Novel operation method for controlling iron passing of crusher

Abstract

The invention relates to a novel operation method for controlling iron passing of a crusher. The novel operation method comprises the steps that the working pressure of a shear pipe in an iron passing protection system of the crusher is obtained; setting the working pressure of the shear pipe; the work limiting pressure of an electric control hydraulic valve of the iron passing protection system is reset; setting an iron passing alarm mechanism according to the power of the crusher and the ore discharge port data; after the iron passing alarm is triggered, an operator is notified to complete bin locking, and iron pieces falling into the crusher are removed; and the crusher is subjected to shutdown inspection, and whether the crusher is damaged or not is judged. By improving the operation process, real-time data monitoring and a mechanism for timely processing abnormities of the crusher, equipment damage and safety accidents are effectively prevented, stable operation of the production process is guaranteed, the production efficiency is improved, risks and hidden dangers in the production process are reduced, and the production cost is reduced. And a safer and more intelligent crusher operation environment is provided for mine enterprises.

Description

Technical Field

[0001] This invention relates to the field of crusher technology, and in particular to a novel operating method for controlling the passage of iron in a crusher. Background Technology

[0002] During mining operations, the physical properties and complexity of ore types make mining equipment susceptible to damage, especially in the use of crushers, where the entry of iron pieces into the crusher is a common problem. When cone crushers process ore, the entry of iron pieces into the crushing chamber often leads to equipment failure.

[0003] Due to the physical properties and complexity of ores, iron pieces or other foreign objects can easily be introduced into the crusher chamber. This can not only damage the equipment but also affect crushing efficiency and even cause safety accidents. When iron pieces enter the crushing chamber, the high-speed rotation of the crusher rapidly increases the internal pressure. When the pressure exceeds a set value, the electrical control system activates a pressure relief valve to temporarily protect the equipment and prevent further damage by releasing excess pressure. However, this automatic pressure relief method cannot fundamentally solve the problem of iron pieces entering the crusher. While the pressure relief valve can prevent equipment damage due to overload to some extent, it cannot prevent iron pieces from continuing to enter the crushing chamber, nor can it reduce the impact of iron pieces on the internal components of the crusher. The impact of iron pieces on the liners, main shaft, and other critical components can cause wear, cracks, and even breakage of parts, thereby affecting the crusher's operating efficiency and equipment stability.

[0004] Regarding the manifestations of equipment damage, high-load components such as liners and main shafts are most susceptible to impact. Excessive impact can cause cracking, breakage, deformation, or even detachment. If the main shaft is impacted, its bearings may be damaged, potentially leading to shaft breakage. Other components, such as the fixed cone and moving cone, can also suffer varying degrees of damage from the ingress of iron, further leading to equipment downtime, extended repair cycles, and production line interruptions. This increases maintenance costs, reduces production efficiency, and impacts the mine's economic benefits. Iron ingress can cause instantaneous stress concentration, resulting in liner cracking, deformation and failure of eccentric bushings and lower frame bushings, and even main shaft breakage. Considering the unavoidable ingress of iron into the crusher during closed-circuit operations, the key to solving this problem lies in "improving the crusher's iron ingress protection capability and reducing the frequency of repeated iron ingress." Summary of the Invention

[0005] To address the aforementioned problems, the purpose of this invention is to provide a novel operating method for controlling the iron flow in a crusher.

[0006] A novel operating method for controlling iron flow in a crusher includes:

[0007] Step 1: Obtain the working pressure of the shear pipe in the overload protection system of the crusher;

[0008] Step 2: Set the working pressure of the shear tube;

[0009] Step 3: Reset the operating pressure limit of the electro-hydraulic valve of the over-iron protection system;

[0010] Step 4: Set up an over-iron alarm mechanism based on the crusher's power and discharge port data;

[0011] Step 5: When the iron overload alarm is triggered, notify the operator to lock the hopper and remove the iron parts that have fallen into the crusher;

[0012] Step 6: Stop the crusher and inspect it to determine if there is any damage.

[0013] Preferably, in step 2, the shearing tube pressure for medium crushing is adjusted from 95 MPa to 60 MPa, and the shearing tube pressure for fine crushing is adjusted from 95 MPa to 85 MPa.

[0014] Preferably, in step 3, the operating pressure limit of the electrically controlled pressure relief valve is adjusted to 9.7 MPa.

