Cone crusher automatic feeding system and control method

Abstract

The application provides a conical crusher automatic feeding system and a control method. The conical crusher automatic feeding system comprises a discharging device and a buffer bin, and the buffer bin is used for receiving the material output by the discharging device. The buffer bin is evenly divided into at least three material areas along the circumference thereof. The control method of the conical crusher automatic feeding system comprises the following steps: acquiring the material height in at least three material areas in real time; and when the material height in at least one material area is higher than or equal to a first preset height, controlling the discharging device to discharge at a reduced speed. The conical crusher automatic feeding system and the control method can accurately detect the material height and prevent the situation of insufficient feeding or excessive feeding.

Description

Technical Field

[0001] This invention relates to the field of cone crusher technology, and in particular to an automatic feeding system and control method for a cone crusher. Background Technology

[0002] Cone crushers are typically fed directly via a belt conveyor. During feeding, issues such as insufficient or excessive feeding frequently occur, leading to overflow from the buffer hopper. Insufficient feeding directly results in insufficient output and wasted energy. Excessive feeding, causing overflow, can lead to production hazards and downtime for maintenance, both resulting in unnecessary losses.

[0003] To address these issues, existing solutions utilize level detection devices to monitor material levels and prevent underfeeding or overfeeding. For example, vertical rotary level gauges or radar level gauges are used to detect the material level. However, because the material falls into the buffer silo in a cone shape, the height at different locations varies. Furthermore, due to falling material deviations, the center of the material pile is not necessarily the center of the buffer silo. Therefore, vertical rotary level gauges or radar level gauges can only detect the height at a specific location on the material pile and cannot reflect the true height of the pile, resulting in measurement errors. Additionally, radar level gauges are more expensive. Summary of the Invention

[0004] In view of the above problems, the present invention is proposed to provide an automatic feeding system and control method for a cone crusher that overcomes or at least partially solves the above problems, and can accurately detect the height of the material to prevent insufficient or excessive feeding.

[0005] Specifically, the present invention provides a control method for an automatic feeding system of a cone crusher. The automatic feeding system of the cone crusher includes a discharge device and a buffer hopper. The buffer hopper is used to receive the material output by the discharge device. The buffer hopper is divided into at least three material zones along its circumference.

[0006] The control method of the automatic feeding system for the cone crusher includes:

[0007] The material height within at least three of the material areas is acquired in real time;

[0008] When the material height in at least one of the material areas is higher than or equal to a first preset height, the discharge device is controlled to reduce the discharge speed.

[0009] Optionally, controlling the discharge device to reduce the discharge speed when the material height in at least one of the material areas is higher than or equal to a first preset height includes:

[0010] The discharge device is controlled to discharge material at a reduced speed at a first rate;

[0011] After a first preset time period, the discharge device is controlled to discharge material at a reduced speed at a second rate;

[0012] The second rate is greater than the first rate.

[0013] Optionally, controlling the discharge device to reduce the discharge speed when the material height in at least one of the material areas is higher than or equal to a first preset height includes:

[0014] Obtain the discharge speed of the discharge device;

[0015] When the discharge speed of the discharge device is lower than the discharge speed threshold, the discharge device is controlled to stop discharging.

[0016] Optionally, after controlling the discharge device to stop discharging, the method further includes:

[0017] When the material height in all material areas is lower than the first preset height, and after a second preset time, the discharge device is activated.

[0018] Optionally, after controlling the discharge device to stop discharging, the method further includes:

[0019] When the material height in at least one of the material areas is lower than the second preset height, the discharge device is activated; wherein the second preset height is lower than the first preset height.

[0020] The present invention also provides an automatic feeding system for a cone crusher, comprising:

[0021] The discharge device is used to output materials externally;

[0022] A buffer hopper is used to receive the material output from the discharge device;

[0023] At least three first level sensors are evenly distributed along the circumference of the buffer silo at a first height on the silo wall; the buffer silo is evenly divided into at least three material zones along the circumference of the buffer silo, and each first level sensor is used to detect the height of the material in one of the material zones and to issue a first control signal based on the height of the material in the material zone.

