Intelligent opening and closing system for hammer crusher gate

Abstract

The invention relates to the technical field of crusher automation, in particular to a hammer crusher gate intelligent opening and closing system which comprises a linkage transmission mechanism, a pneumatic driving assembly and an intelligent control unit. The main gear is fixedly connected with a crusher gate shaft through a spline, and elastic bearings capable of adjusting damping coefficients are arranged at the two ends of a gear shaft of the damping gear and used for attenuating vibration conduction when a crusher works. The pneumatic driving assembly comprises an air cylinder, a pneumatic electromagnetic valve and an air storage tank, and a piston rod of the air cylinder is in rigid connection with the spur rack. According to the intelligent gate opening and closing system of the hammer crusher, through the synergistic effect of the linkage transmission mechanism, the pneumatic driving assembly and the intelligent control unit, automatic and accurate adjustment of the gate is achieved, it is ensured that the crushed particle size is stabilized within the range of 3-18 mm, meanwhile, the stability of equipment is improved, and the service life of the equipment is prolonged.

Description

Technical Field

[0001] The present invention relates to the technical field of crusher automation, in particular to an intelligent switch system for a hammer crusher gate. Background Art

[0002] During the slag treatment process, the hammer crusher uses high-speed rotating hammers to impact, shear and crush the material. The opening degree of the discharge gate directly determines the discharge particle size. In the existing technology, gate adjustment relies on manual operation, which has the following problems:

[0003] 1. Unstable particle size control: Manual adjustment of the gate based on experience makes it difficult to adapt to the material quantity in real time, resulting in large fluctuations in the proportion of qualified particle sizes between 3-18mm, with the lowest being less than 80%;

[0004] 2. Equipment is prone to overload: When too much material accumulates in the crusher, the motor current increases sharply, and manual adjustment lag can easily cause motor overload or even shutdown;

[0005] 3. Vibration affects the life of the equipment: The crusher vibrates violently when working. The traditional transmission mechanism has no effective shock absorption design, and the gears and drive components wear quickly, requiring high maintenance frequency.

[0006] 4. High labor intensity: dedicated personnel are required to operate the machine, especially in continuous production scenarios, resulting in high labor costs and low efficiency.

[0007] In view of the above problems, the present invention proposes an intelligent switching system for a hammer crusher gate. Summary of the Invention

[0008] The main purpose of the present invention is to provide an intelligent switching system for a hammer crusher gate, which can effectively solve the problems in the background technology.

[0009] To achieve the above object, the technical solution adopted by the present invention is:

[0010] An intelligent opening and closing system for a hammer crusher gate includes a linkage transmission mechanism, a pneumatic drive assembly, and an intelligent control unit. The linkage transmission mechanism is composed of a spur rack, a damping gear, and a main gear meshing in sequence. The main gear is fixedly connected to the crusher gate shaft via a spline. Elastic bearings with adjustable damping coefficients are provided at both ends of the gear shaft of the damping gear to attenuate vibration transmission during crusher operation.

[0011] The pneumatic drive assembly includes a cylinder, a pneumatic solenoid valve and an air tank, the piston rod of the cylinder is rigidly connected to the spur rack, and the pneumatic solenoid valve is connected to the air inlet and exhaust port of the air tank and the cylinder respectively through pipelines;

[0012] The intelligent control unit includes a PLC controller, a current sensor and a human-computer interaction interface. The PLC controller has a built-in multi-level current threshold and particle size correlation algorithm, receives the motor current signal and outputs an adjustment instruction;

[0013] The intelligent control unit also has a fault self-diagnosis function. When it detects gear sticking (current mutation ≥3A / s) or cylinder leakage (pressure drop ≥0.1MPa / min), it automatically triggers an audible and visual alarm and records the fault code.

[0014] Preferably, the multi-level current threshold and particle size association algorithm divides the processing capacity of 60-200 tons / h into 8 levels, each level corresponds to a preset current threshold (5-15A), an initial opening degree (30-90°) and a correction coefficient (3-4° / A), and each level is associated with a specific target particle size interval within the range of 3-18mm.

