Crushing control system and program

Abstract

To eliminate influence of external conditions as much as possible, and control a crusher with good accuracy.SOLUTION: A crushing control system comprises: measuring means which measures power or current of electrical equipment that receives a load of a material supplied into a crushing space during operation of a crusher; calculation means (33) which calculates "material load index" that represents an amount of change of power or current per prescribed time on the basis of a measurement result of the measuring means; comparison means (34) which compares the material load index calculated by the calculation means and a preset threshold or range; and adjustment processing means (35) which adjusts a control value including a gap value of the crushing space on the basis of a comparison result of the comparison means.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a crushing control system and program, and more particularly to a crushing control system and program for controlling a crusher that crushes materials supplied to a crushing space. [Background technology]

[0002] The crusher has a crushing space into which the material is supplied, and the particle size of the crushed material (crushed material) is adjusted by adjusting the gap size of this crushing space. In addition, when productivity is emphasized, the gap size of the crushing space may be adjusted as needed based on the load rate and load amount of electrical equipment such as motors.

[0003] In Japanese Patent Laid-Open Publication No. 4-235758 (Patent Document 1), the load factor of the crusher (power consumption / motor rated power) is detected, and the clearance, etc. are adjusted so that the load factor falls within a set range of optimal load factors. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 4-235758 Summary of the Invention [Problem to be solved by the invention]

[0005] As in Patent Document 1, when the load factor is detected from the power consumption or current of the crusher, it is affected by external conditions such as temperature, which poses a problem of reducing the control accuracy of control values ​​such as the gap value. Specifically, the fluidity of the lubricating oil supplied to the crusher's bearings can change depending on the temperature change between seasons (summer and winter) and time periods (morning, evening and daytime), which can cause differences in power consumption and current even if the size and amount of material (processed material) supplied to the crushing space are the same.

[0006] The present invention has been made to solve the above-mentioned problems, and its object is to provide a crushing control system and program that can eliminate the influence of external conditions as much as possible and control a crusher with high precision. [Means for solving the problem]

[0007] A crushing control system according to one aspect of the present invention is a crushing control system for controlling a crusher that crushes materials supplied to a crushing space, and includes: a measuring means for measuring the power or current of an electrical device that receives the load of the materials supplied to the crushing space while the crusher is operating; a calculating means for calculating a "material load index" that represents the amount of change in power or current per specified time based on the measurement results by the measuring means; a comparing means for comparing the material load index calculated by the calculating means with a preset threshold value or range; and an adjusting processing means for adjusting a control value including the gap value of the crushing space based on the comparison results by the comparing means.

[0008] Preferably, the crushing control system further comprises a determining means for determining the presence or absence of material in the crushing space based on the comparison result by the comparing means.

[0009] It is desirable that the adjustment processing means expands the gap value of the crushing space to the standby gap value when the determining means determines that there is no material in the crushing space.

[0010] When the determination means determines that material is present in the crushing space, it is desirable that the adjustment processing means executes target amplitude control to adjust the gap value of the crushing space based on the material load index calculated by the calculation means.

[0011] The material load indicator is, for example, a power or current amplitude value.

[0012] A crushing control program according to another aspect of the present invention is a program for controlling a crusher that crushes materials supplied to a crushing space, and causes a computer to execute the following steps while the crusher is operating: calculating a "material load index" that represents the amount of change in power or current per specified time of an electrical device; comparing the calculated material load index with a preset threshold value or range; and adjusting control values ​​including the gap value of the crushing space based on the comparison result in the comparing step. [Effects of the Invention]

[0013] According to the present invention, the material load index is used to adjust the control values ​​including the gap value, so that the crusher can be controlled with high precision. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a schematic diagram showing a general configuration of a crushing control system according to an embodiment of the present invention; [Figure 2] FIG. 2 is a functional block diagram of a control device according to an embodiment of the present invention. [Figure 3] 3 is a flowchart showing a crushing control method according to an embodiment of the present invention. [Figure 4] 1 is a graph showing the results of determining gap values, current values ​​or load factors, current amplitude values, and material loads along a common time axis. DETAILED DESCRIPTION OF THE INVENTION

[0015] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described in detail with reference to the drawings. In the drawings, the same or corresponding parts are designated by the same reference numerals and description thereof will not be repeated.

[0016] <Overview of the configuration> The outline of the configuration of the crushing control system SYS according to this embodiment will be described with reference to Fig. 1. The crushing control system SYS controls a crusher 1.

