Intelligent gyratory crushing station

Abstract

An intelligent gyratory crushing station relates to the technical field of material crushing equipment and comprises a gyratory crusher and an intelligent sensing feedback, decision making, operation and maintenance and interconnection and intercommunication system. The gyratory crusher comprises a crusher body and a discharge conveyor; the intelligent sensing feedback system comprises an equipment monitoring module, a technological process monitoring module and a material state monitoring module, and is used for realizing crushing equipment monitoring, technological process monitoring and material state monitoring; the intelligent decision-making system is used for dynamically adjusting operation parameters of the crushing equipment according to a monitoring result of the intelligent sensing feedback system; the intelligent operation and maintenance system is used for detecting the health state of the crushing equipment; and the interconnection and intercommunication system is used for carrying out interconnection and intercommunication with the upstream mining operation equipment and the downstream ore grinding operation equipment to realize collaborative operation. The technical problems that the production efficiency is influenced, the labor intensity is high, predictive maintenance cannot be realized, and the equipment operation rate is influenced due to the fact that an existing crushing station needs to manually detect large materials can be solved.

Description

Technical Field

[0001] This invention relates to the field of material crushing equipment technology, specifically to an intelligent gyratory crushing station. Background Technology

[0002] Crushing plants are widely used in the mining industry. When irregular large pieces of material or debris in the material to be crushed enter the crushing plant, it will cause blockage. Once the blockage occurs, it is necessary to stop the machine and manually clear it, which will affect the operating efficiency of the entire crushing system and even the entire production line.

[0003] Currently, monitoring of large materials relies on manual observation. Workers identify large pieces and use a breaker to break them up to prevent blockages. This method not only severely impacts production efficiency but also involves significant manual labor. Furthermore, current equipment maintenance is primarily reactive, failing to provide predictive maintenance and directly affecting equipment uptime. Summary of the Invention

[0004] The purpose of this invention is to provide an intelligent gyratory crushing station that can solve the technical problems of existing crushing stations requiring manual inspection of large materials, which affects production efficiency and labor intensity, and the inability to achieve predictive maintenance, which affects equipment uptime.

[0005] To achieve the above objectives, the present invention adopts the following technical solution.

[0006] An intelligent gyratory crushing station includes a gyratory crusher, an intelligent sensing and feedback system, an intelligent decision-making system, an intelligent operation and maintenance system, and an interconnection system.

[0007] The gyratory crusher includes a crusher body for crushing ore and a discharge conveyor for transporting the crushed ore. The intelligent sensing feedback system includes an equipment monitoring module, a process monitoring module, and a material status monitoring module, used to monitor the crushing equipment, process, and material status. The intelligent decision-making system is used to dynamically adjust the operating parameters of the crushing equipment based on the monitoring results of the intelligent sensing feedback system. The intelligent operation and maintenance system is used to detect the health status of the crushing equipment. The interconnection system is used to interconnect with upstream mining equipment and downstream grinding equipment to achieve collaborative operation.

[0008] Furthermore, the material status monitoring module includes an infeed monitoring component and an outfeed monitoring component.

[0009] The feed monitoring component includes a first camera and a first data processing unit. The first camera is located above the crusher body and is used to acquire image information of the ore in the ore hopper and the upper hopper. The first data processing unit is used to analyze in real time whether there are large pieces of ore in the ore hopper and whether there is bridging or overflow in the upper hopper based on the image information acquired by the first camera. The discharge monitoring component includes a second camera and a second data processing unit. The second camera is located above the discharge conveyor and is used to acquire image information of the ore on the discharge belt. The second data processing unit is used to analyze the particle size of the discharged ore based on the image information from the second camera in real time.

[0010] Furthermore, the equipment monitoring module includes temperature, current, and pressure sensors on the crusher body, used to collect real-time data on the crusher body's start-up and shutdown status, operating temperature, operating current, power, and oil pressure parameters.

[0011] Furthermore, the process monitoring module includes a main shaft height signal acquisition device, a crusher speed signal acquisition device installed on the crusher body, and a conveying frequency signal acquisition device installed on the discharge conveyor, which are used to collect the main shaft speed, main shaft height, and conveying frequency of the crusher body in real time.

[0012] Furthermore, the intelligent decision-making system can dynamically adjust the main shaft height, main shaft speed, and conveying frequency of the discharge conveyor based on data from the intelligent sensing feedback system, thereby improving the crushing effect and efficiency.

