Material processing system and drive for a mobile material processing system

Abstract

The invention relates to a drive for a mobile material processing plant (1), in particular for a rock crusher, comprising an internal combustion engine (12) which drives a mechanical drive train (14) on the drive side thereof, wherein the drive train (14) has an output side with at least one output, wherein at least one crushing unit (10) and preferably a generator (18) for generating electrical energy, in particular for use in the material processing plant (1), and / or at least one hydraulic system with a hydraulic pump (19.1, 19.2) are driven by means of the output(s). For the benefit of optimized operation of the material processing plant, the invention provides that the internal combustion engine (12) is coupled to the drive train (14) via a switchable transmission (13) with a variable transmission ratio.

Description

[0001] The invention relates to a drive for a mobile material processing plant, in particular for a rock crusher, having an internal combustion engine which drives a drive train on its drive train drive side, wherein the drive train has a drive train output side with at least one output, wherein at least one generator for generating electrical energy, in particular for use in the material processing plant, at least one hydraulic system with a hydraulic pump and a crushing unit are driven by means of the output(s).

[0002] Such material processing plants according to the invention, for example, mobile crushing machines, can be equipped with a direct drive. The direct drive offers maximum efficiency with a very compact and robust design. These properties are crucial for material processing plants, especially in contract crushing operations, and therefore place special demands on the drive of the crushing unit.

[0003] With direct drive, an internal combustion engine drives a mechanical drive train to which a clutch is assigned. This clutch can operate using all common clutch methods: friction or positive locking, according to the Föttinger principle or other hydraulic power transmission, or combinations of the aforementioned methods. This clutch is used to engage or disengage the crushing unit. The clutch, for example, drives a belt drive to achieve a suitable crusher speed through the belt drive transmission. Preferably, the mechanical drive train also drives at least one hydraulic pump, which in turn drives one or more auxiliary consumers, such as fans, hydraulic drives, or hydraulic cylinders. These hydraulic pumps can also drive larger consumers, such as drives for conveyor belts, chutes, etc.In highly efficient direct drives, the mechanical drive train also drives at least one power generator (as a replacement or in addition to the hydraulic pumps), which supplies electrical energy to powerful auxiliary devices such as conveyor belts, chutes, screens, and pump drives. Using electric drives for these auxiliary devices instead of hydraulic drives significantly increases machine efficiency.

[0004] In production, crushing machines typically operate in a user-defined application with a constant engine speed and a crusher speed. The crusher speed is preferably based on one or more of the following application requirements: Size of the material to be crushed, e.g. rock material, material properties of the material to be crushed, e.g. rock material, desired final material properties, etc.

[0005] Depending on the type of crushing unit, the crusher speed can be adjusted to meet the requirements of the application. Likewise, the crusher requires a specific drive power depending on the application. The required drive power can vary significantly depending on the application, even at the same crusher speed.

[0006] In current direct-drive crushers, a fixed gear ratio is provided between the combustion engine and the crusher, which is usually determined by the gear ratio of the drive train and the belt drive. The crusher speed is thus controlled as needed by adjusting the speed of the combustion engine. The design is such that the combustion engine can deliver the highest possible power in the required speed range, ensuring sufficient performance even in applications with high power requirements.

[0007] The gear ratios of the drive train to the hydraulic pumps and generator are also typically fixed and are selected so that these components operate within their target operating range for their performance applications. For example, the generator must deliver a specific grid frequency, which must be matched to the drives being operated. The output grid frequency is coupled to the generator's rotational frequency and thus to the gear ratio of the drive train between the combustion engine and generator. Contractor machines, in particular ("contract breakers"), operate in very diverse applications that sometimes have very different performance requirements, even with identical combustion engine speeds. Such machines often operate for long periods in applications that require only a fraction of their maximum possible power.

[0008] Typically, combustion engine maps offer comparatively poor efficiency in the lower load range, and high engine speeds also lead to poorer efficiency.

[0009] State-of-the-art material crushing systems cannot counteract this because the operating speed of the combustion engine is designed for maximum performance and is also tied to the target speed of the crusher. In many applications, this leads to unnecessarily high fuel consumption and CO2 emissions.