[0017] The crusher 1 shown in Fig. 1 is a cone crusher, a compression-type crusher that crushes materials such as rocks and ore fed into a material supply port 11 by sandwiching them between a bowl liner 12 and a mantle 14 and compressing them. The main shaft 13 of the mantle 14 is inclined with respect to a rotation axis 17. The rotation axis 21a of a motor 21 drives the rotation axis 17 via a power transmission mechanism 16 such as a pinion, causing the mantle 14 fixed to the main shaft 13 to orbit (eccentrically) move. The bowl with the bowl liner 12 may be configured to be rotatable on its own axis during load operation when materials are fed into the crushing space 15.

[0018] The crusher 1 in this embodiment can adjust the gap C (gap value) of the crushing space 15 by adjusting the height of the bowl liner 12 relative to the mantle 14. The crushing space 15 is a space (crushing chamber) that is formed between the bowl liner 12 and the mantle 14 and is continuous in the circumferential direction. The gap C of the crushing space 15 becomes "zero" when the bowl liner 12 and the mantle 14 are in contact with each other.

[0019] The gap C of the crushing space 15 can be adjusted by an adjustment mechanism 22 including, for example, a hydraulic cylinder. The configuration of the adjustment mechanism 22 is not particularly limited, and it may be configured so that the height of the bowl liner 12 is fixed and the height of the mantle 14 is adjusted by raising and lowering the main shaft 13. The position (height) of the bowl liner 12 can be measured by the stroke amount of the hydraulic cylinder detected by a position sensor 23. The position sensor 23 may be mounted on the adjustment mechanism 22.

[0020] The motor 21 and adjustment mechanism 22 of the crusher 1 are controlled by a control device 3 such as a PLC (Programmable Logic Controller). The motor 21, for example, drives the main shaft 13 to rotate so that the rotation speed of the mantle 14 is constant. The motor 21 is an electrical device that receives the load of the material supplied to the crushing space, and the current of the motor 21 is higher when under load than when under no load (when no material is supplied). Furthermore, even under the same load, the current of the motor 21 fluctuates depending on the amount and size of the material supplied to the crushing space 15. The same applies to the power of the motor 21.

[0021] In a typical crushing control system, the load factor of the crusher 1 is detected by monitoring the current (or power) of the motor 21. However, the load factor detected in this manner may be affected by external conditions as well as the material load in the crushing space 15 (load due to the amount and size of the material). Specifically, environmental conditions including at least one of temperature and humidity may cause differences in the current of the motor 21 even if the material load in the crushing space 15 is the same.

[0022] Therefore, the load factor detected by the current of the motor 21 may not accurately reflect the material load in the crushing space 15. In other words, if the control value including the gap C of the crushing space 15 is adjusted based on the load factor detected by the current of the motor 21, there is a concern that the crushing accuracy may decrease.

[0023] In contrast, the crushing control system SYS according to this embodiment is characterized in that the control device 3 calculates a value representing the amount of change in current (or power) per predetermined time as a "material load index" in the crushing space 15, and adjusts control values ​​such as the gap value based on the calculated material load index. This is because even if external conditions (environmental conditions, etc.) fluctuate, the amount of change (fluctuation range) in current per predetermined time is less susceptible to the effects thereof.

[0024] The functional configuration and operation of the control device 3 that controls the crusher 1 will be described in detail below.

[0025] <Controller functional configuration> The functional configuration of the control device 3 will be described with reference to Fig. 2. Fig. 2 is a functional block diagram of the control device 3 in this embodiment.

[0026] The control device 3 includes, as its functional configuration, an input unit 31, a memory 32 that stores a gap reference value, a calculation unit 33, a comparison unit 34, and an adjustment processing unit 35. The control device 3 may also include a determination unit 36.

[0027] The input unit 31 inputs the current of the motor 21 in time series while the crusher 1 is in operation. The current (A) of the motor 21 is measured by the measuring means 25 shown in FIG. 1. The measuring means 25 may be mounted on the control device 3.

[0028] The calculation unit 33 calculates a material load index that represents the amount of change (rate of change) in current per predetermined time based on the measurement results from the measurement means 25. The predetermined time that is the calculation unit for the material load index may be the same as the current sampling time, or may be a predetermined multiple of the sampling time.

[0029] A typical example of a material load index is an "amplitude value" that directly or indirectly indicates the range (fluctuation range) between the maximum and minimum values ​​over a given time period. In this embodiment, the calculation unit 33 calculates the amplitude value of the current from the transition of the current value input to the input unit 31 in a time series.

[0030] The comparison unit 34 compares the current amplitude value (material load index) calculated by the calculation unit 33 with a preset threshold value or range. The range to be compared is, for example, a range of amplitude values ​​targeted during material crushing work (hereinafter referred to as the "target range"), and is determined by an upper limit value and a lower limit value. The threshold value to be compared is, for example, a value used in the determination process by the determination unit 36 ​​described below. This value may be the lower limit value of the target range. Note that it is desirable to set the threshold value and target range for each type of material. The threshold value and target range can be set based on the current amplitude value during test operation.