[0013] Furthermore, the intelligent operation and maintenance system includes a vibration detection module, an oil detection module, and a fault diagnosis module. The vibration detection module includes vibration sensors installed on the crusher body, and the oil detection module includes moisture sensors, viscosity sensors, oil temperature sensors, particle sensors, and wear sensors installed in the crusher lubrication station. The fault diagnosis module has a built-in diagnostic algorithm library and a health assessment model, which can perform fault analysis, alarm triggering, and maintenance suggestion generation based on the detection data from the vibration detection module and the oil detection module.

[0014] The operation method of the above-mentioned intelligent gyratory crushing plant includes the following steps: S1. When the material status monitoring module detects that there are large pieces of ore in the ore hopper, or that there is bridging or overflowing in the upper hopper, an early warning signal is sent to the intelligent decision system. S2. When the discharge monitoring component in the material status monitoring module identifies the change in the particle size of the ore conveyed by the discharge belt, it sends the discharge particle size change information to the intelligent decision system. S3. The intelligent decision-making system, based on the signal from the feed monitoring component, first determines whether there are large pieces of material in the hopper of the mining truck or whether there is bridging or overflowing in the upper hopper. If there are large pieces of material in the hopper of the mining truck, the linkage of the mining truck stops the current feeding and controls the crusher body to reduce the speed to allow the large pieces of material to pass smoothly. If there is bridging or overflowing in the upper hopper, the linkage of the mining truck feeding system stops feeding and drives the crusher hammer to crush the material according to the preset interval time, and intelligently adjusts the crusher speed to match it. S4. The intelligent decision-making system, based on the ore particle size change signal identified by the discharge monitoring component, adaptively adjusts the height of the crusher spindle by raising or lowering it through the controller, thereby ensuring that the ore particle size after crushing is within the preset range. S5, the intelligent operation and maintenance system adopts corresponding maintenance strategies based on the data fed back by the vibration detection module and the oil detection module. According to the detection data and parameter changes generated by the detection module, the system uses the built-in diagnostic algorithm library and health assessment model of the fault diagnosis module to diagnose and predict the current health status of the equipment. When the result shows that the probability of failure is high, it prompts to perform shutdown maintenance. S6. The interconnection system connects with upstream mining equipment and downstream grinding equipment, collects operational data of upstream and downstream equipment and processes, and provides feedback on relevant suggestions to achieve production data sharing and collaborative operations.

[0015] By adopting the above technical solution, the present invention has the following beneficial effects: 1. This invention can automatically identify large pieces of material and stop feeding and reduce the speed of the crusher body after the large pieces of material enter the crusher body, so that the large pieces of material can be smoothly transferred without much human intervention, thus ensuring operating efficiency and reducing the labor intensity of workers. 2. This invention can dynamically adjust the height of the crusher spindle according to the particle size of the crushed ore to ensure stable crushing effect, reduce index fluctuations and extend liner life. 3. This invention can detect equipment vibration and oil quality in real time, enabling predictive maintenance and ultimately achieving unmanned and stable production. Attached Figure Description

[0016] Figure 1 This is a schematic diagram illustrating the functional implementation principle of the present invention.

[0017] Figure 2 This is a schematic diagram of the overall structural layout of the present invention.

[0018] Figure descriptions: 11. Crusher body; 111. Upper hopper; 112. Lower hopper; 113. Crusher lubrication station; 12. Discharge conveyor; 211. First camera; 212. First data processing unit; 221. Second camera; 222. Second data processing unit; 223. Supplemental lighting; 3. Intelligent decision-making system; 4. Intelligent operation and maintenance system; 411. Vibration sensor; 421. Moisture sensor; 422. Viscosity sensor; 423. Oil temperature sensor; 424. Particle sensor; 425. Wear sensor; 5. Crusher hammer; 6. Mining truck. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the present invention clearer, the features and performance of an intelligent gyratory crushing station of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0020] Please see the appendix Figure 1 and 2 An intelligent gyratory crushing station includes a gyratory crusher, an intelligent sensing and feedback system, an intelligent decision-making system, an intelligent operation and maintenance system, and an interconnection system.

[0021] The gyratory crusher includes a crusher body 11 for crushing ore and a discharge conveyor 12 for transporting the crushed ore. The crusher body 11 includes an upper hopper 111, a lower hopper 112 and a crusher lubrication station 113. The discharge conveyor 12 is a belt conveyor and is capable of frequency conversion speed regulation.

