Crusher Clamping Pressure Sensor Overload Detection
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Solution Overview
Problem
Crushers used in material comminution are prone to damage during overload events due to large forces involved, leading to downtime and potential failure, despite existing efforts to mitigate these issues.
Innovation Solution
A system comprising a clamping pressure sensor and a processing unit that measures and compares clamping pressure signals to detect overload events, outputting alarm signals and instructions to adjust operation parameters, such as crusher settings or feeding system operations, to manage overload conditions and minimize damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protective cylinder allows the adjustment ring to move relative to the crusher frame during an overload event, then the overload event is resolved by eliminating the bowl float condition, but the crusher is still at risk of damage due to the large forces involved in crushing
Solution Approach 1:
The system performs preliminary detection of overload conditions by monitoring clamping pressure before the protective cylinder activates. The processing unit receives clamping pressure signals from the sensor and compares them to threshold values to detect overload events early, allowing the system to prepare for the overload event before it fully develops and causes damage
Solution Approach 2:
The system implements continuous feedback by monitoring clamping pressure during crusher operation. The processing unit receives real-time clamping pressure signals, compares them to thresholds, and generates alarm signals when overload conditions are detected. This feedback loop enables the system to respond to overload events as they occur, providing continuous monitoring and alerting to minimize damage risk
2Measurement precision
If a clamping pressure sensor and processing unit are added to detect and monitor overload events, then the detection and response capability is improved, but the device complexity increases
Solution Approach 1:
The system replaces complex mechanical overload detection mechanisms with a sensor-based measurement approach. Instead of using purely mechanical indicators of overload, the invention uses a clamping pressure sensor to electronically measure and transmit pressure signals to a processing unit, simplifying the detection mechanism while improving measurement precision
Solution Approach 2:
The processing unit serves multiple functions: receiving clamping pressure signals from the sensor, comparing signals to threshold values, detecting overload events, and generating alarm signals. This multi-functional approach consolidates several operations into a single component, reducing overall system complexity despite adding the sensor
Data Source
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AI summary
The present invention relates to a system for detecting and handling an overload event in a crusher system. The system comprises a crusher system a crusher for comminution of material. The crusher comprises a clamping arrangement, and a clamping pressure sensor configured to measure a clamping pressure of the clamping arrangement. A processing unit communicatively connectable to the clamping pressure sensor, where the processing unit is configured to output an alarm signal and/or an instruction adjust an operation parameter of the crusher system, based on a received clamping pressure signal.