[0031] The adjustment processing unit 35 adjusts the control value including the gap value of the crushing space 15 based on the comparison result by the comparison unit 34. The adjustment processing unit 35 adjusts the gap C so that the amplitude value of the current calculated by the calculation unit 33 falls within a target range. In the following description, such adjustment control is referred to as "target amplitude control".

[0032] The adjustment processing unit 35 adjusts the gap C of the crushing space 15, for example, by controlling the adjustment mechanism 22 based on the gap reference value stored in the memory 32. Specifically, when the amplitude value of the current calculated by the calculation unit 33 exceeds the target range, it determines that the material load is large and performs control to enlarge the gap C. When the amplitude value of the current calculated by the calculation unit 33 falls below the target range, it determines that the material load is small and performs control to narrow the gap C.

[0033] The determination unit 36 ​​determines whether or not there is a material (object to be processed) in the crushing space 15 based on the comparison result by the comparison unit 34. Specifically, when the amplitude value of the current calculated by the calculation unit 33 is equal to or greater than a preset threshold, it determines that there is a material in the crushing space 15 (loaded state). When the amplitude value of the current calculated by the calculation unit 33 is less than the threshold, it determines that there is no material in the crushing space 15 (unloaded state). A specific determination method by the determination unit 36 ​​will be described later.

[0034] The functions of the calculation unit 33, comparison unit 34, adjustment processing unit 35, and determination unit 36 ​​can be realized by a processor executing software. Furthermore, functional units other than the adjustment processing unit 35 may be included in an information processing device such as a personal computer or a tablet terminal, and the information processing device may be configured to output control values ​​including the gap value to a control device (including the adjustment processing unit 35) associated with the crusher 1.

[0035] The control device 3 may also include a display means (not shown) that displays the amplitude value and the like calculated by the calculation unit 33. The display means may display a graph showing the transitions of the current value and the amplitude value along the same time axis, as shown in Fig. 4 described later. Also, at least one of the determination result by the determination unit 36 ​​and the gap value set by the adjustment processing unit 35 may be displayed identifiably along the same time axis.

[0036] <Operation of the crushing control system> The operation of the crushing control system SYS will be described with reference to Figures 3 and 4. Figure 3 is a flowchart showing the crushing control method executed by the control device 3. Figure 4 is a graph showing, along a common time axis, (A) gap value (actual set), (B) current value or load factor (current value / motor rated current), (C) current amplitude value, and (D) no-load judgment result of the material.

[0037] First, the control device 3 starts the operation of the crusher 1 (step S1). During the operation of the crusher 1, the input unit 31 acquires the current value (or power value) of the motor 21 measured by the measuring means 25 (step S3), and the calculation unit 33 calculates the amplitude value of the current as a "material load index" at predetermined time intervals (for example, every 0.1 seconds) (step S4).

[0038] Next, the comparison unit 34 compares the amplitude value of the current with a preset threshold value (step S5). Specifically, it determines whether or not the amplitude value is less than the threshold value (for example, 1.2%).

[0039] As a simple example, if the amplitude value is less than the threshold value (YES in step S5), the determination unit 36 ​​determines that "ingredients are not present" (step S11). If the amplitude value is equal to or greater than the threshold value (NO in step S5), the determination unit 36 ​​determines that "ingredients are present" (step S7).

[0040] In step S5, it is desirable to count the number of times the amplitude value falls below the threshold within a certain period (for example, 10 seconds), and only when the number of times measured reaches a predetermined number (for example, 10 times), to determine that there is no material. This makes it possible to prevent hunting control.

[0041] If the determination unit 36 ​​determines that "material is present," the adjustment processing unit 35 performs target amplitude control (step S9). That is, the adjustment processing unit 35 performs control to enlarge the gap C when the amplitude value exceeds the target range (upper limit), and performs control to reduce the gap C when the amplitude value falls below the target range (lower limit). Note that, even in this case, the number of times the amplitude falls outside the target range within a certain period of time may be counted, and the gap C may be adjusted according to the number of measurements. Furthermore, the adjustment process for the gap C may be performed at any time, or may be performed every certain time period (for example, every 30 minutes).

[0042] If the determination unit 36 ​​determines that there is "no material," the adjustment processing unit 35 does not perform target amplitude control and sets the gap C to a standby gap value (step S13). The standby gap value is typically the same as or larger than the maximum control value (gap value) used in target amplitude control.

[0043] In this way, when it is determined that there is no material, the gap C is not made smaller, but is instead made larger than the maximum control value, thereby preventing clogging of the crushing space 15 with material or malfunctions due to momentary overload even if a large amount of material is suddenly supplied to the crushing space 15.

[0044] The process of determining the presence or absence of material by the determining unit 36 ​​can also be applied when the adjustment processing unit 35 performs the crushing operation with the gap value fixed at a constant value (when target amplitude control is not performed).