[0022] The intelligent sensing and feedback system includes an equipment monitoring module, a process monitoring module, and a material status monitoring module, which are used to monitor crushing equipment, process, and material status.

[0023] The equipment monitoring module includes temperature, current, and pressure sensors on the crusher body 11, used to collect real-time data on the start / stop status, operating temperature, operating current, power, and hydraulic pressure parameters of the crusher body 11. The process monitoring module includes a main shaft height signal acquisition device and a crusher speed signal acquisition device installed on the crusher body 11, and a conveying frequency signal acquisition device installed on the discharge conveyor 12, used to collect real-time data on the main shaft speed and height of the crusher body 11, as well as the conveying frequency of the discharge conveyor 12.

[0024] The material status monitoring module includes a feed monitoring component and a discharge monitoring component. The feed monitoring component includes a first camera 211 and a first data processing unit 212. The first camera 211 is located above the crusher body 11 and is used to acquire image information of the ore in the ore hopper 6 and the upper hopper 111. The first data processing unit 212 is used to analyze in real time whether there are large pieces of ore in the ore hopper 6 and whether there is bridging or overflowing in the upper hopper 111 based on the image information acquired by the first camera 211.

[0025] The discharge monitoring component includes a second camera 221 and a second data processing unit 222. The second camera 221 is positioned above the discharge conveyor 12 and is used to acquire image information of the ore on the discharge conveyor belt. The second data processing unit 222 is used to analyze the particle size of the discharged ore in real time based on the image information from the second camera 221. The discharge monitoring component also includes a supplementary light 223 for providing supplementary lighting for the second camera 221.

[0026] The intelligent decision-making system 3 is used to dynamically adjust the operating parameters of the crushing equipment based on the monitoring results of the intelligent sensing feedback system. The intelligent decision-making system 3 can dynamically adjust the main shaft height and main shaft speed of the crusher body 11, as well as the conveying frequency of the discharge conveyor 12, based on the data from the intelligent sensing feedback system, in order to improve the crushing effect and crushing efficiency.

[0027] The intelligent decision-making system 3 can also control the conveying efficiency of the discharge conveyor 12 based on the degree of material accumulation in the lower silo 112, so as to keep the material in the lower silo 112 within a reasonable range.

[0028] The intelligent operation and maintenance system 4 is used to detect the health status of the crushing equipment. The intelligent operation and maintenance system 4 includes a vibration detection module, an oil detection module, and a fault diagnosis module. The vibration detection module includes a vibration sensor 411 installed on the crusher body 11. The oil detection module includes a moisture sensor 421, a viscosity sensor 422, an oil temperature sensor 423, a particle sensor 424, and a wear sensor 425 installed in the crusher lubrication station 113. The fault diagnosis module has a built-in diagnostic algorithm library and a health assessment model, which can perform fault analysis, alarm triggering, and maintenance suggestion generation based on the detection data from the vibration detection module and the oil detection module.

[0029] The interconnection system is used to interconnect with upstream mining equipment and downstream grinding equipment to achieve collaborative operation.

[0030] In practical implementation, the purpose of this invention is to provide an intelligent crushing station capable of automatically identifying the feeding and discharging conditions of the crusher, adjusting process parameters such as the main shaft height and rotational speed of the crusher body 11, and the conveying frequency of the discharge conveyor 12 according to the feeding and discharging conditions, and performing health diagnosis and autonomous analysis based on vibration and oil detection data of the crusher body 11. This intelligent crushing station has a high degree of autonomy, effectively preventing damage to the crusher from large materials, achieving autonomous predictive maintenance of the crusher, and ultimately realizing unmanned, stable production, reducing performance fluctuations, and extending liner life.

[0031] like Figure 1 As shown, the intelligent sensing feedback system includes an equipment monitoring module, a process monitoring module, and a material status monitoring module, used to realize equipment monitoring, crushing process sensing, and intelligent material status sensing. The equipment monitoring module monitors the equipment's operating status in real time online using basic sensors such as temperature, current, and pressure installed on the crusher body 11, including parameters such as equipment start / stop status, equipment temperature, operating current, power, and oil pressure. The process monitoring module senses the operation of the crushing process online using position sensors, speed sensors, and acceleration sensors installed on the crusher body 11 and the discharge conveyor 12, including spindle speed, spindle height, and belt conveyor frequency.