[0010] US 10,335,800 B2 describes a material crushing system, in particular a rock crusher, comprising an internal combustion engine. This engine drives a hydraulic system. The hydraulic system feeds various hydraulic motors. One of these hydraulic motors drives a crushing unit. When the load conditions of the crushing unit change, a control device regulates the speed of the internal combustion engine, while maintaining the speed of the crushing unit. For this purpose, the flow through the hydraulic motor of the crushing unit is adjusted accordingly.

[0011] EP 3 251 748 B1 discloses a material crushing system using an internal combustion engine as the drive unit. The internal combustion engine drives a crushing unit via a drive train. Furthermore, the internal combustion engine also drives a generator, which generates electrical energy during operation of the internal combustion engine. This energy is stored in a storage unit. An auxiliary motor is assigned to the drive train. This auxiliary motor is driven by an electric motor and provides additional mechanical work to the drive train. If additional mechanical energy must be provided in the drive train due to power peaks that the internal combustion engine cannot cover, these power peaks can be covered by the auxiliary motor. In this way, the power in the drive train can be evened out. This system is complex and prone to failure.

[0012] The object of the invention is to optimize the operation of the combustion engine in a material processing plant of the type mentioned at the beginning, even under changing power requirements, while at the same time ensuring reliable operation of the crushing unit.

[0013] This task is solved by connecting the combustion engine to the drive train via a switchable gearbox with a variable gear ratio.

[0014] By means of the manual transmission between the combustion engine and the drive train, the possible working range and thus the characteristic map range of the combustion engine can be significantly extended, while the output speed of the drive train for the crusher is maintained, or essentially maintained.

[0015] This allows the selectable transmission to be set to the appropriate gear ratio for the specific application, bringing the engine speed to a suitable operating point. This can save fuel and CO2 emissions. At the same time, the crushing unit runs at a constant speed, or within a certain range of a speed range, depending on the selected transmission ratio, thus maintaining optimal crushing results.

[0016] In other words, the combustion engine can be designed to operate at a lower speed range while maintaining the same absolute required power, but at a higher load. The engine map offers significantly better efficiency in this case.

[0017] According to a preferred variant of the invention, the shiftable transmission can be provided with at least two fixed gear stages. This represents a particularly simple and robust mechanical solution.

[0018] Alternatively, the switchable transmission can also be a continuously variable transmission. This allows for a nearly ideal adjustment of the combustion engine's operating point depending on the power requirements of the crushing unit.

[0019] If the material processing plant according to the invention is a mineral processing facility, for example, a rock crusher, it can advantageously be provided that the gear ratio (i = input speed / output speed) of the switchable transmission is variable in the range between i = 0.5:1 and i = 1.5:1. This essentially covers the requirements placed on such a machine for different applications.

[0020] If the gear ratio of the selectable transmission is selected such that, when the input speed at the transmission input changes, the output speed at the transmission output of the selectable transmission or at the input of the drive train remains unchanged within a deviation of + / - 10%, preferably + / - 5%, then this ensures that the drive train operates at essentially the same speed even when the input speed of the combustion engine changes. This can ensure that the crushing unit and / or the other units connected to the drive train via assigned outputs can also be operated at essentially the same speed. In particular, it may be the case that no additional speed adjustments need to be made to optimally drive the crushing unit or the additional units, which significantly simplifies the technical effort.

[0021] If the combustion engine is connected to the shiftable transmission via a clutch, the shiftable transmission can be shifted to the appropriate gear during crushing operation. It is also conceivable to use a powershift transmission that can be shifted without the clutch, for example, a quick-shifter speed adjustment.

[0022] A possible variant of the invention may be such that the mechanical drive train has a main shaft, and that the generator, the hydraulic pump, and / or the crushing unit are coupled to the main shaft. Thus, the main shaft represents a mechanically fixed connection of the drive train between the combustion engine and these units.

[0023] In particular, it can be provided that the main shaft is connected to a crusher clutch via a drive shaft, and that the crusher clutch is connected directly or indirectly to the crushing unit at its output. This allows the crushing unit to be decoupled from the drive train as needed. Nevertheless, the drive train can continue to be operated by the combustion engine in order to continue to utilize additional functions provided by the units connected to the drive train.