[0015] Preferably, the algorithm of the PLC controller performs the following steps:

[0016] S1. Calculate the current deviation △Ι = real-time current - current threshold;

[0017] S2. Corrected opening θ = initial opening + correction coefficient · △ Ι;

[0018] S3. Perform ±5° secondary correction based on particle size feedback;

[0019] The constraints of the algorithm include: opening degree limit 0-90°, k value temporarily increases by 20% when ΔI lasts for 3 seconds and is greater than 2A, and the gear is automatically switched when the processing capacity changes by ±10 tons / h.

[0020] Preferably, the straight rack is made of 45 steel surface quenching treatment (hardness HRC50-55), the tooth profile parameter is 3-mode, the cross-sectional size is 30×30mm, the rack length is adapted to the maximum stroke of the cylinder, and a guide rail is provided on the back (straightness error ≤0.1mm / m).

[0021] Preferably, the main gear parameters are 3 modules, 65 teeth, and a thickness of 30 mm. The tooth surface is carburized (the depth of the carburized layer is 0.8-1.2 mm). The spline fit clearance with the gate shaft is ≤0.03 mm, and there is no transmission idle travel.

[0022] Preferably, the parameters of the shock-absorbing gear are 3 modules, 28 teeth, and a thickness of 30 mm. A wave spring washer is provided between the gear and the elastic bearing, and the damping effect can be adjusted by the preload force.

[0023] Preferably, the pneumatic drive assembly further includes an air filter (filtration accuracy 5 μm) and a pressure relay. When the air tank pressure is lower than 0.6 MPa, the pressure relay sends an air replenishment signal to the PLC controller to suspend the gate adjustment action.

[0024] Preferably, the PLC controller is further connected to a current signal isolation transmitter to convert the motor current (0-20A) into a 4-20mA standard signal to improve the anti-electromagnetic interference capability.

[0025] Preferably, the end of the cylinder piston rod is provided with a stroke fine-tuning mechanism (adjustment range ±5mm), which is fixed to the spur rack through a threaded connection to ensure that the gear meshing clearance is controlled within 0.05-0.1mm.

[0026] Preferably, the linkage transmission mechanism is provided with a dustproof and soundproof cover (protection grade IP65) on the outside, and a lubricating oil mist spraying device (spraying 0.5 ml of molybdenum disulfide lubricant per hour) is provided inside the cover to automatically lubricate the gear meshing surface.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] 1. Significantly improved particle size stability: Through multi-speed algorithms and automatic adjustment, the particle size of 3-18mm accounts for 90.5%-99.5% (processing capacity 60-200 tons / h), which is 10%-15% higher than manual operation;

[0029] 2. Enhanced equipment safety: Real-time current monitoring and rapid response (adjustment lag ≤ 2 seconds), reduced motor overload failure rate; fault self-diagnosis function reduces downtime for maintenance;

[0030] 3. Improved vibration resistance and wear resistance: The shock-absorbing gear set increases the vibration attenuation rate, the gear wear rate is ≤0.01mm / 1000h, and the trouble-free operation time of the equipment is extended;

[0031] 4. High degree of automation: no need for dedicated personnel on duty, saving labor costs and adapting to continuous production needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a block diagram of the overall structure of an intelligent switch system for a hammer crusher gate according to the present invention;

[0033] Figure 2 This is a flow chart of the intelligent control algorithm of the intelligent switch system for the gate of a hammer crusher according to the present invention;

[0034] Figure 3 This is a schematic diagram of the pneumatic system of an intelligent switch system for a hammer crusher gate according to the present invention;

[0035] Figure 4This is a comparison chart of the particle size qualification rate of the intelligent switch system for the hammer crusher gate of the present invention. DETAILED DESCRIPTION

[0036] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below with reference to the accompanying drawings and specific implementation methods.

[0037] An automatic gate opening device for a hammer crusher includes a linkage transmission mechanism, a pneumatic drive assembly, and an intelligent control unit. The specific structure is as follows:

[0038] 1. Linkage transmission mechanism

[0039] Straight rack: Made of 45# steel with surface quenching treatment (hardness HRC50-55), the tooth profile is 3-mode, the cross-sectional dimensions are 30×30mm, and the rack length is adapted to the maximum stroke of the cylinder; a guide rail is provided on the back, and the straightness error is ≤0.1mm / m to ensure smooth movement.