[0032] The material status monitoring module is used to detect key parameters of the crushing process online. It includes a feed monitoring component and a discharge monitoring component, which are used for feed particle size, bridging or bridging detection and discharge particle size detection, respectively.

[0033] The first camera 211 in the feed monitoring component is used to acquire images of the input material. The images are transmitted to the first data processing unit 212, which processes them and identifies large pieces in the material. If large pieces are present, a signal indicating their presence is emitted. The intelligent decision-making system 3 can receive the signal from the feed monitoring component. When a signal indicating a large piece is received, the intelligent decision-making system 3 automatically issues a warning, stops the material feeding from the ore car 6, and simultaneously sends a command to the crusher body 11 to change the crusher speed, ensuring a smooth transition for large pieces of material. If bridging or overflow is detected in the upper hopper 111, a signal is sent to the crusher hammer 5, which automatically crushes the large pieces of material. After the relevant issues are confirmed and resolved, the original working state is restored.

[0034] The second camera 221 in the discharge monitoring component is used to acquire images of the material on the belt of the discharge conveyor 12. The images are transmitted to the second data processing unit 222, which processes them and identifies the particle size distribution of the ore in the material. If the particle size changes, a change signal is issued. The intelligent decision system 3 can receive the signal issued by the discharge monitoring component. When a change in particle size is detected, the intelligent decision system 3 can automatically issue an early warning and control the crusher body 11 to change the height of the main shaft to control the discharge particle size, replacing manual adjustment and maintaining stable production.

[0035] The vibration detection module of the intelligent operation and maintenance system 4 includes a vibration sensor 411 installed on the crusher body 11. Data acquisition is achieved via a wired acquisition station, and edge services integrate, cache, and convert the data according to protocols. The data is then transmitted to the intelligent operation and maintenance system 4 via MQTT through a 4G module, enabling data storage, algorithm application, data display, and graph analysis. The oil detection module connects the monitoring system to the return oil pipeline of the gyratory crusher lubrication station 113. It is used for online data acquisition of lubricating oil, periodic real-time monitoring, and real-time online monitoring of oil parameters such as temperature, viscosity, density, dielectric constant, moisture content, and ferromagnetic and non-ferrous particles. It analyzes the changes in various indicators of the lubricating oil in use in real time and uploads the data to the intelligent operation and maintenance system 4.

[0036] The intelligent operation and maintenance system 4 receives data from the vibration detection module and the oil detection module. The fault diagnosis module, based on the system's diagnostic algorithm library, provides alarm-triggered diagnosis. Alarm-triggered diagnosis can determine the specific fault after an equipment alarm occurs, thus providing maintenance personnel with support for maintenance decisions, replacing manual inspections, and preventing major equipment accidents.

[0037] The interconnection system is used to connect with upstream mining equipment and downstream grinding equipment, and to promptly feed back changes in upstream and downstream operating conditions and demands to the intelligent sensing feedback system, so as to achieve coordinated and optimized control of upstream and downstream mining, crushing and grinding.

[0038] like Figure 2 As shown, the intelligent sensing feedback system acquires images of the material on the ore car 6 through the first camera 211 in the feed monitoring component. The image information is transmitted to the first data processing unit 212, which processes the data and identifies large pieces in the material. If large pieces are present, a signal is issued. Upon receiving the large piece signal from the feed monitoring component, the intelligent decision system 3 automatically issues a warning, stops the material feeding from the ore car 6, and sends a command to the crusher body 11 to reduce the crusher speed, ensuring a smooth transition of large pieces of material. If the upper hopper 111 bridge or bridle is detected, the intelligent decision system 3 sends a command to the crusher hammer 5, which automatically crushes the large pieces of material.

[0039] The second camera 221 and supplementary light 223 in the discharge monitoring component acquire images of the material on the belt of the discharge conveyor 12. The image information is transmitted to the second data processing unit 222, which processes the data and identifies the particle size distribution of the ore in the crushed material. If there is a change in particle size, a change signal is issued. The intelligent decision system 3 can receive the change signal issued by the discharge monitoring component and issue instructions to the crusher body 11. When the discharged ore particle size is too coarse, the main shaft height is increased; when the discharged ore particle size is too fine, the main shaft height is decreased.