[0024] A controller connected to the discharge device, the controller being configured to control the start-up, shutdown, and speed of the discharge device based on at least one of the first control signals.

[0025] Optionally, the automatic feeding system for the cone crusher further includes:

[0026] At least three second level sensors are evenly distributed along the circumference of the buffer silo at a second height on the silo wall; the second height is lower than the first height.

[0027] Each of the second level sensors is used to detect the height of the material in one of the material areas and to issue a second control signal based on the height of the material in the material area;

[0028] The controller is also configured to control the start-up, shutdown, and speed of the discharge device according to at least one of the second control signals.

[0029] Optionally, the automatic feeding system of the cone crusher further includes a time delay switch, which is configured to start timing when the discharge device stops discharging material, and send a replenishment signal to the controller after a preset time.

[0030] Optionally, both the first level sensor and the second level sensor are non-contact level sensors;

[0031] The discharge device is a belt conveyor.

[0032] Optionally, the automatic feeding system for the cone crusher further includes a cone crusher, which is used to receive the material from the buffer hopper and crush the material.

[0033] In the automatic feeding system of the cone crusher of the present invention, the detection areas of at least three first material level sensors installed on the wall of the buffer hopper form a plane, allowing the material height in each material area of ​​the buffer hopper to be detected. This provides a true reflection of the material accumulation in the buffer hopper, and the discharge device is controlled based on the material accumulation, preventing detection deviations that could lead to overfeeding or underfeeding when detecting only a single material position. Furthermore, controlling the start, stop, and speed of the discharge device based on the material height in at least one material area prevents overflow when the material height in a certain area is too high, or insufficient feeding when the material height in a certain area is too low. This design further avoids overfeeding or underfeeding.

[0034] In the control method of the automatic feeding system of the cone crusher of the present invention, since the material height in multiple material areas is obtained, the material accumulation in the buffer hopper can be accurately reflected. The discharge device is controlled according to the material accumulation, so as to prevent detection deviation when the material is detected at a single position, which would result in overfeeding or underfeeding.

[0035] Furthermore, when the material height in at least one material area is higher than or equal to the first preset height, the discharge device is controlled to decelerate. This can prevent overflow when the material height in a certain material area is too high, or insufficient material supply when the material height in a certain material area is too low.

[0036] The above and other objects, advantages and features of the present invention will become more apparent to those skilled in the art from the following detailed description of specific embodiments of the invention in conjunction with the accompanying drawings. Attached Figure Description

[0037] The following sections will describe some specific embodiments of the invention in detail by way of example and not limitation, with reference to the accompanying drawings. The same reference numerals in the drawings denote the same or similar parts or portions. Those skilled in the art should understand that these drawings are not necessarily drawn to scale. In the drawings:

[0038] Figure 1 This is a schematic structural diagram of an automatic feeding system for a cone crusher according to an embodiment of the present invention;

[0039] Figure 2 This is a schematic top view of a buffer hopper and a first level sensor according to an embodiment of the present invention;

[0040] Figure 3 This is a schematic flowchart of a control method for an automatic feeding system of a cone crusher according to an embodiment of the present invention;

[0041] Figure 4 It is based on Figure 3 A schematic flowchart of one step in the process;

[0042] Figure 5 This is a schematic flowchart illustrating the control method for stopping the discharge device of an automatic feeding system for a cone crusher according to an embodiment of the present invention.

[0043] Figure 6 This is a schematic flowchart illustrating the control method for starting the discharge device of an automatic feeding system for a cone crusher according to an embodiment of the present invention.

[0044] Figure 7 This is a schematic flowchart illustrating the control method for starting the discharge device of an automatic feeding system for a cone crusher according to another embodiment of the present invention. Detailed Implementation

[0045] The following reference Figures 1 to 7This invention describes an automatic feeding system and control method for a cone crusher according to embodiments of the present invention. In this description, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature, that is, include one or more of that feature. In the description of the present invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified. When a feature "includes or contains" one or more of the features it encompasses, unless otherwise specifically described, this indicates that other features are not excluded and may be further included.

