensor and the permanent magnet;

[0018] Figure 5 is a perspective view showing magnetic flux lines generated by a permanent magnet;

[0019] Figure 6 is a schematic diagram showing the relationship between magnetic field and magnetic flux; and

[0020] Figure 7 is an electrical schematic diagram of the control system of the present disclosure. DETAILED DESCRIPTION

[0021] Figure 1 and Figure 2 A gyratory rock crusher 10 constructed in accordance with the present disclosure is generally shown. Figure 2 As shown, the gyratory rock crusher 10 includes a housing assembly 12 formed of an upper top housing 14 joined to a lower top housing 16. The top housings 14, 16 support a series of recesses 18 positioned along the interior surface of the housing assembly 12 to define a generally tapered frusto-conical interior surface 20 that guides material from an open top end 22 downwardly through a converging crushing cavity 24 formed between the interior surfaces 20 of the rows of recesses 18 and an exterior surface 26 of a frusto-conical shroud 28 positioned on a gyratory spindle 30. As the spindle 30 rotates, material is crushed across the height of the crushing cavity 24 between the interior and exterior surfaces 20, 26, with final crushing occurring within a crushing gap 32.

[0022] Best as Figure 2 and Figure 3 As shown, the upper end 34 of the spindle is supported within a spider bushing 36 contained within a central hub 38 of a spider 40. The spider 40 is mounted to an upper rim 41 of the upper top housing 14 and includes at least one pair of spider arms 42. Figure 4As shown, each spider arm 42 houses a spider arm shroud 44 that provides wear protection for the underlying spider arm 42. Each spider arm 42 includes a generally hollow, open cavity 46. The spider arms 42 support the central hub 38 so that the central hub 38 can provide rotational support for the upper end 34 of the rotating spindle 30.

[0023] Return to reference Figure 2 and Figure 4 , the center hub 38 includes a circular inner ridge 48 that helps support the spider cover 50. The spider cover 50 includes an outer wall 51 that is supported on a shoulder 53 of the center hub 38. The spider cover 50 provides additional wear protection and forms a spider cover cavity 52. Figure 3 In the illustrated embodiment, a metal cover plate 54 is attached to the inner spine 48 of the central hub 38. The cover plate 54 includes a cylindrical center portion 56 having a circular outer wall 58 extending upwardly from the cover plate 54. The outer wall 58 supports a top wall 60. The cover plate 54 is securely attached to the inner spine 48 such that the cover plate 54 forms an enclosed spider wheel bushing cavity 62.

[0024] like Figure 3 and Figure 4 As shown, the spider bushing 36 is secured to the central hub 38 by a series of connectors 64. The connectors 64 hold the spider bushing 36 securely in place while allowing the upper end 34 of the main shaft to move vertically and rotate within the fixed central hub 38.

[0025] like Figure 2 and Figure 3 As shown, the upper end 34 of the main shaft houses a lifting eye 66 mounted to a top portion 67. The lifting eye 66 and top portion 67 are attached to the upper end 34 of the main shaft and provide an attachment point for the main shaft so that the entire main shaft can be lifted using mechanical equipment such as an overhead crane. The lifting eye 66 is formed of a ferromagnetic metal material and includes a lifting hole 68 extending across the width of the lifting eye 66. The lifting hole 68 provides an attachment point for lifting the entire main shaft during assembly of the gyratory crusher.

[0026] like Figure 3 and 4 As shown, the ears 66 are generally aligned with the central portion 56 of the cover plate 54. In this manner, the ears 66 are completely contained within the spider bushing cavity 62 defined by the cover plate 54 and the sidewalls 70 of the upper portion of the central hub 38, which terminate at the inner ridge 48. Because both the central hub 38 and the cover plate 54 are made of ferromagnetic material, the spider bushing cavity 62 forms a "Faraday cage" around the ears 66.