[0024] According to a conceivable variant of the invention, it can be provided that the at least one hydraulic pump, the generator, and / or a cooling fan for dissipating the heat loss of the combustion engine is / are connected to the drive train, in particular the main shaft, via an output associated with these functional units with a fixed, non-variable gear ratio. This supports a compact and robust design. Because the drive train runs at the same or approximately the same output speed in the different gear positions of the shiftable transmission, these units are then also operated at an optimal or approximately optimal operating point. This further improves the efficiency of the system.

[0025] If the drivetrain is provided with an additional drive side via which a drive, in particular an electric motor, drives the drivetrain, then the drivetrain can be supplied with additional drive power. In this case, the electric motor can be provided to assist the combustion engine. However, it is preferably provided that the electric motor replaces the combustion engine in one operating state, for which purpose the engine can, for example, be decoupled from the drivetrain.

[0026] The object of the invention is also achieved with a mineral processing device with a drive according to one of claims 1 to 13.

[0027] The invention is explained in more detail below with reference to an embodiment illustrated in the drawings. They show: Figure 1 is a schematic representation of a material processing plant 1 with a crushing unit 10 in side view and Figure 2 is a schematic representation of a drive of the material processing plant according to Figure 1 .

[0028] Figure 1 shows a material processing plant 1 in the form of a crushing plant with a material processing unit in the form of a crushing unit 10. The material processing plant 1 is designed as a mobile material processing plant 1 and therefore has chassis 1.5. However, it is also conceivable that the material processing plant 1 is a stationary material processing plant 1.

[0029] The material processing system 1 comprises a chassis 1.1, which supports the machine components or at least some of the machine components. At its rear end, the chassis 1.1 can preferably have a boom 1.2. A material feed area is formed in the region of the boom 1.2.

[0030] The material feed area may comprise a feed hopper 2 and a material feed device 9.

[0031] The feed hopper 2 can be formed at least partially by hopper walls 2.1, which extend in the longitudinal direction of the material processing system 1, and a rear wall 2.2 extending transversely to the longitudinal direction. The feed hopper 2 leads to the material feed device 9.

[0032] The material feed device 9 can, as shown in the present embodiment, have a conveyor trough that can be driven by a vibration drive. Material to be shredded can be fed into the material processing system 1 via the feed hopper 2, for example, using a wheel loader, and placed onto the conveyor trough.

[0033] From the conveyor chute, the material to be shredded enters the area of ​​a screening unit 3. This screening unit 3 can also be referred to as a pre-screening arrangement. At least one screening deck 3.1, 3.2 is arranged in the area of ​​the screening unit 3. In the present embodiment, two screening decks 3.1, 3.2 are used.

[0034] A partial fraction of the material to be crushed is screened out on the upper screen deck 3.1. This partial fraction already has a sufficient grain size and no longer requires crushing in the material processing plant 1. Therefore, this screened partial fraction can be routed past the crushing unit 10 in a bypass channel 3.5.

[0035] If a second screen deck 3.2 is used in the screening unit 3, an additional fine particle fraction can be screened from the fraction generated below screen deck 3.1. This fine particle fraction can be conveyed below screen deck 3.2 to a side discharge belt 3.4. From the side discharge belt 3.4, the fine particle fraction is diverted and conveyed to a stockpile 7.2 located to the side of the machine.

[0036] How Figure 1As illustrated, the screening unit 3 can be a vibrating screen with a screen drive 3.3. The screen drive 3.3 sets the screen deck 3.1 and / or the screen deck 3.2 in vibrational motion. Due to the inclined arrangement of the screen decks 3.1, 3.2 and in conjunction with the vibrational motions, material is transported on the screen decks 3.1, 3.2 toward the crushing unit 10 or the bypass channel 3.5.

[0037] The material to be crushed coming from the screen deck 3.1 is fed to the crushing unit 10, as Figure 1 can be recognized.

[0038] The crushing unit 10 can be designed, for example, in the form of a rotary impact crushing unit or a jaw crushing unit. As shown in Figure 1 If a rotary impact crushing unit is used, it has an impact rotor 11 which is driven by an internal combustion engine 12. In Figure 1The rotation axis 17 of the impact rotor 11 runs horizontally in the direction of the image depth. The impact rotor 11 is housed in a crushing chamber 16.1.