[0046] Unless otherwise expressly specified and limited, the terms "set up," "install," "connect," "link," "fix," and "couple" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art should be able to understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0047] Furthermore, in the description of this embodiment, "above" or "below" the second feature can include direct contact between the first and second features, or it can include contact between the first and second features through another feature between them. That is, in the description of this embodiment, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," or "below" of the second feature can mean the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0048] In the description of this embodiment, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0049] Figure 1 This is a schematic structural diagram of an automatic feeding system 100 for a cone crusher according to an embodiment of the present invention, as shown below. Figure 1 As shown, and refer to Figure 2 and Figure 3 This invention provides an automatic feeding system 100 for a cone crusher, including a discharge device 110, a buffer hopper 120, at least three first level sensors 130, and a controller. The discharge device 110 is used to output material. The buffer hopper 120 is used to receive the material output by the discharge device 110. At least three first level sensors 130 are evenly distributed along the circumference of the buffer hopper 120 at a first height on the hopper wall. The buffer hopper 120 is evenly divided into at least three material zones along its circumference. Each first level sensor 130 is used to detect the height of the material in one material zone and issues a first control signal based on the height of the material in that zone. The controller is connected to the discharge device 110 and is configured to control the start, stop, and speed of the discharge device 110 according to at least one first control signal.

[0050] In the automatic feeding system 100 of the cone crusher in this embodiment of the invention, the detection areas of at least three first level sensors 130 arranged on the wall of the buffer hopper 120 form a plane, allowing the height of material in each material area of ​​the buffer hopper 120 to be detected. This accurately reflects the material accumulation in the buffer hopper 120, and the discharge device 110 is controlled according to the material accumulation to prevent detection deviations when detecting material at a single position, which could lead to overfeeding or underfeeding. Furthermore, controlling the start, stop, and speed of the discharge device 110 based on the material height in at least one material area can prevent overflow when the material height in a certain material area is too high, or insufficient feeding when the material height in a certain material area is too low. This configuration further avoids overfeeding or underfeeding.

[0051] In some embodiments of the present invention, the cone crusher automatic feeding system 100 further includes at least three second level sensors, evenly distributed along the circumference of the buffer hopper 120 at a second height on the hopper wall of the buffer hopper 120. The second height is lower than the first height. Each second level sensor is used to detect the height of material in a material area and to issue a second control signal based on the height of material in the material area. The controller is also configured to control the start, stop, and speed of the discharge device 110 based on at least one second control signal.

[0052] In this embodiment, the detection areas of at least three second level sensors on the wall of the buffer silo 120 form a plane, so that the height of the material in each material area of ​​the buffer silo 120 can be detected, thereby accurately reflecting the accumulation of material in the buffer silo 120. The discharge device 110 is controlled according to the accumulation of material to prevent detection deviation when the material is detected at a single position.

[0053] The second level sensor can be called a low-level sensor, and correspondingly, the first level sensor 130 can be called a high-level sensor. The first level sensor 130 can be used to detect the highest position of the material, and the second level sensor can be used to detect the lowest position of the material. Specifically, when at least one first level sensor 130 detects that the material height is higher than the highest position, the discharge device 110 is controlled to decelerate or stop to prevent overfeeding and overflow. When at least one second level sensor detects that the material height is lower than the lowest position, the discharge device 110 is controlled to start or accelerate to replenish the material and prevent underfeeding, resulting in insufficient output and wasted energy.

[0054] Therefore, the first level sensor 130 and the second level sensor work together to keep the material height within the normal range, preventing both overfeeding and underfeeding, thus ensuring production output.

[0055] In some other embodiments of the present invention, the cone crusher automatic feeding system 100 further includes a time delay switch configured to start timing when the discharge device 110 stops discharging material, and to send a replenishment signal to the controller after a preset time.