[0040] In the intelligent operation and maintenance system, the vibration sensor 411 of the vibration detection module is used to collect vibration data of the crusher body 11. The vibration data is transmitted to the fault diagnosis module. The fault diagnosis module combines the vibration data with monitoring data from other sensors, processes the data, and if abnormal vibration is detected, it issues a maintenance signal. The moisture sensor 421, viscosity sensor 422, oil temperature sensor 423, particle sensor 424, and wear sensor 425 in the oil detection module are used to collect oil data from the crusher. The oil data is transmitted to the intelligent operation and maintenance module 4. After analysis, if abnormal oil is detected, it issues a signal requiring equipment maintenance and generates a health assessment report.

[0041] The interconnection system is capable of interconnecting with upstream mining equipment and downstream grinding equipment, collecting operational data of upstream and downstream equipment and processes, and providing feedback on relevant suggestions to achieve production data sharing and collaborative operations.

[0042] This invention can adaptively detect and handle abnormal situations during the operation of the crushing plant and adaptively adjust the operating parameters. At the same time, it can autonomously diagnose the health status, realize the unmanned operation of the crushing plant, effectively avoid the impact of large materials on subsequent processes, ensure the qualified rate of the particle size of the discharged products, and also realize predictive maintenance of the equipment.

[0043] It should be noted that the parts not described in detail in this solution are all prior art. The above embodiments are only used to illustrate the present invention, but the present invention is not limited to the above embodiments. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. An intelligent gyratory crushing station, characterized in that: Including a gyratory crusher, an intelligent sensing and feedback system, an intelligent decision-making system (3), an intelligent operation and maintenance system (4), and an interconnection system. The gyratory crusher includes a crusher body (11) for crushing ore and a discharge conveyor (12) for transporting the crushed ore out. The intelligent sensing and feedback system includes an equipment monitoring module, a process monitoring module, and a material status monitoring module, used to monitor crushing equipment, process, and material status. The intelligent decision-making system (3) is used to dynamically adjust the operating parameters of the crushing equipment based on the monitoring results of the intelligent sensing feedback system. The intelligent operation and maintenance system (4) is used to detect the health status of the crushing equipment. The interconnection system is used to interconnect with upstream mining equipment and downstream grinding equipment to achieve collaborative operation.

2. The intelligent gyratory crushing station as described in claim 1, characterized in that: The material status monitoring module includes an infeed monitoring component and an outfeed monitoring component. The feed monitoring component includes a first camera (211) and a first data processing unit (212). The first camera (211) is located above the crusher body (11) and is used to acquire image information of the ore in the ore hopper (6) and the upper hopper (111). The first data processing unit (212) is used to analyze in real time whether there are large pieces of ore in the ore hopper (6) and whether there is bridging or overflowing in the upper hopper (111) based on the image information acquired by the first camera (211). The discharge monitoring component includes a second camera (221) and a second data processing unit (222). The second camera (221) is located above the discharge conveyor (12) and is used to acquire image information of the ore on the discharge belt. The second data processing unit (222) is used to analyze the particle size of the discharged ore in real time based on the image information of the second camera (221).

3. The intelligent gyratory crushing station as described in claim 1, characterized in that: The equipment monitoring module includes temperature, current and pressure sensors on the crusher body (11) for real-time acquisition of the crusher body (11) start-up and shutdown status, operating temperature, operating current, power and oil pressure parameters.

4. The intelligent gyratory crushing station as described in claim 1, characterized in that: The process monitoring module includes a main shaft height signal collector, a crusher speed signal collector, and a conveying frequency signal collector on the crusher body (11) and the discharge conveyor (12), which are used to collect the main shaft speed and main shaft height of the crusher body (11) and the conveying frequency of the discharge conveyor (12) in real time.

5. The intelligent gyratory crushing station as described in claim 1, characterized in that: The intelligent decision-making system (3) can dynamically adjust the main shaft height, main shaft speed and conveying frequency of the crusher body (11) and the discharge conveyor (12) based on the data of the intelligent sensing feedback system, so as to improve the crushing effect and crushing efficiency.

6. The intelligent gyratory crushing station as described in claim 1, characterized in that: The intelligent operation and maintenance system (4) includes a vibration detection module, an oil detection module and a fault diagnosis module. The vibration detection module includes a vibration sensor (411) installed on the crusher body (11). The oil detection module includes a moisture sensor (421), a viscosity sensor (422), an oil temperature sensor (423), a particle sensor (424), and a wear sensor (425) installed in the crusher lubrication station (113). The fault diagnosis module has a built-in diagnostic algorithm library and a health assessment model, which can perform fault analysis, alarm triggering and maintenance suggestions based on the detection data of the vibration detection module and the oil detection module.

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