Method of measuring a reference value of a crusher load and a crusher control method

Abstract

The application discloses a kind of measuring crusher load benchmark value operation method and crusher control method, control system in crusher gathers the load of crusher once in a period of time, long enough time is continuously collected;The average of these load values is reference value A0, A0 is comprehensive load benchmark value;The average of load value greater than A0 is peak load benchmark value A1;The average of load value less than A0 is low load benchmark value A2;Control system automatically records above numerical value, and as the benchmark value of load related parameter;Control system statistics in a certain period of time, the number of load value greater than or equal to A1, and the average value N in the whole test data is calculated as peak quantity benchmark value;The number of load value less than or equal to A2 and the average value M in the whole test data are calculated as low load quantity benchmark value;These parameter values are automatically or manually changed after the next operation benchmark load test function;Make crusher can maintain optimal performance, maintain efficient work.

Description

Technical Field

[0001] This invention relates to a crusher control method, specifically to a working method and control process for measuring the load reference value of a crusher. Background Technology

[0002] Cone crushers (such as cone crushers and gyratory crushers) achieve material crushing through the rotation of an eccentric shaft and the change in the gap between the crushing chambers. Therefore, their load characteristics are pulsating. The number of peak loads per unit time for a crusher with pulsating load can more accurately and quickly reflect the true load situation of the crusher. At the same time, under the long-term high-load operation of the crusher, even a slight change in control parameters and the external environment can cause the crusher to overload. Similarly, it is difficult to avoid uncrushable materials entering the crusher, which may cause damage to the crusher. Quickly identifying overload is the key to the automatic control of crushers. In current automatic control systems for crushers, the method of measuring peak load is mostly used to calculate the current load status of the crusher. In order to automatically adjust the crusher to operate in the optimal state, it is necessary to set the peak load reference value and the peak quantity reference value of the crusher. Since the peak load of the crusher is different for different types and models of crushers, and even for the same model of crusher when processing different materials, the number of peak loads per unit time is also different. These parameter values ​​are often obtained through manual observation and measurement, and often require multiple long-term adjustments to obtain the ideal parameter values.

[0003] Patent CN 101316658 B proposes a control method for measuring and recording the number of maximum load values, but does not provide a method for judging the maximum value or a method for measuring the number of maximum values ​​under normal working conditions; it cannot solve the problem that the maximum peak load of the crusher is different when crushing different materials. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a method for measuring the load reference value of a crusher. Using this method, the reference parameters required for control can be obtained quickly and accurately, maximizing the crushing force or crushing power of the crusher; enabling the crusher's control system to respond more quickly to changes in the crusher load, thereby minimizing the risk of damage to the crushing machinery and avoiding damage to the crushing machinery as much as possible.

[0005] When measuring real-time parameters such as power or pressure of a crusher, and stress of the crushing mechanism, these parameters are characterized by a wide random distribution and rapid changes and fluctuations. These parameters can characterize the instantaneous load characteristics of the crusher. Continuous and rapid detection of these parameters can quickly obtain information on the load changes of the crusher, allowing the control system to automatically intervene before failures and damage occur, thus avoiding crusher failures and damage. Traditional data acquisition methods that calculate averages have a long time cycle; however, the material entering the crushing chamber is constantly changing, and excessively long reaction and processing times may cause the crusher to overload and be damaged.

[0006] To maximize the crusher's load and achieve its maximum working efficiency, the load could be the crushing power, the stress on the crushing mechanism, or the pressure of the hydraulic system—that is, maximizing these parameters. A reference parameter serves as the adjustment benchmark; if inappropriate, it could cause the crusher load to frequently exceed its allowable limits, leading to damage. The peak crusher load is obtained when the crusher is operating at full load, recorded, and used as a benchmark to adjust the crusher load, ensuring both maximum working efficiency and preventing damage from overloading.

[0007] To ensure stable operation of the crusher and high-quality products, frequent adjustments to the crushing process, especially the discharge port, are necessary. The crusher receives a continuous, large volume of feed materials with varying properties, resulting in different peak load values ​​and frequent occurrences exceeding the reference peak. During parameter acquisition, transformation, and calculation, interference is constantly present in the control system, and these erroneous signals often exceed the reference peak. Traditional average value filtering and methods that remove maximum and minimum values ​​are unsuitable. Average value filtering has too long a time period, failing to meet the control system's rapid response requirements. Removing maximum and minimum values ​​cannot determine their validity, potentially leading to the loss of true values, incorrect judgments, and damage to the crusher. Counting the number of times the load exceeds the reference peak within a specified time period effectively solves these problems. Using counting and comparison operations requires fewer controller resources, has a faster processing speed, and meets the crusher's rapid adjustment requirements. Counting multiple values ​​exceeding the reference effectively filters out system interference signals. Therefore, accurately obtaining the number of times the load exceeds the reference peak within a specified time period under normal operating conditions is essential for ensuring the stable and reliable operation of the control system and is a primary condition for determining whether the crusher is overloaded.