[0039] If a jaw crusher unit is used, two crushing jaws are positioned opposite each other, enclosing a converging crushing shaft between them, which leads to a crushing gap.

[0040] The impact rotor 11 can, for example, be equipped with impact bars 11.2 on its outer circumference. Opposite the impact rotor 11, wall elements, preferably in the form of impact rockers 20, can be arranged. As the impact rotor 11 rotates, the material to be crushed is propelled outward by the impact bars 11.2. This material strikes the impact rockers 20 and is crushed due to the high kinetic energy. If the material to be crushed has a sufficient grain size to allow the material particles to pass through a crushing gap 15 between the impact rockers 20 and the radially outer ends of the impact bars 11.2, the crushed material leaves the crushing unit 10 via the crusher outlet 16.

[0041] It is conceivable that, in the area of ​​the crusher outlet 16, the crushed material coming from the crushing unit 10 is combined with the material coming from the bypass channel 3.5 and transferred to a belt conveyor 1.3. The belt conveyor 1.3 can be used to transport the material out of the working area of ​​the crushing unit 10.

[0042] As the drawings show, the belt conveyor 1.3 can comprise a continuously rotating conveyor belt having a load side 1.6 and a slack side 1.7. The load side 1.6 serves to collect and transport the crushed material falling from the crusher outlet 16 of the crushing unit 10. At the belt ends, the conveyor belt can be deflected between the load side 1.6 and the slack side 1.7 by means of deflection rollers 1.4. Guides, in particular support rollers, can be provided in the area between the deflection rollers 1.4 to change the conveying direction of the conveyor belt, give the conveyor belt a specific shape, and / or support the conveyor belt.

[0043] The belt conveyor 1.3 has a belt drive by means of which the belt conveyor 1.3 can be driven. The belt drive can preferably be arranged at the discharge end 1.9 or in the region of the discharge end 1.9 of the belt conveyor 1.3.

[0044] The belt conveyor 1.3 can be connected, for example by means of the belt drive, to a control device by means of a control line.

[0045] One or more additional belt conveyors 6 and / or a return conveyor 8 may be used, which essentially have the same design as the belt conveyor 1.3. In this respect, reference can be made to the above explanations.

[0046] A magnet 1.8 can be arranged above the load strand 1.6 in the area between the feed end and the discharge end 1.9. The magnet 1.8 can be used to lift iron parts from the crushed material and move them out of the conveying area of ​​the belt conveyor 1.3.

[0047] A secondary screening device 5 can be arranged downstream of the belt conveyor 1.3 in the transport direction. The secondary screening device 5 has a screening housing 5.1 in which at least one screening deck 5.2 is housed. A housing lower section 5.3 is formed below the screening deck 5.2, which serves as a collecting space for the material screened out at the screening deck 5.2.

[0048] The housing base 5.3 creates a spatial connection to another belt conveyor 6 via an opening. Here, the additional belt conveyor 6 forms its feed area 6.1, with the screened material in the feed area 6.1 being guided onto the load side of the additional belt conveyor 6. The additional belt conveyor 6 conveys the screened material to its discharge end 6.2. From there, the screened material is transferred to a stockpile 7.1.

[0049] The material not screened out on the screen deck 5.2 of the secondary screening device 5 is conveyed from the screen deck 5.2 to a stub belt 5.4. The stub belt 5.4 can also be designed as a belt conveyor, so that reference can be made to the explanations given above with regard to the belt conveyor 1.3. The transport direction of the stub belt 5.4 runs in Figure 1 in the direction of the image depth.

[0050] At its discharge end, the stub conveyor 5.4 transfers the unscreened material, also referred to as oversize, to a feed area 8.1 of the return conveyor 8. The return conveyor 8, which can be designed as a belt conveyor, conveys the oversize toward the feed hopper 2. At its discharge end 8.2, the return conveyor 8 transfers the oversize into the material flow, particularly into the material feed area. The oversize can then be re-fed to the crushing unit 10, where it can be crushed to the desired particle size.

[0051] Figure 2 shows a drive of the material processing plant 1 according to Figure 1 As this illustration illustrates, the drive comprises a mechanical drive train 14, which can be designed in particular as a transmission unit, for example, as a gear transmission. The drive train 14 can be provided with a main shaft that directly or indirectly drives units of the material processing system 1.