[0027] Now refer to Figure 4According to the present disclosure, a gyratory crusher comprises a system for monitoring at least one motion parameter of the main shaft during operation. The monitoring system is capable of detecting the rotational motion of the main shaft (e.g. Figure 4 ) and the vertical movement of the spindle (also shown as arrow 72 in FIG. Figure 4 As shown by arrow 74 in FIG. Figure 3 As shown, the sensing system includes a magnetic sensor 76 positioned within the spider bushing cavity 62. The magnetic sensor 76 is supported by a mounting bracket 78, which is in turn mounted to the top end of the spider bushing 36 by a connector 80. A sensor cable 82 extends through the open cavity 46 of the spider arm 42 and extends beyond an outer rim 84. The cable 82 is connected to a controller 86, as shown. Figure 1 Controller 86 receives the output signal from magnetic sensor 76 and interprets the output signal from the magnetic sensor to monitor the rotational movement of the spindle and the vertical movement of the spindle in a manner that will be described in more detail below.

[0028] In a preferred embodiment of the present disclosure, the magnetic sensor 76 is a fixed magnetometer that is operable to detect changes in magnetic flux within the spider bushing cavity 62. A magnetometer is a special type of magnetic sensor that can measure the vector components of a magnetic field. The magnetometer generates an output signal based on the vector components of the magnetic field. If a magnetic member formed of ferromagnetic material moves into the magnetic field near the fixed magnetometer, the ferromagnetic material will interfere with the magnetic field and produce a change in the magnetic flux sensed by the magnetometer. The change in magnetic flux caused by the magnetic member can be interpreted to determine the direction of movement of the ferromagnetic member.

[0029] In the present disclosure, the magnetic component sensed by the magnetometer is the lug 66. The lug 66 is formed of a relatively large portion of ferromagnetic metal material. During rotation or beating of the spindle head, the lug 66 will rotate or move vertically within the spider bushing cavity 62. The movement of the lug 66 is sufficient to interfere with the magnetic flux, enabling the magnetometer to identify the rotational movement of the lug or the vertical movement of the lug. In an alternative embodiment where the spindle does not include the lug 66, another piece of ferromagnetic material can be mounted to the top of the spindle. This piece of material will also be sensed by the magnetometer. As previously mentioned, the spider bushing cavity 62 typically forms a "Faraday cage" that prevents magnetic / electrical interference from affecting the magnetometer readings. In this way, the magnetometer will only sense the movement of the lug.

[0030] Although the use of a magnetic sensor to sense the rotational and vertical movement of a lifting lug or similar magnetic member is one embodiment of the present disclosure, in another embodiment of the present disclosure, the magnetic member may be a permanent magnet 88 mounted to the top end of the spindle. The permanent magnet 88 may be mounted separately or may be mounted to the piece of ferromagnetic material. In the illustrated embodiment, the permanent magnet 88 is inserted into the lifting hole 68 formed in the lifting lug 66, as shown in FIG. Figure 5 Best shown. Figure 5 In the illustrated embodiment, the permanent magnet 88 has a cylindrical shape and extends from a first end 90 to a second end 92. As is known, the permanent magnet 88 generates a magnetic field 94 that extends between the first end 90 and the second end 92. If the permanent magnet 88 is used, it is installed after the main shaft 30 has been installed in the crusher, and the lifting lug 66 is no longer needed during operation. If the lifting lug 66 needs to be replaced or repaired, the permanent magnet 88 can be removed later.

[0031] like Figure 5 As can be understood, the magnetic field 94 generated by using the permanent magnet 88 as the magnetic element enhances the magnetic field within the spider bushing cavity 62, as shown in FIG. Figure 4 As clearly shown in Figure 4 As shown, the magnetic sensor 76 is positioned in close proximity to the permanent magnet 88 so that the magnetic field 94 can be easily sensed by the magnetic sensor 76. If the spindle begins to rotate (as shown by arrow 72) or move vertically (as shown by arrow 74), the change in the magnetic field caused by the movement of the permanent magnet 88 will be sensed by the magnetic sensor 76. The change in magnetic flux is sensed by the magnetic sensor 76, and an output signal is forwarded to the controller 86 so that the controller 86 can provide an indication to the user / operator that vertical movement of the spindle has been detected or that rotational movement of the spindle has been detected.

