Continuous-Feed Cone Crusher Protection Via Metal Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mobile crushing machines face inefficiencies and throughput reduction due to the need to completely stop the feed conveyor and remove undesirable metallic materials, which can damage the crusher or cause jams.
Innovation Solution
A system with a diverter chute and metal detector that diverts aggregate material away from the crusher device without stopping the conveyor, using a control unit to manage the diverter's position based on detector signals, ensuring continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the feed conveyor is completely stopped to remove metallic material, then the crusher device is protected from damage, but the operating efficiency and throughput of the crushing system are reduced
Solution Approach 1:
The metal detector is positioned upstream to detect metallic material before it reaches the crusher device. The system takes preliminary action by identifying contaminants early in the feed stream, allowing for selective removal without interrupting the overall conveyor operation. This prevents damage before it occurs while maintaining continuous material flow.
Solution Approach 2:
The system segments the material flow by using a diverter mechanism to separate detected metallic material from the continuous aggregate feed. Instead of stopping the entire conveyor, only the problematic metallic pieces are diverted away from the crusher, while the rest of the aggregate material continues to be processed normally. This segmentation allows protection of the crusher without interrupting throughput.
2Reliability
If the feed conveyor is completely stopped to physically remove metallic material, then the crusher device is protected from damage, but the operating efficiency is reduced
Solution Approach 1:
A diverter mechanism acts as an intermediary between the detected metallic material and the crusher device. When metal is detected, the diverter redirects the material away from the crusher without requiring physical removal by operators or complete system shutdown. This intermediary mechanism enables continuous operation while still protecting the crusher from damage.
Solution Approach 2:
The system replaces manual physical removal of metallic material with an automated detection and diversion mechanism. The metal detector and diverter system automatically identify and redirect contaminants without requiring operator intervention or mechanical stopping of the conveyor, thereby eliminating shutdown time and maintaining continuous operation.
3Reliability
If a metal detector is used to detect metallic material, then the crusher device is protected from damage, but the system complexity increases
Solution Approach 1:
The metal detector and diverter system serves multiple functions: it detects metallic material, triggers the diversion mechanism, and protects the crusher device. By integrating these functions into a single coordinated system, the patent reduces overall complexity compared to having separate systems for detection, removal, and protection. The multi-functional approach streamlines the protection mechanism while maintaining effectiveness.
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
Prevents crusher damage and jams by diverting undesirable materials while maintaining conveyor operation, enhancing efficiency and throughput.
Implementation Method 1
one or more metal detectors is positioned somewhere along the feed conveyor to detect the presence of a metallic material in the feed of the aggregate material
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A crushing machine that includes a crusher device fed by a feed conveyor for processing a feed of aggregate material. A detector is positioned along the feed conveyor to detect the presence of an undesirable material, such as a portion of metallic material. Upon detection of the undesirable material, a diverter is moved from a first mode to a second mode to divert the feed of material away from the crusher device. Once the detected undesirable material is no longer present in the feed of material, the diverter is returned to the first mode after a delay to direct the feed of aggregate material back to the crusher device. The operating speed of the feed conveyor is not adjusted during the movement of the diverter. The diverted feed of aggregate material is directed to a discharge chute located away from the infeed end of the crusher device.