Crusher Control Circuit for Overload Prevention
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Solution Overview
Problem
Existing crushers for processing construction and demolition debris face frequent downtime due to material sticking or overload, requiring continuous monitoring and resulting in significant productivity losses and increased operational costs.
Innovation Solution
A crusher equipped with amperometric sensors and control circuits that monitor current absorption and adjust pusher intensity to prevent overload, allowing for automatic reduction of load on the crushing assembly and minimizing the need for specialized personnel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pushers continuously push elements to be recycled to the crushing assembly, then crushing efficiency is improved, but the risk of overload and material sticking increases
Solution Approach 1:
The control system continuously monitors the current absorbed by the crushing assembly and uses this feedback to automatically adjust the push force of the pushers. When current exceeds a threshold indicating overload, the system reduces push force; when current is within normal range, the system increases or maintains push force to optimize crushing efficiency.
Solution Approach 2:
The push force applied by the pushers is made dynamically adjustable rather than fixed. The system varies the intensity of pushing action in real-time based on the operational state of the crushing assembly, allowing optimal performance while preventing overload conditions.
2Productivity
If the crusher operates continuously without stops, then productivity increases, but the risk of material sticking and failure increases
Solution Approach 1:
The monitoring system detects early signs of material sticking through current measurement and provides feedback to the control system, which then adjusts pusher intensity to prevent complete blockage and continuous operation stops.
Solution Approach 2:
The system takes preliminary action by reducing push force before material sticking completely blocks the crushing assembly, preventing the harmful effect from occurring in the first place rather than reacting after the problem arises.
3Reliability
If specialized personnel continuously monitor the crusher operation, then reliability is improved, but operational costs increase
Solution Approach 1:
The crusher system performs self-monitoring and self-adjustment through automated sensors and control circuits that continuously track operational parameters and modify pusher intensity without human intervention, making the system serve itself rather than requiring specialized personnel.
Solution Approach 2:
The manual monitoring and decision-making process is replaced by an automated electronic control system that uses sensors to detect operational conditions and automatically adjusts pusher intensity, substituting mechanical/human monitoring with an automated control system.
4Reliability
If the crusher is stopped for material removal or maintenance, then reliability is maintained, but productivity decreases
Solution Approach 1:
The real-time monitoring and feedback control system detects and corrects operational issues before they require complete shutdowns, maintaining continuous operation while ensuring operational stability through automatic adjustments.
Solution Approach 2:
The system maintains continuous crushing operation by dynamically adjusting pusher intensity to prevent stoppages, ensuring the useful action of crushing continues without interruption rather than requiring periodic stops for maintenance or material removal.
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 solution reduces machine downtime, increases productivity, and decreases operational costs by automatically managing overload situations and optimizing push force distribution, thereby enhancing processing yield and reducing the need for manual intervention.
Implementation Method 1
a control circuit (23) connected to said amperometric sensor (22) and to said pushers (20)
Data Source
AI summary
A control method of a crusher for elements to be recycled or disposed of, which includes a crushing assembly, to which the elements to be recycled or disposed of are provided, and pushers acting toward the crushing assembly to push the elements to be recycled or disposed of, includes a measuring step of the current absorbed by the crusher, a comparing step of the current value measured against a first predetermined value, and a reducing step of the push intensity of one or more of the pushers toward the crushing assembly in case the measured current exceeds the first predetermined value, the pushers being controlled separately from each other in order to partialize the push force and the push areas.