[0015] Preferably, in step 4, when the power of the crusher reaches 570kw or more and lasts for more than 3 seconds, the crusher overload occurs; when the hydraulic pressure of the crusher exceeds the preset operating range, the crusher overload occurs; when the medium crushing discharge opening of the crusher is greater than 55mm and the fine crushing discharge opening is greater than 27mm, the crusher overload occurs.

[0016] Preferably, in step 5, when the iron overload alarm is triggered, the operator in the central control room is notified to lock the hopper within 1 minute, and at the same time, the position of the trolley is adjusted to move it to the lowest position of the hopper, and the operation of the downstream belt of the hopper is stopped to prevent iron parts from flowing into other warehouses.

[0017] Preferably, in step 6, the shutdown inspection includes checking the return oil filter, the eccentric assembly and thrust assembly, the moving and fixed cone liners, the cutting ring, the coupling, and the clearance between the upper and lower frames.

[0018] Preferably, in step 6, check whether the return oil filter screen is clogged with iron filings or debris; whether the eccentric assembly and thrust assembly are damaged; check whether the moving and fixed cone liners and cutting ring are damaged or cracked, and whether there are iron parts remaining in the crushing chamber; check whether the coupling is seized; check whether the gap between the upper and lower frames exceeds 0.07mm.

[0019] According to specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0020] 1. By optimizing the shear tube pressure and the operating pressure of the electro-hydraulic valve, the crusher can respond more sensitively to iron overflow and avoid equipment damage. The adjusted shear tube pressure (60MPa for medium crushing and 85MPa for fine crushing) and the operating pressure of the electro-hydraulic valve (9.7MPa) greatly improve the system's response speed to iron overflow, preventing the crusher from being subjected to excessive impact and damage, thereby effectively improving the service life and production efficiency of the equipment.

[0021] 2. By setting an alarm mechanism, an alarm can be triggered in a timely manner when the power exceeds 570kw for more than 3 seconds, and a warning will be issued when there is an abnormality at the discharge port, ensuring that the operator can confirm the abnormality and take corresponding emergency measures within 2 minutes. This mechanism improves the response speed, avoids iron parts from entering the crushing chamber and repeatedly passing iron, thereby ensuring the continuity of production.

[0022] 3. By establishing a clear fixed-position operation procedure and implementing central control operation, the location of iron parts can be accurately locked, preventing them from entering other warehouses or repeatedly entering the crusher. Central control operators can adjust the position of the trolley and stop the downstream belt to ensure that the iron parts do not flow to other places. This not only avoids equipment damage, but also improves the efficiency and accuracy of post-iron processing and reduces the possibility of human error.

[0023] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 The present invention provides a flowchart of a novel operation method for controlling iron flow in a crusher. Detailed Implementation

[0026] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0027] Furthermore, 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 technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0028] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0029] Please see Figure 1 A novel operating method for controlling iron flow in a crusher, comprising:

[0030] Step 1: Obtain the working pressure of the shear pipe in the overload protection system of the crusher;

[0031] Step 2: Set the working pressure of the shear tube;

[0032] In step 2, the shearing pressure of the medium crushing tube is adjusted from 95 MPa to 60 MPa, and the shearing pressure of the fine crushing tube is adjusted from 95 MPa to 85 MPa.

[0033] Step 3: Reset the operating pressure limit of the electro-hydraulic valve of the over-iron protection system;

[0034] Step 4: Set up an over-iron alarm mechanism based on the crusher's power and discharge port data;

[0035] In step 4, when the power of the crusher reaches 570kw or more and lasts for more than 3 seconds, the crusher overload occurs; when the hydraulic pressure of the crusher exceeds the preset operating range, the crusher overload occurs; when the discharge opening of the medium crushing crusher is greater than 55mm and the discharge opening of the fine crushing crusher is greater than 27mm, the crusher overload occurs.

[0036] Step 5: When the iron overload alarm is triggered, notify the operator to lock the hopper and remove the iron parts that have fallen into the crusher;

[0037] In step 5, when the iron overload alarm is triggered, the operator in the central control room is notified to lock the hopper within 1 minute. At the same time, the position of the trolley is adjusted to move it to the lowest position of the hopper, and the operation of the downstream belt of the hopper is stopped to prevent iron parts from flowing into other warehouses.

[0038] Step 6: Stop the crusher and inspect it to determine if there is any damage.

