Independent Vibrator Control for Cone Crusher Phase Adjustment
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Solution Overview
Problem
Existing crushing and grinding machines face issues with vibration phase adjustment, leading to imprecise and unreliable operation due to complex pulley and belt systems, which result in increased maintenance complexity and potential machine stoppages, impacting continuous processing.
Innovation Solution
A crushing machine with independently controlled vibrators that can adjust their phase shift between minimum, maximum, and intermediate positions, allowing for continuous operation and precise adjustment of grinding power without stopping, using a motor control system and flexible couplings for efficient energy transmission and recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pulleys and belts are used to transmit rotation between vibrators, then mechanical synchronization is achieved, but the system becomes complex and unreliable due to wear and tension issues
Solution Approach 1:
The patent replaces the mechanical pulley and belt transmission system with an electronic control system. Each vibrator is equipped with an independent motor (e.g., variable speed motor or servo motor) controlled by a programmable logic controller (PLC) or microprocessor-based control system. This electronic control mechanism eliminates the mechanical transmission components, thereby reducing device complexity and improving reliability by removing wear-prone elements while maintaining precise synchronization through digital control algorithms.
2Adaptability or versatility
If pulleys and belts are used for phase adjustment, then phase shift between vibrators is achieved, but maintenance complexity increases due to wear and tension monitoring requirements
Solution Approach 1:
The patent replaces mechanical phase adjustment mechanisms (pulleys and belts) with an electronic control system that can dynamically adjust the phase relationship between vibrators. The control system receives feedback from sensors detecting the position and operation of each vibrator, then automatically adjusts motor speeds and phases to achieve the desired phase shift. This eliminates the need for manual maintenance of mechanical transmission components while maintaining full adaptability in phase adjustment.
Solution Approach 2:
The patent implements a feedback control mechanism where sensors monitor the position, speed, and phase of each vibrator in real-time. This feedback information is fed back to the control system, which automatically adjusts motor operations to maintain the desired phase relationship. This closed-loop control eliminates the need for manual monitoring and adjustment of mechanical components, significantly reducing maintenance complexity while preserving adaptability.
3Measurement precision
If belt tension and pulley wear are monitored to maintain fine setting, then phase precision is maintained, but operational interruptions increase due to frequent maintenance
Solution Approach 1:
The patent replaces the mechanical pulley and belt system with an electronic control system that maintains phase precision without wear. The electronic motors and control system can maintain consistent rotational speeds and phase relationships indefinitely without degradation, eliminating the need for periodic maintenance interruptions. This ensures continuous operation while maintaining measurement precision through digital control algorithms and feedback mechanisms.
4Adaptability or versatility
If hydraulic cylinders are used for pivoting vibrator shafts, then phase shift adjustment is achieved, but leakage problems occur due to seals and vibrations
Solution Approach 1:
The patent replaces hydraulic cylinders with electronic motor-driven adjustment mechanisms. Each vibrator shaft is equipped with an independent motor that can pivot or adjust the shaft position and phase angle. This electronic actuation system eliminates hydraulic seals and fluid connections, thereby eliminating leakage problems while maintaining full adaptability in phase shift adjustment through precise electronic control.
5Adaptability or versatility
If intermediate position is held by hydraulic cylinders, then partial phase shift is achieved, but position holding becomes unreliable over time
Solution Approach 1:
The patent replaces hydraulic position holding mechanisms with electronic motor control systems. The motors can maintain precise intermediate positions through continuous or micro-stepping control, eliminating the drift and reliability issues associated with hydraulic seals under vibration. The electronic control system can hold positions indefinitely with high precision by maintaining minimal corrective torque, ensuring reliable intermediate position capability over time.
Solution Approach 2:
The patent implements feedback control where sensors continuously monitor the actual position of each vibrator shaft. This position information is fed back to the control system, which makes real-time adjustments to maintain the desired intermediate positions. This closed-loop control ensures reliable position holding over time by compensating for any disturbances or drift, unlike open-loop hydraulic systems that rely solely on seal integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous operation with precise adjustment of grinding power, reducing maintenance needs and operational costs by allowing for real-time adaptation of grinding force based on material characteristics, enhancing the machine's responsiveness and reliability.
Implementation Method 1
a device for vibrating the tank with respect to the frame in a transverse plane so that material is crushed between the internal and external grinding tracks by the relative movement of the tank with respect to the cone
Implementation Method 2
a flexible coupling in the longitudinal direction, so that the vibrator shaft can move in the longitudinal direction relative to the motor shaft over a determined maximum stroke
Data Source
AI summary
A crushing machine includes: a frame, a tank, a cone placed inside the tank, the machine further including a device for vibrating the tank with respect to the frame; the machine being characterized in that the device for vibrating the tank includes at least two vibrators which are mounted on the frame, each vibrator being rotated about a longitudinal axis of the frame by a motor, each motor driving the vibrator with which it is associated independently from one another.