[0040] Shock-absorbing gear: The parameters are 3 modules, 28 teeth, and a thickness of 30 mm. Elastic bearings with adjustable damping coefficients (0.3-0.6 N·s / m) are provided at both ends of the gear shaft. A wave spring washer is provided between the gear and the bearing to adjust the damping effect through preload to attenuate the vibration transmission of the crusher.

[0041] Main gear: The parameters are 3 modules, 65 teeth, and a thickness of 30mm. The tooth surface is carburized (the depth of the carburized layer is 0.8-1.2mm). It is fixedly connected to the crusher gate shaft through a spline. The fit clearance is ≤0.03mm, and there is no transmission idle travel. The rotation of the gear directly drives the gate shaft to rotate, realizing the adjustment of the opening degree (0-90°).

[0042] 2. Pneumatic drive components

[0043] Cylinder: The end of the piston rod is equipped with a stroke fine-tuning mechanism (adjustment range ±5mm), which is fixed to the spur rack through a threaded connection to ensure that the gear meshing clearance is controlled at 0.05-0.1mm; the extension and retraction of the piston rod drives the spur rack to move linearly, thereby driving the gear transmission.

[0044] Pneumatic solenoid valve: connects the air tank to the air inlet and exhaust port of the cylinder through pipelines, receives instructions from the intelligent control unit, controls the air intake / exhaust of the cylinder, and realizes the extension and retraction of the piston rod.

[0045] Gas storage tank: provides a stable gas source for the cylinder; equipped with an air line filter (filtration accuracy 5μm) and a pressure relay. When the pressure in the tank is lower than 0.6MPa, the pressure relay sends an air replenishment signal to the intelligent control unit to suspend gate adjustment.

[0046] 3. Intelligent control unit

[0047] PLC controller: built-in multi-gear current threshold and particle size correlation algorithm, receives motor current signal and outputs adjustment instruction to pneumatic solenoid valve; with fault self-diagnosis function, when gear jamming (current mutation ≥ 3A / s) or cylinder air leakage (pressure drop ≥ 0.1MPa / min) is detected, automatically triggers audible and light alarm and records fault code.

[0048] Current sensor: connected in series in the power supply circuit of the crusher motor, real-time acquisition of motor running current; matched with current signal isolation transmitter, converts current (0-20A) into 4-20mA standard signal (common mode rejection ratio ≥ 120dB), improves anti-electromagnetic interference ability.

[0049] Human-computer interaction interface: supports input of slag treatment capacity, target particle size and other parameters, real-time display of current value, gate opening degree and alarm information.

[0050] 4. Multi-gear current threshold and particle size correlation algorithm

[0051] Gear division: divided into 8 gears according to slag treatment capacity (60-200 tons / h), each gear corresponds to preset parameters as follows:

[0052]

[0053]

[0054] Adjustment logic:

[0055] Calculate current deviation: ΔI = real-time current - current threshold;

[0056] Correct opening degree: θ = initial opening degree + k·ΔI;

[0057] Particle size closed-loop verification: if the actual particle size exceeds the target range, perform ±5° secondary correction;

[0058] Constraint condition: opening degree limit 0-90°; when ΔI lasts for 3 seconds > 2A, temporarily increase k by 20%; when treatment capacity changes ±10 tons / h, automatically switch gears.

[0059] 5. Auxiliary structure

[0060] Dustproof and soundproof cover: installed outside the linkage transmission mechanism, protection level IP65, prevents slag dust from entering the gear meshing surface;

[0061] Lubricating oil mist spraying device: installed in the cover, sprays 0.5ml of molybdenum disulfide lubricant to the gear meshing surface every hour, reducing wear and tear.

[0062] Example

[0063] Example 1: Gate adjustment under 60 tons / h slag handling capacity (G1 gear)

[0064] Application scenario: A certain household waste incineration plant slag handling line, the handling capacity is stable at 60 tons / h, the target broken particle size is 3-8mm.

[0065] Device configuration and parameters

[0066] Linkage transmission mechanism: straight rack (30x30mm, 3 modules) meshed with damping gear (28 teeth, 3 modules), main gear (65 teeth, 3 modules) connected with gate shaft spline, damping gear damping coefficient adjusted to 0.3N·s / m;

[0067] Pneumatic drive assembly: SC125-500 type cylinder (stroke 0-500mm), air tank pressure maintained at 0.8MPa, air filter filtration precision 5μm;

[0068] Intelligent control unit: PLC controller loads G1 gear parameters (current threshold 5A, initial opening 30°, correction coefficient k=3° / A).