[0039] In step 6, check if the return oil filter screen is clogged with iron filings or debris; check if the eccentric assembly and thrust assembly are damaged; check if the moving and fixed cone liners and cutting ring are damaged or cracked, and if there are any iron parts remaining in the crushing chamber; check if the coupling is seized; check if the gap between the upper and lower frames exceeds 0.07mm.

[0040] The novel operation method for controlling iron flow in a crusher according to the present invention will be further explained below with reference to specific embodiments:

[0041] Example 1:

[0042] A novel operating method for controlling iron ingress in a crusher is presented. The iron ingress protection device typically includes multiple components such as a hydraulic system, sensors, an alarm system, and a control system. During crusher operation, hard objects such as iron blocks can easily be fed into the crusher. Without timely protection measures, this can lead to equipment damage. The core task of the iron ingress protection device is to protect the equipment promptly upon detecting an iron block entering the equipment, preventing damage. Through an advanced hydraulic protection system, when an iron ingress event occurs, the hydraulic system quickly activates, releases pressure, and stops the crusher's operation, preventing further entry of foreign objects into the crusher cavity, thus avoiding equipment damage. Before proceeding with the formal operation procedure, the crusher's iron ingress protection system must be thoroughly inspected and tested. The specific operating steps are as follows:

[0043] S1: Setting of Over-Iron Protection System

[0044] The crusher is equipped with safety protection measures for overload, such as the installation of shear pipes on the coupling and the installation of electro-hydraulic valves. The shear pipe is installed on the horizontal shaft coupling of the cone crusher. Its main function is to cut off the shear pipe when the crusher passes over overload or non-crushable materials. When the torque of the coupling increases sharply, the torque in the coupling exceeds the limit torque. The brake disc cuts off the shear pipe, which disconnects the main motor from the horizontal shaft and cuts off the power source to protect the main shaft and the main motor transmission from damage.

[0045] S2: Debugging of electro-hydraulic valves

[0046] The electro-hydraulic valve is one of the core components of the over-iron protection system. It plays a crucial role when an over-iron event occurs. The hydraulic valve monitors the working status of the crusher in real time through the electro-control system, controls the flow of oil, and thus adjusts the working status of the crusher. During system debugging, it is necessary to ensure that the hydraulic valve can respond in a timely manner and can quickly close.

[0047] S3: Abnormal Data Detection

[0048] After iron is passed through the crusher, the operating status of the crusher will change significantly, especially in key data such as power, pressure, and discharge port. By monitoring and analyzing these data in real time, it is possible to quickly detect whether the crusher has passed through the iron.

[0049] S4: Configure alarm mechanism

[0050] The PLC program is programmed to trigger an iron overload alarm when the power exceeds 570kw for more than 3 seconds. At the same time, an alarm will also be triggered when the discharge port exceeds the set threshold. The operator must confirm the abnormal data within 2 minutes to prevent iron from entering the closed-loop system and to prevent the crusher from repeatedly overloading iron.

[0051] S5: Iron part position lock

[0052] When iron is passed over the crusher, the iron alarm is triggered. It is necessary to locate the iron part as soon as possible and take corresponding measures. In order to prevent the iron part from reappearing in the system, the position of the iron part needs to be accurately locked.

[0053] S6: Picking up iron parts

[0054] The iron picking position was adjusted to downstream of belt #18. Through centralized control, operators can pick up iron on belt #18, ensuring safety during the process. By adjusting the speed of the dry separation feed belt to 30 Hz, a lower belt speed is maintained to facilitate operators' observation and detection of iron pieces. At the same time, the tail vibratory feeder continues to run to ensure that the material layer thickness is controlled within an appropriate range, thus improving iron picking efficiency. When an iron piece is found, the operator stops the machine by pulling the rope or pressing the emergency stop button. After the belt stops running, the iron piece is picked up. This process ensures the safety of the operator and prevents the iron piece from slipping into the lower section of the belt and causing damage.

[0055] S7: Equipment inspection after iron passage

[0056] After the crusher passes iron, the equipment must be stopped and inspected to ensure that it has not been damaged.

[0057] Example 2:

[0058] S1: Setting of Over-Iron Protection System

[0059] In S1, by adjusting the shear tube pressure, the shear tube pressure of the medium crusher is adjusted from 95MPA to 60MPA and the shear tube pressure of the fine crusher is adjusted from 95MPA to 85MPA, respectively, according to the different operating conditions of the medium crusher and the fine crusher. This change can increase the sensitivity of the over-iron protection without damaging the crusher, thereby effectively improving the protection capability of the equipment.

