Crusher Arm Bridging Detection via Strain Sensors
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Solution Overview
Problem
Gyratory and cone crushers experience efficiency reductions and potential damage due to bridging, where material accumulates and causes the support cone to be carried, leading to bearing failure and contamination, with existing solutions like wipers having short lifespans and inadequate detection methods.
Innovation Solution
A method for detecting bridging by measuring stress and strain variations on the arms of the crusher using sensors, such as strain-gauge strips and displacement sensors, to identify abnormal stress patterns and prevent damage by adjusting the crusher operation, including stopping the crusher or reducing material feed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wipers are arranged to wipe the arms to prevent bridging, then bridging prevention is improved, but the wiper has short life due to breaking and heavy abrasion
Solution Approach 1:
The patent replaces the mechanical wiper system with a sensor-based detection system that uses strain gauges and displacement sensors to monitor arm stress and detect bridging conditions electronically, eliminating the need for physical contact components that wear out
Solution Approach 2:
The detection system enables the crusher to monitor its own operational state automatically, detecting bridging conditions through stress measurements and triggering appropriate responses without requiring mechanical intervention from wipers
2Ease of operation
If the operator trusts the presence of the wiper, then operation simplicity is improved, but the operator does not recognize beginning of bridging before damaging the crusher
Solution Approach 1:
The patent implements a feedback system where sensors continuously monitor arm stress and provide real-time information about bridging conditions to the control system and operator, enabling timely detection and response to prevent damage
Solution Approach 2:
The system replaces reliance on mechanical wipers with electronic sensing and automated monitoring that provides direct feedback about actual operational conditions, eliminating the false security that mechanical presence alone provides
3Measurement precision
If bridging is detected by measuring stress and strain variations on the arms, then detection accuracy is improved, but device complexity increases due to additional sensors
Solution Approach 1:
The patent uses stress and strain measurements that serve multiple purposes: detecting bridging conditions, monitoring arm loading, and providing operational feedback, allowing the same sensing infrastructure to perform multiple diagnostic functions
Solution Approach 2:
The control system acts as an intermediary that processes sensor data and translates complex stress/strain measurements into simple bridging detection signals and automated responses, reducing the complexity burden on the overall system
4Duration of action of stationary object
If the crusher is stopped or material feed is reduced to prevent damage, then component lifespan is improved, but productivity decreases
Solution Approach 1:
The system performs preliminary detection of bridging conditions through stress monitoring and triggers preventive actions before actual damage occurs, allowing for planned interruptions rather than emergency shutdowns and enabling faster recovery
Solution Approach 2:
The automated detection and response system allows the crusher to operate continuously through normal variations by quickly detecting and responding to actual bridging conditions, minimizing unnecessary interruptions while preventing damage
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
Timely detection of bridging prevents bearing failure and contamination, improving crusher efficiency and extending the lifespan of components by allowing for proactive measures like reducing material feed or issuing alarms.
Implementation Method 1
measuring stress and strain variations on the arms of the crusher using sensors, such as strain-gauge strips
Implementation Method 2
displacement sensors, to identify abnormal stress patterns
Data Source
AI summary
A method, crusher, computer program and crushing plant, in which bridging generated on an arm is detected in a crusher that has a body, an outer wear part fixed to the body, an outer wear part fixed to the body; a support cone rotatable inside the body via a main shaft); an inner wear part on a cone surface of the support cone; and a support of the support cone. The support contains a group of arms inside the body and extending inwards from the body; a main shaft radially supported to the arms; and a thrust bearer supported by the arms for supporting the main shaft and for axially supporting the support cone via the main shaft. The crusher crushes mineral material between the inner wear part and the outer wear part. Measurement information is received describing stress of the support of the support cone; and bridging formed onto an arm is detected from the measurement information.