Conveyor Feed-Layer Height Sensing for Crusher Load Regulation
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Solution Overview
Problem
Existing material processing devices face challenges in determining the layer height of feed material without impairing operation, particularly in mobile setups where superstructures are undesirable.
Innovation Solution
The method involves using a sensor array with sensors whose detection volumes have longitudinal axes extending partially in or counter to the conveying direction, allowing for reliable layer height determination without obstructing the device's operation, and incorporating sensors like radar or ultrasonic devices to measure layer height and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are positioned above the conveyor device to measure layer height, then measurement capability is improved, but the device complexity and installation height requirements increase
Solution Approach 1:
The patent positions sensors laterally adjacent to the conveyor device rather than above it, changing the measurement dimension from vertical to horizontal. This allows layer height measurement without requiring superstructures, reducing installation height requirements and device complexity while maintaining measurement capability.
Solution Approach 2:
The measurement function is extracted from a centralized superstructure position and distributed to lateral sensor positions adjacent to the conveyor device. This extraction eliminates the need for overhead mounting structures and reduces overall device complexity.
2Device complexity
If sensors are positioned laterally adjacent to the conveyor device, then device complexity is reduced, but measurement precision may be compromised
Solution Approach 1:
By measuring layer height from a lateral position rather than from above, the system uses a different geometric approach to achieve the same measurement objective, avoiding superstructures while maintaining precision through angular detection geometry.
Solution Approach 2:
The system changes the detection parameters by using sensors that measure at an angle to the conveyor device, with detection volumes oriented at specific angles (e.g., 45 degrees) to the conveying direction, allowing accurate layer height determination from lateral positions.
3Ease of operation
If the detection volumes are oriented perpendicular to the conveying direction, then installation is simplified, but the ability to accurately determine layer height is reduced
Solution Approach 1:
The detection volumes are oriented at specific angles (e.g., 45 degrees) to the conveying direction rather than perpendicular to it. This angular orientation optimizes the measurement geometry for layer height determination while still allowing straightforward sensor installation adjacent to the conveyor device.
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
This approach enables accurate regulation of the feed material, preventing overload and underload, improving production efficiency, quality, and reducing mechanical wear, while maintaining a compact and robust design.
Implementation Method 1
the sensors each detect waves, which are reflected at the feed material at least partially along detection volume of respective sensors, as signals
Data Source
AI summary
The invention relates to a method for determining the layer height of a feed material, which is supplied to a crushing and/or screening plant of a material processing device, wherein a conveyor device is used to convey the feed material in a conveying direction, wherein a sensor array comprising a plurality of sensors is used to determine the layer height of the feed material. A reliable method that can be performed with little effort and without impairing the operation of the material processing device is achieved by the longitudinal axes of the detection volumes of the sensors extending at least partially in and/or counter to the conveying direction.