[0032] Figure 6 is a diagram illustrating the relationship between the magnetic field 94 generated by the permanent magnet and the magnetic flux. The relationship between the changing magnetic flux generated by the changing magnetic field is sensed by the magnetic sensor 76 and used by the controller to determine whether the spindle is moving vertically or rotating. Although the permanent magnet 88 is shown in the embodiment of the accompanying drawings, the permanent magnet 88 can be eliminated, and the interference with the magnetic flux sensed by the magnetic sensor 76 will be caused solely by the ferromagnetic material of the lug 66. This interference can be sensed by the magnetic sensor and analyzed by the controller. However, the use of the permanent magnet 88 is believed to produce a stronger magnetic field, which will make it easier to identify smaller changes in the magnetic flux.

[0033] Figure 7A schematic diagram of a sensing system 95 of the present disclosure is provided. The sensing system 95 includes a controller 86 in communication with a magnetic sensor 76. The magnetic sensor 76 is positioned in close association with a magnetic element such as a lifting lug 66, which may or may not include a permanent magnet. As previously described, the lifting lug 66 is both vertically movable and rotatable depending on the operation of the gyratory crusher and associated spindle. The magnetic sensor 76 senses changes in magnetic flux caused by vertical or rotational movement of the spindle. The magnetic sensor 76 operates to generate an electrical signal representative of the movement and changes in the magnetic flux. The electrical signal generated by the magnetic sensor 76 is forwarded to the controller 86. The controller 86 is, in turn, programmed to interpret the changing electrical output signal from the magnetic sensor 76 and generate an output signal providing information regarding the rotational movement of the spindle or the vertical movement of the spindle. In Figure 7 In the illustrated embodiment, the controller 86 is connected to a visual display 96 so that sensed information can be relayed to the operator / user. Although a display 96 is shown, it should be understood that the controller 86 can relay information to the operator / user in other ways, such as through visual indicators, audible indicators, or any other means acceptable to the operator of the gyratory crusher.

[0034] exist Figure 7 In the illustrated embodiment, a user input 98 is also connected to the controller 86 so that an operator / user can input operating parameters and control values ​​into the controller 86. The user input 98 can be any type of conventional user input, such as a keyboard, a touch screen, or any other type of input device that allows a user to input information into the controller. The controller 86 is also connected to a power source 100, which provides power not only to the controller 86 but also to the magnetic sensor 76. Depending on the location and configuration of the controller 86, the power source 100 can be a battery power source or a mains power source.

[0035] It is envisioned that an electrical signal from the magnetic sensor 76 will be provided to a controller 86 and that the controller 86 can monitor changes in the electrical signal from the magnetic sensor. Changes in the magnetic sensor electrical output signal provided to the controller will indicate changes in the magnetic flux caused by the rotational movement of the lifting lug 66 or the vertical movement of the lifting lug. Based on this information, the controller 86 will be able to determine whether the main shaft is moving vertically or rotating. It is envisioned that the magnetic sensor 76 will be arranged to be able to operate as long as the crusher is powered. Therefore, during normal operation, the magnetic sensor 76 will be able to monitor the movement of the main shaft within the gyratory crusher. It is envisioned that the sensor 76 can be turned off depending on the specific requirements and circumstances of the operation of the gyratory crusher. However, the use of the magnetic sensor 76 will provide additional information about the operating status and health of the gyratory crusher.

[0036] This specification uses examples to disclose the invention, including the best mode, and also to enable those skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. If such other examples have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims, they are intended to be within the scope of the claims.