[0008] To achieve the above objectives, the technical solution adopted by this invention is: a working method for measuring the load reference value of a crusher, the specific working method of which is as follows:

[0009] S1: Run the crusher;

[0010] S2: The crusher's control system switches to the reference load test state;

[0011] S3: The control system collects the load of the crusher once within a certain period of time;

[0012] S4: The crusher runs continuously for a sufficient period of time under the benchmark load test condition, continuously collecting the load of the crusher during operation and recording the load value in the control system;

[0013] S5: When the crusher stops running or leaves the benchmark load test state, the control system calculates the average value of all recorded load values ​​as the reference value A0, where A0 is the comprehensive load benchmark value.

[0014] S5: Calculate the average value of all load values ​​greater than A0, and use this average value as the peak load reference value A1; use the average value of load values ​​less than A0 as the low load reference value A2; the control system automatically records the peak load reference value A1 and the low load reference value A2, and uses them as reference values ​​for load-related parameters.

[0015] S6: The control system counts the number of load values ​​greater than or equal to A1 within a certain time period, and calculates the average value of the entire test data as the peak quantity reference value N; the number of load values ​​less than or equal to A2, and calculates the average value of the entire test data as the low load quantity reference value M.

[0016] S7: The comprehensive load benchmark value, peak load benchmark value A1, low load benchmark value A2, low load quantity benchmark value M, and peak load quantity benchmark value N mentioned in S3 to S5 above will be automatically updated after the next run of the benchmark load test function, or they can be changed manually.

[0017] Furthermore, during normal operation of the crusher, values ​​greater than A1 are counted as effective peak reference values ​​by the control system, and values ​​less than A2 are counted as effective low load values ​​by the control system, serving as parameters for controlling the operation of the crusher.

[0018] Furthermore, when collecting the load of the crusher in S3, the operating speed of the control system, the crusher's tolerance, the properties of the material being crushed, the type of crusher, and the crushing cycle should be taken into account.

[0019] Based on the above technology, the control process of the crusher has been further improved, and the control method of the control system in the crusher is as follows:

[0020] Sa: The crusher enters normal working condition, and the control system continuously monitors and records the instantaneous load of the crusher.

[0021] Sb: The instantaneous load value is compared with the peak load baseline value A1, and values ​​greater than A1 are recorded and statistically analyzed;

[0022] Sc: The number of peak loads greater than A1 within the statistical time period T;

[0023] Sd: Compare the number of peak loads with the baseline value N. If the number of peak loads is greater than N, the control system controls the crusher to reduce the load.

[0024] Se: If the number of peak loads is equal to or less than N, and the average load is less than the comprehensive load benchmark value A0, the control system controls the crusher to increase the load;

[0025] Sf: If the number of peak loads is less than or equal to N, and the average load value is greater than or equal to the comprehensive load benchmark value A0, the control system controls the crusher to remain unchanged;

[0026] Sg: The crusher repeats the above steps in a cycle to maintain continuous and efficient operation.

[0027] Furthermore, the Sd control system controls the crusher to reduce the load by increasing the crusher's discharge port or decreasing the feed rate.

[0028] The beneficial effects of this invention are as follows: The advantage of this control method is that the peak reference point is derived from the actual working process and is the average of the peak values. Therefore, it is close to the maximum load of the crusher and has a certain margin. This ensures the safety of the crusher and makes the crusher work efficiently. The control parameters can be changed quickly. Even when different materials to be crushed are fed into the crusher (these materials to be crushed can be rocks of different hardness or ores with different water content; coal and other materials to be crushed), the control system can quickly, conveniently and correctly obtain the control parameters. The control system can control the crusher to work at its best performance level based on these parameters. The crusher can maintain optimal performance, provide qualified crushed products, and maintain efficient operation. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of the present invention;

[0030] Figure 2 This is a schematic diagram of the structure of the present invention;

[0031] Figure 3 This is a schematic diagram of the structure of the present invention.