[0060] S2: Debugging of electro-hydraulic valves

[0061] In S2, the electric pressure relief valve is installed within the main shaft positioning system. When the crusher passes through iron, the hydraulic system pressure rises instantaneously, reaching the working limit pressure of the electric pressure relief valve. Then, the main valve of the electric pressure relief valve opens, quickly releasing pressure and causing the main shaft to descend rapidly, thus achieving the purpose of expelling the iron parts. The original 11MPA was adjusted to 9.7MPA, further improving the response speed of the hydraulic system to more quickly and effectively eliminate the pressure problem caused by passing through iron.

[0062] S3: Abnormal Data Detection

[0063] In S3, data such as the crusher's power, pressure, and discharge port are displayed in the operating system. Historical curves can also reflect the crusher's working status. When iron is passed through the crusher, the following abnormal changes usually occur: the crusher's power will increase rapidly, reaching over 570 kW, and lasting for more than 3 seconds; the crusher's hydraulic pressure will change drastically, exceeding the normal operating range; the crusher's discharge port will increase in size, with the medium crushing discharge port exceeding 55 mm and the fine crushing discharge port exceeding 27 mm.

[0064] S4: Configure alarm mechanism

[0065] The PLC program is programmed to trigger an iron overload alarm when the power exceeds 570kw for more than 3 seconds. At the same time, an alarm will also be triggered when the discharge port exceeds the set threshold. The operator must confirm the abnormal data within 2 minutes to prevent iron from entering the closed-loop system and to prevent the crusher from repeatedly overloading iron.

[0066] S5: Iron part position lock

[0067] In S5, when the iron overload alarm is triggered, the operator in the central control room completes the locking of the hopper within 1 minute to ensure that the iron parts are in a fixed hopper. The operator moves the trolley to the lowest position of the hopper by adjusting the position of the trolley and stops the operation of the downstream conveyor belt of the hopper to prevent the iron parts from flowing into other warehouses. By establishing a clear hopper fixing operation procedure, it is ensured that the warehouse where the iron parts are located can be quickly and accurately locked every time an iron overload event occurs, and the iron parts are prevented from entering other warehouses and being repeatedly overloaded.

[0068] S6: Picking up iron parts

[0069] The iron picking position was adjusted to downstream of belt #18. Through centralized control, operators can pick up iron on belt #18, ensuring safety during the process. By adjusting the speed of the dry separation feed belt to 30 Hz, a lower belt speed is maintained to facilitate operators' observation and detection of iron pieces. At the same time, the tail vibratory feeder continues to run to ensure that the material layer thickness is controlled within an appropriate range, thus improving iron picking efficiency. When an iron piece is found, the operator stops the machine by pulling the rope or pressing the emergency stop button. After the belt stops running, the iron piece is picked up. This process ensures the safety of the operator and prevents the iron piece from slipping into the lower section of the belt and causing damage.

[0070] S7: Equipment inspection after iron passage

[0071] In the S7, the post-iron inspection includes checking the return oil filter, eccentric assembly and thrust assembly, moving and fixed cone liners, cutting ring, coupling, and upper and lower frame clearance. The return oil filter inspection primarily checks for iron filings or debris blockage. The eccentric assembly and thrust assembly inspection ensures no damage, preventing abnormal crusher operation due to foreign objects. The moving and fixed cone liners and cutting ring inspection checks for damage or cracks, and for any iron residue remaining in the crushing chamber. The coupling inspection ensures the coupling is not seized, preventing the crusher from losing protection. The upper and lower frame clearance inspection ensures the clearance does not exceed 0.07mm, preventing crusher failure.

[0072] According to specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0073] 1. By optimizing the shear tube pressure and the operating pressure of the electro-hydraulic valve, the crusher can respond more sensitively to iron overflow and avoid equipment damage. The adjusted shear tube pressure (60MPa for medium crushing and 85MPa for fine crushing) and the operating pressure of the electro-hydraulic valve (9.7MPa) greatly improve the system's response speed to iron overflow, preventing the crusher from being subjected to excessive impact and damage, thereby effectively improving the service life and production efficiency of the equipment.

[0074] 2. By setting an alarm mechanism, an alarm can be triggered in a timely manner when the power exceeds 570kw for more than 3 seconds, and a warning will be issued when there is an abnormality at the discharge port, ensuring that the operator can confirm the abnormality and take corresponding emergency measures within 2 minutes. This mechanism improves the response speed, avoids iron parts from entering the crushing chamber and repeatedly passing iron, thereby ensuring the continuity of production.