[0052] As the present example shows, it may be the case that the drive train 14, for example with a main shaft, drives a generator 18 on a drive train output side for generating electrical energy for use in the material processing plant 1.

[0053] The generated electrical energy can, for example, be used to supply electrical energy to a unit of the material processing system 1. For example, the electrical energy can be used to drive the undercarriages 1.5, at least one of the belt conveyors 1.3, the screen drive 3.3, the side discharge belt 3.4, the stub belt 5.4, the return conveyor 8, and / or the crushing unit 10.

[0054] It is also conceivable that at least one hydraulic pump 19.1, 19.2 of a hydraulic system can be driven by the drive train 14 on a drive train output side. The hydraulic pump 19.1, 19.2 can drive the carriages 1.5, at least one of the belt conveyors 1.3, the screen drive 3.3, the side discharge belt 3.4, the branch belt 5.4, and / or the return conveyor 8.

[0055] The internal combustion engine 12 is coupled to the mechanical drive train 14 on a drive train drive side via a switchable transmission 13. The switchable transmission 13 may be indirectly coupled to the internal combustion engine 12, for example, via a non-switchable clutch. Preferably, an elastic rubber coupling may be used, which Figure 2 is not shown in detail. Accordingly, the clutch can be used to connect / disconnect the internal combustion engine 12 from the drive train 14. In this case, the internal combustion engine 12 can be decoupled by means of the clutch to enable shifting of the switchable transmission 13 during operation of the internal combustion engine 12.

[0056] The switchable transmission 13 can be designed as a mechanical transmission, in particular as a gear transmission. The switchable transmission 13 can offer at least two gear ratio variants. It can be designed as a planetary bevel gear transmission (PKF), in particular also as a commercial vehicle transmission. It is also conceivable for the switchable transmission 13 to be a continuously variable transmission, for example, a transmission with pulleys of variable diameter. The use of a CVT (Continuously Variable Transmission) or an IVT (Infinitely Variable Transmission) is conceivable.

[0057] The switchable transmission 13 can be designed as a powershift transmission 13 or as a non-powershift transmission 13.

[0058] If the switchable transmission 13 is designed as a powershift transmission 13, a change in the gear ratio provided by the switchable transmission 13 can be achieved during operation of the internal combustion engine 12. Thus, the switchable transmission 13 can then be switched to a desired operating state during operation of the internal combustion engine 12.

[0059] Figure 2further illustrates that the drive train 14 drives a switchable crusher clutch 30 on its drive train output side by means of a drive shaft 31. On the output side, the crusher clutch 30 is connected via a transmission shaft 32 to a speed transmission 33 with a fixed gear ratio. The speed transmission 33 may be formed by a belt drive. For this purpose, a drive gear 33.1 may be connected to the output shaft 32, which drives an output gear 33.2 via a belt 33.2. The output gear 33.2 is connected in a rotationally fixed manner to a drive shaft 34, which drives the crusher 10.

[0060] During operation of the material processing plant 1, the combustion engine 12 drives the drive train 14 via the shiftable transmission 13. This also drives the generator 18 and / or at least one hydraulic pump 19.1, 19.2. Additionally, when the clutch 30 is engaged, the speed transmission 33 and thus the crusher 10 are also driven via the drive train 14.

[0061] The crusher 10 thus runs at a specific speed that is suitable for the crushing task at hand.

[0062] Now, it may be the case that during this crushing task, the combustion engine 12 is operated at a speed / power ratio that is not fuel-efficient. This results in unnecessarily high fuel consumption and thus unnecessary CO2 emissions.

[0063] In order to avoid this, the gear ratio with which the combustion engine 12 is coupled to the drive train 14 is now changed with the switchable transmission 13, for which purpose the switchable transmission 13 assumes a changed switching state.

[0064] The internal combustion engine 12 can then be operated at a speed / power output ratio that optimizes fuel consumption as best as possible. Preferably, the speed of the internal combustion engine 12 is adjusted to the gear ratio of the selectable transmission 13 such that the same output speed or approximately the same output speed is applied to the output side(s) of the drive train 14, regardless of the selected gear ratio. In other words, the same or approximately the same speed is applied to the drive shaft 31 regardless of the change in the sound state of the selectable transmission 13, in order to operate the crusher 10 at as constant a speed as possible. The same applies to the drives of the hydraulic pump 19.1, 19.2 and / or the generator 18.