[0032] In the diagram: 0. Crusher; 1. Hydraulic cylinder assembly; 2. Lower frame assembly; 3. Main shaft assembly; 4. Conical liner; 5. Upper frame liner; 6. Upper frame assembly; 7. Crushing gap; 8. Horizontal drive shaft assembly; 9. Cylinder displacement sensor; 21. Control system; 22. Crusher motor power tester; 23. Hydraulic system; 24. Hydraulic oil pump;

[0033] S: Discharge port size. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. However, it should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of the invention.

[0035] like Figure 1 As shown, a crusher 0 includes: a hydraulic cylinder assembly 1, a lower frame assembly 2, a main shaft assembly 3, an upper frame assembly 6, and a horizontal drive shaft assembly 8. The upper frame assembly 6 and the lower frame assembly 2 have internal grooves. The upper frame assembly 6 is installed above the lower frame assembly 2, forming a crushing chamber between the grooves on the upper frame assembly 6 and the lower frame assembly 2. One end of the main shaft assembly 3 passes through the lower frame assembly 2 and extends into the crushing chamber. A cone is provided on the main shaft assembly 3 extending into the crushing chamber, and a conical liner 4 is installed on the surface of the cone. A frame liner 4 is installed on the inner wall of the upper frame assembly 6. The frame liner 5 forms a crushing gap 7 around the conical liner 4. The upper frame assembly 6 is equipped with a feed inlet, and the ore enters the crushing gap 7 from the feed inlet of the upper frame assembly 6. The hydraulic cylinder assembly 1 is located at the lower end of the main shaft assembly 3. The hydraulic cylinder assembly 1 supports and adjusts the up and down movement of the main shaft assembly 3 to adjust the size of the crushing gap 7. The horizontal drive shaft assembly 8 is installed on the side of the lower frame assembly 2. The horizontal drive shaft assembly 8 drives the main shaft assembly 3 to make a swinging motion, so that the crushing gap 7 between the conical liner 4 and the upper frame liner 5 changes continuously, thereby continuously squeezing the ore and completing the crushing of the ore.

[0036] The crushing gap 7 between the upper frame liner 5 and the conical liner 4 gradually decreases from top to bottom. The upper end of the crushing gap 7 is larger and the lower end is smaller. The outlet at the lower end of the crushing gap 7 is called the discharge port S. The horizontal drive shaft assembly 8 is connected to an external motor.

[0037] The crusher 0 also includes a control system 21, which includes: a controller, a monitoring unit, a detection part consisting of a sensor group, a power drive part, and an electrical control part required to control the operation of the crusher 0.

[0038] A controller typically includes a CPU, storage unit, and input / output interfaces. It is generally composed of a PLC, industrial computer, or DCS system. Its core feature is its computing capability, enabling it to perform logical and mathematical operations. The monitoring unit's main function is human-machine interaction. It typically displays and outputs the crusher's operating status, controls commands, and inputs parameters. Input components usually consist of a keyboard, mouse, or touchscreen, while output components include a monitor, printer, alarm lights (bells), and network display.

[0039] The detection section of the control system 21 mainly includes: a cylinder displacement sensor 9 for detecting the spindle displacement, a pressure sensor for detecting the pressure of the hydraulic system 23, a power sensor for detecting the energy consumption of the crusher, and temperature sensors for detecting the temperature of the boom bearing and the lubricating oil of the crusher.

[0040] The parameters collected by the above detection section can directly or indirectly express the load of the crusher 0. In this example, the crusher 0 is driven by a motor, so the power of the motor is used to characterize the load of the crusher 0. The power sensor for detecting the energy consumption of the crusher 0 is the crusher 0 motor power tester. Its function is to measure the real-time power of the crusher motor and convert it into a suitable electrical signal input to the controller.

[0041] The cylinder displacement sensor 9 is installed on the hydraulic cylinder assembly 1 to measure the displacement of the piston in the hydraulic cylinder, thereby measuring the displacement of the main shaft assembly 3. The displacement of the main shaft assembly 3 and the discharge port S have a fixed functional relationship. This functional relationship depends on the structural parameters of the crusher 0. The functional relationship is different for crushers 0 with different structures, but for crushers 0 with the same structural dimensions, the functional relationship is definite.