[0075] 3. By establishing a clear fixed-position operation procedure and implementing central control operation, the location of iron parts can be accurately locked, preventing them from entering other warehouses or repeatedly entering the crusher. Central control operators can adjust the position of the trolley and stop the downstream belt to ensure that the iron parts do not flow to other places. This not only avoids equipment damage, but also improves the efficiency and accuracy of post-iron processing and reduces the possibility of human error.

[0076] 4. By setting the iron-collecting position downstream of the 18# conveyor belt, operators can perform iron-collecting operations from a relatively safe location. Simultaneously, by controlling the rotation speed of the feed conveyor belt to maintain a low belt speed, operators can more accurately identify and collect iron pieces. Iron-collecting speed control and safety measures (such as operators stopping the machine by pulling a rope or using the emergency stop button) effectively avoid safety risks for operators, improving both the efficiency and safety of iron-collecting.

[0077] 5. After an iron spill occurs, promptly inspect the equipment, including components such as the return oil filter, eccentric assembly, thrust assembly, moving and fixed cone liners, and cutting ring. This will enable timely detection and repair of potential damage caused by the iron spill. Through meticulous inspection, long-term damage caused by iron residue can be prevented, ensuring that the equipment is quickly repaired after an iron spill, thus avoiding production interruptions or wider equipment damage due to equipment failure.

[0078] This invention significantly improves the safety and stability of the production line by refining the iron-passing control process of the crusher. The detailed operation process, real-time data monitoring, and timely handling mechanism for anomalies effectively prevent equipment damage and safety accidents, ensuring the smooth operation of the production process. This not only improves production efficiency but also reduces risks and hidden dangers in the production process, providing mining enterprises with a safer and more intelligent crusher operating environment.

[0079] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A novel operating method for controlling iron flow in a crusher, characterized in that, include: Step 1: Obtain the working pressure of the shear pipe in the overload protection system of the crusher; Step 2: Set the working pressure of the shear tube; Step 3: Reset the operating pressure limit of the electro-hydraulic valve of the over-iron protection system; Step 4: Set up an over-iron alarm mechanism based on the crusher's power and discharge port data; Step 5: When the iron overload alarm is triggered, notify the operator to lock the hopper and remove the iron parts that have fallen into the crusher; Step 6: Stop the crusher and inspect it to determine if there is any damage.

2. The novel operation method for controlling iron passage in a crusher according to claim 1, characterized in that, In step 2, the shearing pressure of the medium crushing tube is adjusted from 95 MPa to 60 MPa, and the shearing pressure of the fine crushing tube is adjusted from 95 MPa to 85 MPa.

3. A novel operating method for controlling iron passage in a crusher according to claim 1, characterized in that, In step 3, the operating pressure limit of the electrically controlled pressure relief valve is adjusted to 9.7 MPa.

4. A novel operating method for controlling iron passage in a crusher according to claim 1, characterized in that, In step 4, when the power of the crusher reaches 570kw or more and lasts for more than 3 seconds, the crusher overload occurs; when the hydraulic pressure of the crusher exceeds the preset operating range, the crusher overload occurs; when the discharge opening of the medium crushing crusher is greater than 55mm and the discharge opening of the fine crushing crusher is greater than 27mm, the crusher overload occurs.

5. A novel operating method for controlling iron passage in a crusher according to claim 1, characterized in that, In step 5, when the iron overload alarm is triggered, the operator in the central control room is notified to lock the hopper within 1 minute. At the same time, the position of the trolley is adjusted to move it to the lowest position of the hopper, and the operation of the downstream conveyor belt of the hopper is stopped to prevent iron parts from flowing into other warehouses.

6. A novel operating method for controlling iron passage in a crusher according to claim 1, characterized in that, In step 6, the shutdown inspection includes checking the return oil filter, the eccentric assembly and thrust assembly, the moving and fixed cone liners, the cutting ring, the coupling, and the clearance between the upper and lower frames.

7. A novel operating method for controlling iron passage in a crusher according to claim 6, characterized in that, In step 6, check if the return oil filter screen is clogged with iron filings or debris; check if the eccentric assembly and thrust assembly are damaged; check if the moving and fixed cone liners and cutting ring are damaged or cracked, and if there are any iron parts remaining in the crushing chamber; check if the coupling is seized; check if the gap between the upper and lower frames exceeds 0.07mm.

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