[0056] In this embodiment, since the discharge device 110 stops discharging material, and the material in the buffer hopper 120 is continuously consumed, the material will gradually decrease, and the material level will decrease. To prevent the material from falling below the minimum position, a delay switch can be set. Specifically, the delay switch starts timing when the discharge device 110 stops discharging material, and after a preset time, sends a replenishment signal to the controller. After receiving the replenishment signal, the controller controls the discharge device 110 to start and replenish the material. Because of the delay switch, automatic material supply can be resumed without the need for a second material level sensor, making control more convenient and reducing costs. The preset time can be set according to the material situation in the buffer hopper 120, the material consumption rate, and the height of the minimum position. Of course, it can also be determined through experiments based on actual conditions.

[0057] In some embodiments of the present invention, both a second level sensor and a time-delay switch are included. This configuration ensures that material can be replenished promptly when the material level is low, providing a double safety measure. The material level corresponding to the second level sensor may or may not be equal to the material level corresponding to the time-delay switch issuing the replenishment signal; the higher of the two material levels will be used as the reference.

[0058] In some embodiments of the present invention, both the first level sensor 130 and the second level sensor are non-contact level sensors.

[0059] In this embodiment, since both the first level sensor 130 and the second level sensor are non-contact level sensors, the first level sensor 130 and the second level sensor have a wide detection range for materials. They can detect the material height without direct contact with the material, and can also avoid direct contact between the material and the first level sensor 130 and the second level sensor during flow, thus preventing damage to the first level sensor 130 and the second level sensor.

[0060] In some embodiments of the present invention, the first level sensor 130 and the second level sensor can be ultrasonic level gauges. The measurement process of the ultrasonic level gauge is as follows: the probe on the ultrasonic level gauge emits an ultrasonic signal, which is reflected back by the surface of the solid material or the wall of the buffer silo and received by the same probe. The entire discharge time of the ultrasonic wave is measured to determine whether the material height has reached the first height, thereby realizing the measurement of the material height. Ultrasonic level gauges have the advantages of good directionality, strong penetration ability, simplicity, economy, and convenient installation and maintenance, and can meet the usage requirements.

[0061] In some embodiments of the present invention, the first level sensor 130 and the second level sensor may be laser level gauges. A laser level gauge emits a continuous or high-speed pulsed laser beam from a semiconductor laser. The laser beam is reflected upon encountering the surface of the material or the wall of a buffer silo, and the reflected light is received by a laser receiver. The time difference between laser emission and reception is accurately recorded to determine the distance between the laser and the measured object, thereby determining whether the material height has reached a first height, thus achieving material height measurement. Laser level gauges have advantages such as large measuring range, fast measurement speed, simple operation, and high measurement accuracy.

[0062] In other embodiments of the present invention, the first level sensor 130 and the second level sensor may be capacitive level sensors or radio frequency admittance level gauges.

[0063] In some embodiments of the present invention, the discharge device 110 is a belt conveyor. A belt conveyor, short for belt-type conveyor, is a continuous conveying machine that uses a flexible conveyor belt as the material-carrying and traction component. A belt conveyor includes a drive roller, a redirecting roller, and an endless conveyor belt that wraps around the drive roller and the redirecting roller. The upper and lower branches between the two rollers are each supported by several idlers. Material is placed on the upper branch, and the conveyor belt and material are discharged by the friction between the drive roller and the belt. Belt conveyors have advantages such as simple structure, stable and reliable operation, strong adaptability to materials, large conveying capacity, and low power consumption. Of course, the discharge device 110 can also be a screw conveyor, bucket elevator, roller conveyor, plate chain conveyor, mesh belt conveyor, and chain conveyor, as long as it can perform the function of conveying materials.

[0064] In some embodiments of the present invention, such as Figure 1 As shown, the cone crusher automatic feeding system 100 also includes a cone crusher 140, which is used to receive the material from the buffer hopper 120 and crush the material.