[0042] Hydraulic oil is filled into the hydraulic cylinder assembly, the piston moves upward, the main shaft assembly 3 moves upward, the crushing gap 7 decreases, the discharge port S decreases, and the load on the crusher 0 increases; hydraulic oil flows out of the hydraulic cylinder assembly, the piston moves downward, the main shaft assembly 3 moves downward, the crushing gap 7 increases, the discharge port S increases, and the load on the crusher 0 decreases. The movement of the hydraulic cylinder assembly is driven and controlled by the externally connected hydraulic oil pump 24.

[0043] like Figure 2 The hydraulic system 23 includes a hydraulic oil pump 24, valve group and pipeline. Its main function is to drive and control the up and down movement of the hydraulic cylinder assembly 1, thereby driving the main shaft assembly 3 to move up and down, and completing the change of the crushing chamber gap and the discharge port S.

[0044] The specific working method for measuring the zero-load reference value of a crusher is as follows:

[0045] S1: Running crusher 0;

[0046] S2: The control system 21 of the crusher 0 switches to the reference load test state;

[0047] S3: The control system 21 collects the load of the crusher 0 once every certain period of time. This period of time should take into account the controller's processing speed, the crusher 0's tolerance, the properties of the material being crushed (hardness, brittleness, ductility, etc.), the type of crusher 0, the crushing cycle, etc. Generally, this period of time should be selected within 2-5 ms. This time range is only a suggestion, and exceeding this time range is also allowed.

[0048] S4: The crusher 0 runs continuously for a sufficient period of time under the reference load test condition, and the load of the crusher 0 is continuously collected during operation and recorded in the control system 21;

[0049] S5: When the crusher 0 stops running or leaves the benchmark load test state, the control system 21 calculates the average value of all recorded load values ​​as the reference value A0, where A0 is the comprehensive load benchmark value.

[0050] S5: Calculate the average value of all load values ​​greater than A0, and use this average value as the peak load reference value A1; use the average value of load values ​​less than A0 as the low load reference value A2; control system 21 automatically records the peak load reference value A1 and the low load reference value A2, and uses them as reference values ​​for load-related parameters.

[0051] S6: Control system 21 statistically analyzes a certain time period, which is recorded as ΔT, typically ranging from 50 to 200 ms; the number of load values ​​greater than or equal to A1, and calculates the average value across the entire test data as the peak load baseline N; the number of load values ​​less than or equal to A2, and calculates the average value across the entire test data as the low load baseline M; the detection results are attached. Figure 3 As shown;

[0052] S7: The above steps can be changed automatically or manually after the next run of the baseline load test function.

[0053] When the crusher 0 is working normally, values ​​greater than A1 are counted as effective peak reference values ​​by the control system 21, and values ​​less than A2 are counted as effective low load values ​​by the control system 21, which are used as parameters to control the operation of the crusher 0.

[0054] When collecting the load of crusher 0 in S3, the operating speed of control system 21, the tolerance of crusher 0, the properties of the material being crushed, the type of crusher 0, and the crushing cycle should be considered.

[0055] The baseline value for iron overflow in the crusher can be estimated based on the value of A1. Once a load value greater than or equal to this value appears, and this load value appears a specified number of times within a specified time, the control system can determine that the crusher is experiencing iron overflow and start the crusher iron overflow handling program to prevent the fault from escalating and to protect the crusher from damage due to iron overflow in a timely manner. Iron overflow refers to uncrushable materials blocking the crusher.

[0056] The control method of the control system 21 in the crusher 0 includes the following steps:

[0057] Sa: The crusher 0 enters normal working state, and the control system 21 continuously monitors and records the instantaneous load of the crusher 0;

[0058] Sb: The instantaneous load value is compared with the peak load baseline value A1, and values ​​greater than A1 are recorded and statistically analyzed;

[0059] Sc: The number of peak loads greater than A1 within the statistical time period T;

[0060] Sd: Compare the number of peak loads with the benchmark value N. If the number of peak loads is greater than N, the control system 21 controls the crusher 0 to reduce the load.

[0061] Se: If the number of peak loads is equal to or less than N, and the average load is less than the comprehensive load benchmark value A0, the control system 21 controls the crusher 0 to increase the load;

[0062] Sf: If the number of peak loads is less than or equal to N, and the average load value is greater than or equal to the comprehensive load reference value A0, the control system 21 controls the crusher 0 to remain unchanged;

[0063] Sg: The crusher 0 repeats the above steps in a cycle to keep the crusher 0 running continuously and efficiently.

[0064] In Sd, control system 21 controls crusher 0 to reduce load: increase the discharge port of crusher 0 or decrease the feed rate.