[0065] Thus, the crusher 10, at least one of the hydraulic pumps 19.1, 19.2 and / or the generator 18 can be operated at an approximately optimal operating point when the gear stage of the switchable transmission 13 is changed.

[0066] According to a variant of the invention, the operation of the internal combustion engine 12 can be monitored with regard to its speed and power output by means of a monitoring device of an engine control system. The characteristic map of the internal combustion engine 12 can be stored in a memory unit of the engine control system. The engine control system determines the current characteristic map position of the internal combustion engine 12 continuously or at intervals.

[0067] The engine control system then determines whether the internal combustion engine 12 is running at the most optimal operating point possible. If this is not the case, it is determined whether the shiftable transmission 13 provides a gear ratio that results in a significantly better operating point, at which the output speed at least at the drive shaft 31 can be maintained at the same or approximately the same level. If such an optimized operating point is present, the shiftable transmission 13 is shifted to the optimized gear ratio, either manually or automatically.

[0068] This means that the drive train 14 can always be operated at the optimal or nearly optimal operating point with regard to consumption and CO2 emissions.

Claims

1. Drive for a mobile material processing plant (1), in particular for a rock crusher, with an internal combustion engine (12) which drives a mechanical drive train (14) on its drive side, wherein the drive train (14) has an output side with at least one output, wherein by means of the output(s) at least one crushing unit (10) and preferably a generator (18) for generating electrical energy, in particular for use in the material processing plant (1) and / or at least one hydraulic system with a hydraulic pump (19.1, 19.2) are driven, characterized by that the combustion engine (12) is coupled to the drive train (14) via a switchable transmission (13) with a variable transmission ratio.

2. Drive according to claim 1, characterized in that the switchable transmission (13) has at least two fixed gear stages.

3. Drive according to claim 1, characterized in thatthe switchable transmission (13) is a continuously variable transmission (13).

4. Drive according to one of claims 1 to 3, characterized in that the gear ratio of the switchable gearbox (13) (i=input speed / output speed) can be changed in the range between i=0.5:1 to i=1.5:

1.

5. Drive according to one of claims 1 to 4, characterized in that the transmission ratio of the switchable transmission (13) is selected such that when the input speed at the transmission input changes, the output speed at the transmission output of the switchable transmission (13) or at the input of the drive train (14) remains unchanged with a deviation of +-10%, preferably +-5%.

6. Drive according to one of claims 1 to 5, characterized in that the combustion engine (12) is coupled to the switchable transmission (13) via a clutch.

7. Drive according to one of claims 1 to 6, characterized in thatthe mechanical drive train (14) has a main shaft, to which the generator (18), the hydraulic pump (19.1, 19.2) and / or the crushing unit (10) is / are coupled.

8. Drive according to claim 7, characterized in that the main shaft is connected to a crusher coupling (30) via a drive shaft (31), and that the crusher coupling (30) is connected at its output directly or indirectly to the crushing unit (10).

9. Output according to one of claims 1 to 8, characterized in that the at least one hydraulic pump (19.1, 19.2), the generator (18) and / or a cooling fan for dissipating the heat loss of the internal combustion engine (12) is / are connected to the drive train (14), in particular the main shaft, via an output associated with each of these functional units with a fixed, non-variable transmission ratio.

10. Drive according to claim 9, characterized in thatthe crushing unit (10) is connected to the crushing unit (10) via a speed transmission, in particular an endlessly rotating belt drive.

11. Drive according to one of claims 1 to 10, characterized in that the drive train (14) has a further drive side via which a drive, in particular an electric motor, drives the drive train (14).

12. Drive according to one of claims 1 to 11, characterized in that With one output on the drive train output side, several units, in particular several hydraulic pumps of the hydraulic system, can be driven simultaneously.

13. Drive according to one of claims 1 to 12, characterized in that the crushing unit (10) is a jaw crusher, an impact crusher, a cone crusher or a roller crusher.

14. Mineral processing equipment with a drive according to one of claims 1 to 13.

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