[0065] In this embodiment, the cone crusher 140 includes a motor, a drive shaft, a cone section, an eccentric sleeve, and a moving cone section. The working principle of the cone crusher 140 is as follows: the motor drives the drive shaft to rotate, the drive shaft drives the eccentric sleeve to rotate via gears, and the eccentric sleeve drives the moving cone section to oscillate in a circular motion, thereby achieving continuous crushing of stones. The cone crusher 140 can be widely used in medium, fine, and ultrafine crushing operations in industries such as metal and non-metal mining, cement, sand and gravel, and metallurgy. It has advantages such as high crushing efficiency, low production cost, convenient maintenance and adjustment, and excellent particle shape of the crushed products.

[0066] This invention also provides a control method for an automatic feeding system 100 for a cone crusher, such as... Figure 1 As shown, the cone crusher automatic feeding system 100 includes a discharge device 110 and a buffer hopper 120, which receives the material output from the discharge device 110. The buffer hopper 120 is divided into at least three material zones along its circumference.

[0067] like Figure 3 As shown, the control method of the cone crusher automatic feeding system 100 includes:

[0068] Step S102: Obtain the material height in at least three material areas in real time;

[0069] Step S104: When the material height in at least one material area is higher than or equal to the first preset height, control the discharge device 110 to reduce the discharge speed.

[0070] In step S102, as Figure 1As shown, in order to obtain the material height, at least three first material level sensors 130 can be evenly distributed on the wall of the buffer silo 120. Each first material level sensor 130 detects the material height in a material area, thereby obtaining the material height in multiple material areas. This setting can truly reflect the material situation in the buffer silo 120 and prevent detection deviation when detecting the material at a single position.

[0071] In step S104, the material is distributed in a cone shape and the height is not the same. When the height of the material in at least one material area is detected to be higher than or equal to the first preset height, it indicates that there is a risk of material overflow. At this time, the discharge device 110 is controlled to reduce the discharge speed, that is, to feed the material slowly to prevent material overflow.

[0072] In the control method of the automatic feeding system 100 of the cone crusher in this embodiment of the invention, since the material height in multiple material areas is obtained, the material accumulation in the buffer hopper 120 can be accurately reflected. The discharge device 110 is controlled according to the material accumulation to prevent detection deviation when the material is detected at a single position, which could lead to overfeeding or underfeeding.

[0073] Furthermore, when the material height in at least one material area is higher than or equal to the first preset height, the discharge device 110 is controlled to decelerate, which can prevent overflow when the material height in a certain material area is too high, or insufficient material supply when the material height in a certain material area is too low.

[0074] In some embodiments of the present invention, such as Figure 4 As shown, in step S104, when the material height in at least one of the material areas is higher than or equal to a first preset height, the discharge device 110 is controlled to reduce the discharge speed, including:

[0075] Step S1042: Control the discharge device 110 to discharge material at a reduced speed using a first rate;

[0076] Step S1044: After a first preset time, control the discharge device 110 to discharge material at a reduced speed at a second rate; wherein the second rate is greater than the first rate.

[0077] In this embodiment, the discharge device 110 is first controlled to discharge material at a first rate, i.e., a slow rate. After a first preset time, since the material height in the material area is still relatively high, the discharge device 110 is then controlled to discharge material at a second rate, i.e., a fast rate. This setting allows the discharge device 110 to decelerate and feed material more quickly, preventing material overflow. For example, the first rate and the second rate can be the amount of material output reduced by the discharge device 110 per unit time. When the discharge device 110 is a rotating mechanism, such as a belt conveyor, the first rate and the second rate can also be the amount of reduction in the belt conveyor's operating speed per unit time.

[0078] In some embodiments of the present invention, such as Figure 5 As shown, in step S104, after controlling the discharge device 110 to reduce the discharge speed when the material height in at least one of the material areas is higher than or equal to the first preset height, the method further includes:

[0079] Step S106: Obtain the discharge speed of the discharge device 110;

[0080] Step S108: When the discharge speed of the discharge device 110 is lower than the discharge speed threshold, control the discharge device 110 to stop discharging.

[0081] In step S106, the discharge speed can be expressed by the discharge amount per unit time. For example, the discharge amount per unit time can be obtained by the ratio of the discharge amount over a period of time to the discharge time, which is the discharge speed.

