Crusher Control Method Optimizing Cycle Frequency

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Solution Overview

Problem

Existing crusher control methods, based on power consumption and crushing force, fail to effectively adjust grain size distribution and production capacity, especially in crushers with long strokes, leading to inefficient operation and varying material quality.

Innovation Solution

Controlling the cycle frequency of the crushing means in crushers, such as cone crushers, based on power input, crushing force, and particle distribution, using measuring devices and a control unit to adjust the rotation speed of the actuator, thereby optimizing productivity and utilization regardless of stroke length.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the crusher setting is adjusted based on power consumption and/or crushing force, then the operation efficiency is improved, but the grain size distribution control is insufficient

Engineering Contradiction:

Improveoperation efficiencyVSAvoidgrain size distribution control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The control system continuously monitors power consumption, crushing force, and particle distribution, using this feedback to dynamically adjust crusher settings and cycle frequency to achieve both high efficiency and precise grain size control

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system changes multiple operating parameters simultaneously (crusher settings, cycle frequency, power input) to achieve coordinated optimization of both productivity and manufacturing precision, rather than adjusting single parameters in isolation

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the cycle frequency is increased to increase production capacity, then the productivity is improved, but the power consumption increases

Engineering Contradiction:

Improveproduction capacityVSAvoidpower consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The cycle frequency is made dynamically adjustable rather than fixed, allowing the system to optimize the balance between productivity and power consumption based on real-time operating conditions, material properties, and desired output specifications

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If the crusher setting is adjusted to change grain size, then the manufacturing precision is improved, but the productivity decreases

Engineering Contradiction:

Improvegrain sizeVSAvoidproduction capacity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system maintains continuous optimal operation by dynamically adjusting settings and cycle frequency, avoiding the need to reduce productivity when grain size adjustments are required. The coordinated control ensures that precision adjustments do not come at the cost of production capacity

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS8899502B2Crusher and control method for a crusher

Publication Date: 2014.12.02 METSO OUTOTEC FINLAND OY

AI summary

A method for controlling the crusher, which crusher includes at least a frame, a crushing means with a cycle, as well as an actuator for moving the crushing means. In the method, at least first data is determined, which is at least one of the following: the power input in the actuator, the crushing force, the particle distribution of the crushed material produced by the crusher, or the quantity of crushed material produced by the crusher. The cycle frequency of the crushing means is controlled on the basis of the first data. The invention also relates to a crusher, in which the cycle frequency of the crushing means is adjusted according to control data from the control unit.