[0045] <Action and effect> As described above, the control device 3 in the embodiment of the present invention adjusts and controls the gap C using the amplitude value rather than the current value (absolute value) of the motor 21. Changes in temperature between seasons (summer and winter) and times of day (morning, evening and daytime) can change the fluidity of the lubricating oil supplied to the bearings (bearings that rotatably support the rotating shaft 17) of the crusher 1, which can cause load fluctuations. However, by using the amplitude value of the current, the influence of such weather conditions (environmental conditions) can be eliminated. In other words, the gap C can be adjusted in a state that appropriately reflects the material load based on the size and amount of material supplied to the crushing space 15, allowing the crusher 1 to be controlled with high precision.

[0046] <Modification> (1) In this embodiment, an example is shown in which the amplitude value of the current of the motor 21 is calculated as the material load index in the crushing space 15, but the present invention is not limited to such an example. The material load index may be the amplitude value of the power of the motor 21. Moreover, the material load index may be expressed by a change amount (fluctuation range) other than the amplitude.

[0047] (2) Furthermore, the material load index is not limited to the example in which it represents the amount of change based on the current or power of the motor 21, but instead / in addition to this, it may represent the amount of change based on the current or power of other electrical equipment (electrical equipment that receives the load of the material supplied to the crushing space 15). Furthermore, the crusher 1 is not limited to a cone crusher, and this system can be applied to other types of crushers.

[0048] (3) The material load index calculated by the calculation unit 33 of the control device 3 may be used for controlling something other than the gap C of the crushing space 15. For example, it may be used to control the amount of material supplied or the rotation speed of the main shaft 13 of the mantle 14. That is, the adjustment processing unit 35 of the control device 3 can adjust the control value including at least one of the gap C of the crushing space 15, the amount of material supplied, and the rotation speed of the main shaft 13, based on the material load index.

[0049] (4) The crushing control method executed by the control device 3 can also be provided as a program. Such a program can be provided by being recorded on an optical medium such as a CD-ROM (Compact Disc-ROM) or a computer-readable non-transitory recording medium such as a memory card. The program can also be provided by downloading it over a network.

[0050] The program according to the present invention may execute processing by calling necessary modules in a predetermined sequence at a predetermined timing among program modules provided as part of a computer's operating system (OS). In this case, the program itself does not include the modules, and executes processing in cooperation with the OS. Programs that do not include such modules may also be included in the program according to the present invention.

[0051] Furthermore, the program according to the present invention may be provided as a part of another program. In this case, the program itself does not include the modules included in the other program, and executes processing in cooperation with the other program. Such a program incorporated in another program may also be included in the program according to the present invention.

[0052] The embodiments disclosed herein should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is defined by the claims, not by the above description, and is intended to include all modifications within the meaning and scope of the claims. [Explanation of symbols]

[0053] 1 Crusher, 3 Control device, 11 Material supply port, 12 Bowl liner, 13 Main shaft, 14 Mantle, 15 Crushing space, 16 Power transmission mechanism, 21 Motor (electrical equipment), 22 Adjustment mechanism, 25 Measuring means, 31 Input unit, 32 Memory, 33 Calculation unit, 34 Comparison unit, 35 Adjustment processing unit, 36 Determination unit, C Gap, SYS Crushing control system.

Claims

1. A crushing control system for controlling a crusher that crushes material supplied to a crushing space, a measuring means for measuring the power or current of an electrical device that receives a load of material supplied to the crushing space during operation of the crusher; a calculation means for calculating a material load index representing a change in power or current per predetermined time based on the measurement results by the measurement means; a comparison means for comparing the material load index calculated by the calculation means with a preset threshold value or range; and an adjustment processing means for adjusting a control value including the gap value of the crushing space based on the comparison result by the comparison means.

2. 2. The crushing control system according to claim 1, further comprising a determining means for determining whether or not a material is present in said crushing space based on a comparison result by said comparing means.

3. 3. The crushing control system according to claim 2, wherein said adjustment processing means increases the gap value of said crushing space to a standby gap value when said determining means determines that there is no material in said crushing space.

4. The crushing control system according to claim 2 or 3, wherein the adjustment processing means executes target amplitude control to adjust the gap value of the crushing space based on the material load index calculated by the calculation means when the determination means determines that there is material in the crushing space.

5. The crushing control system of claim 1 , wherein the material load indicator is a power or current amplitude value.

6. A program for controlling a crusher that crushes materials supplied to a crushing space, calculating a material load index representing a change in power or current per predetermined time of an electrical device during operation of the crusher; comparing the calculated material load index with a pre-defined threshold or range; and a step of adjusting a control value including the gap value of the crushing space based on the comparison result in the comparing step.

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