[0082] In this embodiment, when the discharge speed of the discharge device 110 is lower than the discharge speed threshold, it indicates that the discharge speed of the discharge device 110 is already very small. At this time, there is no need to replenish the buffer hopper 120, so the discharge device 110 is controlled to stop discharging.

[0083] In some embodiments of the present invention, such as Figure 6 As shown, in step S108, after controlling the discharge device 110 to stop discharging, the method further includes:

[0084] Step S110: When the material height in all material areas is lower than the first preset height, and after a second preset time, control the discharge device 110 to start.

[0085] In this embodiment, since the discharge device 110 stops discharging material, and the material in the buffer hopper 120 is continuously consumed, the material will gradually decrease, and the material height will also decrease. To prevent the material height from falling below the minimum material height, the discharge device 110 can be restarted after a second preset time to replenish the material, preventing insufficient material from causing insufficient output and wasting energy. In this embodiment, a delay switch can be set to start timing after the discharge device 110 stops discharging material, and after the second preset time, a replenishment signal is sent to the controller of the cone crusher automatic feeding system 100. The controller then controls the discharge device 110 to start, thus replenishing the material. In this embodiment, the resumption of feeding is achieved by setting a delay time, which simplifies control and saves costs.

[0086] In other embodiments of the invention, such as Figure 7 As shown, in step S108, after controlling the discharge device 110 to stop discharging, the method further includes:

[0087] Step S112: When the material height in at least one of the material areas is lower than the second preset height, the discharge device 110 is activated; wherein the second preset height is lower than the first preset height.

[0088] In this embodiment, since the second preset height is lower than the first preset height, and the material height in at least one material area is lower than the second preset height, it indicates that the material quantity is low and timely replenishment is necessary to prevent insufficient material, resulting in insufficient production and wasted energy. To obtain the material height, at least three second level sensors can be evenly distributed on the wall of the buffer silo 120. The second level sensors are located below the first level sensor 130. Each second level sensor detects the material height in one material area, thereby obtaining the material height in multiple material areas. The second level sensor can be called a low level sensor, and correspondingly, the first level sensor 130 can be called a high level sensor.

[0089] Therefore, those skilled in the art should recognize that although numerous exemplary embodiments of the present invention have been shown and described in detail herein, many other variations or modifications conforming to the principles of the present invention can be directly determined or derived from the disclosure of the present invention without departing from the spirit and scope of the invention. Thus, the scope of the present invention should be understood and construed as covering all such other variations or modifications.

Claims

1. A control method for an automatic feeding system of a cone crusher, characterized in that, The cone crusher automatic feeding system includes a discharge device and a buffer hopper. The buffer hopper is used to receive the material output by the discharge device. The buffer hopper is divided into at least three material zones along its circumference. The control method of the automatic feeding system for the cone crusher includes: The material height within at least three of the material areas is acquired in real time; When the material height in at least one of the material areas is higher than or equal to a first preset height, the discharge device is controlled to reduce the discharge speed. After controlling the discharge device to reduce its discharge speed when the material height in at least one of the material areas is higher than or equal to a first preset height, the method further includes: Obtain the discharge speed of the discharge device; When the discharge speed of the discharge device is lower than the discharge speed threshold, the discharge device is controlled to stop discharging. After the discharge device stops discharging, the method further includes: When the material height in all material areas is lower than the first preset height, and after a second preset time, the discharge device is activated. When the material height in at least one of the material areas is lower than a second preset height, the discharge device is activated; wherein the second preset height is lower than the first preset height.

2. The control method for the automatic feeding system of the cone crusher according to claim 1, characterized in that, The method of controlling the discharge device to reduce the discharge speed when the material height in at least one of the material areas is higher than or equal to a first preset height includes: The discharge device is controlled to discharge material at a reduced speed at a first rate; After a first preset time period, the discharge device is controlled to discharge material at a reduced speed at a second rate; The second rate is greater than the first rate.

Images