[0069] Adjustment process

[0070] Current acquisition: current sensor real-time monitors motor current, converted to 4-20mA signal (corresponding current 0-20A) by isolation transmitter;

[0071] Initial state: motor current stabilized at 4.5A (<5A), gate maintained at 30° opening, particle size detection showed 5mm (consistent with 3-8mm);

[0072] Dynamic adjustment:

[0073] When the slag feed quantity increases to 65 tons / h, the motor current rises to 5.8A (△I=0.8A);

[0074] PLC controller calculates the opening: θ=30°+3° / A×0.8A=32.4°;

[0075] Command sent to pneumatic electromagnetic valve, air tank charges air to cylinder, piston rod extends 13.3mm (5.56mm / °x2.4°), driven gear set rotates through straight rack, gate opening adjusted to 32.4°;

[0076] Stable results: within 10 seconds after adjustment, motor current fell to 4.7A, continuous operation for 8 hours, 3-8mm particle size accounted for 99.5%, no transmission abnormal noise caused by vibration.

[0077] Example 2: Fault self-diagnosis under 200 tons / h slag handling capacity (G8 gear)

[0078] Application scenario: An industrial slag treatment plant with a peak processing capacity of 200 tons / h and a target crushing particle size of 15-18mm needs to verify the stability and fault response capabilities of the equipment under high load.

[0079] Device configuration and parameters

[0080] Linkage transmission mechanism: The damping coefficient of the shock-absorbing gear is adjusted to 0.6N·s / m (to cope with high vibration), and the clearance between the main gear and the gate shaft is 0.02mm;

[0081] Pneumatic drive assembly: The cylinder stroke fine-tuning mechanism is pre-adjusted by +3mm to ensure the gear meshing clearance is 0.08mm;

[0082] Intelligent control unit: The PLC controller loads the G8 gear parameters (current threshold 15A, initial opening degree 90°, correction coefficient k = 4° / A).

[0083] Operation and fault response

[0084] High load regulation:

[0085] The motor current rises to 16.2A (△Ι = 1.2A). Because the initial opening degree has reached 90° (mechanical limit), the PLC controller maintains the current state. The particle size detection display is 17mm (satisfactory 15-18mm).

[0086] Fault simulation and response:

[0087] Artificially set the cylinder to leak (the pressure dropped from 0.8MPa to 0.6MPa in 40 seconds, and the pressure drop rate was 0.3MPa / min≥0.1MPa / min);

[0088] The PLC controller triggers fault self-diagnosis: the screen displays the code "E02 (cylinder leakage)", the sound and light alarm is activated, and the pneumatic solenoid valve signal is cut off at the same time, and the gate maintains a 90° opening degree;

[0089] The system records the fault time and pressure change curve, making it easier for maintenance personnel to replace cylinder seals;

[0090] Operation after recovery: After the repair, the system was restarted. The current stabilized to 15A within 30 minutes and continued to operate for 8 hours. The particle size of 15-18mm accounted for 90.5%.

[0091] Verification of the effect of the embodiments: The two embodiments cover a processing capacity range of 60-200 tons / h. Through the algorithm adjustment and fault diagnosis function of the intelligent control unit, the particle size control accuracy (90.5%-99.5%) and reliability of the device under different loads are verified.

[0092] In summary, the present invention provides an intelligent switch system for the gate of a hammer crusher, which includes a linkage transmission mechanism, a pneumatic drive assembly, and an intelligent control unit: the linkage transmission mechanism is composed of a spur rack, a shock-absorbing gear, and a main gear meshing in sequence, the main gear is spline-connected to the gate shaft, and the shock-absorbing gear attenuates vibration through an elastic bearing; the pneumatic drive assembly drives the transmission mechanism through a cylinder, a pneumatic solenoid valve, and an air tank; the intelligent control unit includes a PLC controller, a built-in multi-speed current threshold and particle size correlation algorithm, receives the motor current signal to realize automatic adjustment of the gate, and has a fault self-diagnosis function. This system ensures that the particle size of the crushed material is stable at 3-18mm under a processing capacity of 60-200 tons / h through the correlation control of current and particle size, improves the particle size qualification rate and equipment safety, and reduces labor costs. It is suitable for gate control of hammer crushers in the slag industry.