[0065] The above example only illustrates one operating condition of the crusher 0. For other operating conditions, the load on the crusher 0 can also be reduced in other ways, such as reducing the feed rate of the crusher 0.

[0066] This example is only for illustrating the process and structure of the present invention with respect to one type of crusher 0. The present invention is not limited to any specific type of crusher 0. It can be applied to any crusher 0 consisting of a crushing chamber, such as a single-cylinder cone crusher, a multi-cylinder cone crusher 0, a jaw crusher 0, a hammer crusher 0, and other forms of crushers 0. The crusher 0 referred to in the present invention is mainly characterized by the adjustable size of the crushing gap 7 and the size of the discharge port, or the above parameters of the crusher 0 can be measured and adjusted.

[0067] The power type of the crusher 0 of this invention can be of various types, such as hydraulic transmission, electric transmission or mechanical transmission, and is not limited by any power type of the crusher 0.

[0068] This invention is not limited to any particular measurement or sensing technology. Alternatively, any type of sensor can be used, as long as they can reflect sufficient information about the characteristics and parameters of the crusher.

[0069] This invention is not limited to any specific material that can be crushed. Any material that can be crushed can be called a mineral, such as rock, ore, pebbles, brick, asphalt, concrete, ceramics, glass, etc.

[0070] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention.

[0071] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions or improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A working method for measuring the reference value of crusher load, characterized in that: The specific working methods are as follows: S1: Run the crusher; S2: The crusher's control system switches to the reference load test state; S3: The control system collects the load of the crusher once within a certain period of time; S4: The crusher runs continuously for a sufficient period of time under the benchmark load test condition, continuously collecting the load of the crusher during operation and recording the load value in the control system; S5: When the crusher stops running or leaves the benchmark load test state, the control system calculates the average value of all recorded load values ​​as the reference value A0, where A0 is the comprehensive load benchmark value. S5: Calculate the average value of all load values ​​greater than A0, and use this average value as the peak load reference value A1; use the average value of load values ​​less than A0 as the low load reference value A2; the control system automatically records the peak load reference value A1 and the low load reference value A2, and uses them as reference values ​​for load-related parameters. S6: The control system counts the number of load values ​​greater than or equal to A1 within a certain time period, and calculates the average value of the entire test data as the peak quantity reference value N; the number of load values ​​less than or equal to A2, and calculates the average value of the entire test data as the low load quantity reference value M. S7: Parameter updates and changes. The comprehensive load benchmark value A0, peak load benchmark value A1, low load benchmark value A2, low load quantity benchmark value M, and peak quantity benchmark value N mentioned in S3 to S5 above will be automatically updated after the next run of the benchmark load test function, or they can be changed manually.

2. The working method for measuring the load reference value of a crusher according to claim 1, characterized in that: During normal operation of the crusher, values ​​greater than A1 are counted as effective peak reference values ​​by the control system, and values ​​less than A2 are counted as effective low load values ​​by the control system, which are used as parameters for controlling the operation of the crusher.

3. The working method for measuring the load reference value of a crusher according to claim 1, characterized in that: When collecting the load of the crusher in S3, the operating speed of the control system, the crusher's tolerance, the properties of the material being crushed, the type of crusher, and the crushing cycle must be taken into account.

4. A crusher control method having the operating method for measuring the crusher load reference value as described in claim 1, characterized in that: The control method includes the following steps: Sa: The crusher enters normal working condition, and the control system continuously monitors and records the instantaneous load of the crusher. Sb: The instantaneous load value is compared with the peak load baseline value A1, and values ​​greater than A1 are recorded and statistically analyzed; Sc: The number of peak loads greater than A1 within the statistical time period T; Sd: Compare the number of peak loads with the baseline value N. If the number of peak loads is greater than N, the control system controls the crusher to reduce the load. Se: If the number of peak loads is equal to or less than N, and the average load is less than the comprehensive load benchmark value A0, the control system controls the crusher to increase the load; Sf: If the number of peak loads is less than or equal to N, and the average load value is greater than or equal to the comprehensive load benchmark value A0, the control system controls the crusher to remain unchanged; Sg: The crusher repeats the above steps in a cycle to maintain continuous and efficient operation.

5. The crusher control method according to claim 4, characterized in that: In the Sd control system, the crusher can be controlled to reduce the load by increasing the discharge port of the crusher or increasing or decreasing the feed rate.

6. The crusher control method according to claim 4, characterized in that: The SE control system controls the crusher to increase the load by increasing the discharge port of the crusher and decreasing or increasing the feed rate.

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