Claims

1. A system for monitoring at least one motion parameter of a main shaft in a gyratory or cone crusher, the gyratory or cone crusher including a crushing chamber in which material is crushed as the main shaft rotates, the system comprising: a star-shaped support bushing cavity defined by the sidewalls and cover plate of the gyratory or cone crusher, wherein the star-shaped support bushing cavity forms a Faraday cage; a magnetic element mounted on the top end of the spindle and located in the cavity of the star-shaped bracket bushing, wherein the magnetic element is a lug formed of a ferromagnetic material capable of influencing a magnetic field; a magnetic sensor positioned within the spider bushing cavity adjacent the magnetic element and operable to detect changes in magnetic flux caused by movement of the magnetic element relative to the magnetic sensor; and A controller is coupled to the magnetic sensor to determine the at least one motion parameter based on the detected changes in magnetic flux.

2. The system according to claim 1, wherein: The magnetic element includes a permanent magnet mounted to a top end of the spindle.

3. The system according to claim 1, wherein: The magnetic element includes a permanent magnet fixed to the lifting lug.

4. The system according to claim 1, wherein: The at least one motion parameter is a head rotation of the spindle.

5. The system according to claim 1, wherein The at least one motion parameter is the vertical displacement of the main axis.

6. The system according to claim 1, wherein: The controller is operable to determine a head rotation of the spindle and a vertical displacement of the spindle.

7. A gyratory or cone crusher comprising: spindle; A crushing cavity, in which the material is crushed as the main shaft rotates; a star support assembly having a star support bushing cavity defined by the sidewalls and cover plate of the gyratory or cone crusher, wherein the star support bushing cavity forms a Faraday cage; and A system for monitoring at least one motion parameter of the spindle, comprising: a magnetic element mounted on the top end of the spindle and located in the cavity of the star-shaped bracket bushing, wherein the magnetic element is a lug formed of a ferromagnetic material capable of influencing a magnetic field; a magnetic sensor positioned within the spider bushing cavity adjacent the magnetic element and operable to detect changes in magnetic flux caused by movement of the magnetic element relative to the magnetic sensor; and A controller is coupled to the magnetic sensor to determine the at least one motion parameter based on the detected changes in magnetic flux.

8. The crusher according to claim 7, wherein: The magnetic element includes a permanent magnet.

9. The crusher according to claim 7, wherein: The magnetic element includes a permanent magnet mounted to the lifting lug.

10. The crusher according to claim 7, wherein: The at least one motion parameter is a head rotation of the spindle.

11. The crusher according to claim 7, wherein: The at least one motion parameter is the vertical displacement of the main axis.

12. The crusher according to claim 7, wherein: The controller is operable to determine a head rotation of the spindle and a vertical displacement of the spindle.

13. A method for determining at least one motion parameter of a main shaft of a gyratory or cone crusher, the gyratory or cone crusher comprising a magnetic element mounted to the main shaft, the magnetic element being a lug formed of a ferromagnetic material capable of influencing a magnetic field, the method comprising the steps of: positioning the magnetic element within a star-shaped bracket bushing cavity defined by the sidewalls and cover plate of the gyratory or cone crusher, wherein the star-shaped bracket bushing cavity forms a Faraday cage; positioning a magnetic sensor within the star-shaped bracket bushing cavity adjacent to the magnetic element; operating the magnetic sensor to detect changes in magnetic flux caused by movement of a magnetic element mounted to the spindle relative to the magnetic sensor; determining the at least one motion parameter using a controller; and The at least one motion parameter is provided to analyze the motion of the spindle.

14. The method according to claim 13, wherein The at least one motion parameter includes a head rotation of the spindle and a vertical displacement of the spindle.

15. The method according to claim 13, wherein The magnetic sensor is a magnetometer.

16. The method of claim 13, further comprising the step of mounting a permanent magnet to the magnetic element such that the permanent magnet further modifies changes in magnetic flux caused by movement of the spindle relative to the magnetic sensor.

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