[0093] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. An intelligent switch system for a hammer crusher gate, comprising a linkage transmission mechanism, a pneumatic drive assembly, and an intelligent control unit, characterized in that: The linkage transmission mechanism is composed of a spur rack, a damping gear and a main gear meshing in sequence. The main gear is fixedly connected to the crusher gate shaft through a spline. Both ends of the gear shaft of the damping gear are provided with elastic bearings with adjustable damping coefficients to attenuate the vibration transmission when the crusher is working. The pneumatic drive assembly includes a cylinder, a pneumatic solenoid valve and an air tank, the piston rod of the cylinder is rigidly connected to the spur rack, and the pneumatic solenoid valve is connected to the air inlet and exhaust port of the air tank and the cylinder respectively through pipelines; The intelligent control unit includes a PLC controller, a current sensor and a human-computer interaction interface. The PLC controller has a built-in multi-level current threshold and particle size correlation algorithm, receives the motor current signal and outputs an adjustment instruction; The intelligent control unit also has a fault self-diagnosis function. When a gear is stuck or a cylinder leaks, it automatically triggers an audible and visual alarm and records a fault code.

2. The intelligent switch system for a hammer crusher gate according to claim 1, characterized in that: The multi-level current threshold and particle size association algorithm divides the processing capacity of 60-200 tons / h into 8 levels, each level corresponds to a preset current threshold, initial opening degree and correction coefficient, and each level is associated with a specific target particle size range within the range of 3-18mm.

3. The intelligent switch system for a hammer crusher gate according to claim 1, characterized in that: The PLC controller algorithm performs the following steps: S1. Calculate the current deviation △Ι = real-time current - current threshold; S2. Corrected opening θ = initial opening + correction coefficient · △ Ι; S3. Perform ±5° secondary correction based on particle size feedback; The constraints of the algorithm include: opening degree limit 0-90°, k value temporarily increases by 20% when ΔI lasts for 3 seconds and is greater than 2A, and the gear is automatically switched when the processing capacity changes by ±10 tons / h.

4. The intelligent switch system for a hammer crusher gate according to claim 1, characterized in that: The straight rack is made of 45 steel with surface quenching treatment, the tooth profile parameter is 3-mode, the cross-sectional size is 30×30mm, the rack length is adapted to the maximum stroke of the cylinder, and a guide rail is provided on the back.

5. The intelligent switch system for a hammer crusher gate according to claim 1, characterized in that: The main gear parameters are 3 modules, 65 teeth, and a thickness of 30 mm. The tooth surface is carburized, and the spline fit clearance with the gate shaft is ≤0.03 mm, with no transmission idle travel.

6. The intelligent switch system for a hammer crusher gate according to claim 1, characterized in that: The parameters of the shock-absorbing gear are 3 modules, 28 teeth, and a thickness of 30 mm. A wave spring washer is provided between the gear and the elastic bearing, and the damping effect can be adjusted by the preload force.

7. The intelligent switch system for a hammer crusher gate according to claim 1, characterized in that: The pneumatic drive assembly also includes an air line filter and a pressure relay. When the pressure in the air storage tank is lower than 0.6 MPa, the pressure relay sends an air replenishment signal to the PLC controller to suspend the gate adjustment action.

8. The intelligent switch system for a hammer crusher gate according to claim 1, characterized in that: The PLC controller is also connected to a current signal isolation transmitter to convert the motor current into a 4-20mA standard signal to improve the anti-electromagnetic interference capability.

9. The intelligent switch system for a hammer crusher gate according to claim 1, characterized in that: The end of the cylinder piston rod is provided with a stroke fine-tuning mechanism, which is fixed to the spur rack through a threaded connection to ensure that the gear meshing clearance is controlled within 0.05-0.1mm.

10. The intelligent switch system for a hammer crusher gate according to claim 1, characterized in that: The linkage transmission mechanism is provided with a dustproof and soundproof cover on the outside, and a lubricating oil mist spraying device is provided inside the cover to automatically lubricate the gear meshing surface.

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