Crusher Feed Control Using Effective Grain Diameter Sensing
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Solution Overview
Problem
Existing methods for controlling vibratory conveyors that feed crushers struggle to handle bulk materials with inhomogeneous particle size distributions, leading to potential overload, blockage, or inefficient crushing.
Innovation Solution
The method involves determining the effective diameter of grains in the capturing region and adjusting the power of the crushing tool or the drive of the vibratory conveyor based on predetermined threshold values to ensure consistent crushing and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the power of the crushing tool is increased to crush large grains, then the crushing capability is improved, but the risk of motor depression and equipment damage increases
Solution Approach 1:
The system performs preliminary detection of grain size using a sensor before the material reaches the crushing tool. When a large grain is detected, the control unit pre-increases the power of the crushing tool, ensuring the grain can be crushed without causing motor depression or equipment damage.
Solution Approach 2:
The system uses a sensor to detect grain size and provides feedback to the control unit, which adjusts the crushing tool power accordingly. This closed-loop control ensures the crushing tool has sufficient power for large grains while preventing excessive power application that could damage equipment.
2Stability of the object's composition
If the vibration amplitude of the vibratory conveyor is controlled to feed material uniformly, then the feeding uniformity is improved, but the system cannot handle large grains with inhomogeneous particle size distribution
Solution Approach 1:
The system dynamically adjusts the vibration amplitude of the vibratory conveyor based on real-time detection of grain size. When large grains are detected, the vibration amplitude is modified to ensure proper feeding, allowing the system to handle inhomogeneous particle size distributions while maintaining feeding uniformity.
Solution Approach 2:
The control unit changes the vibration amplitude parameter of the vibratory conveyor based on detected grain characteristics. This parameter adjustment allows the system to adapt to different material conditions, including large grains with inhomogeneous distribution, while maintaining stable feeding.
3Measurement precision
If a sensor is used to detect grain size, then the control precision is improved, but the system complexity increases
Solution Approach 1:
The system replaces complex mechanical measurement methods with a sensor-based detection system. The sensor optically or electronically detects grain size, providing precise measurement without requiring complex mechanical gauges or manual measurement mechanisms.
Solution Approach 2:
The sensor acts as an intermediary between the material flow and the control system. It converts physical grain characteristics into detectable signals that the control unit can process, simplifying the overall system architecture while maintaining high measurement precision.
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 allows for efficient crushing of bulk materials with varying grain sizes without risking damage to the crusher, ensuring a constant crushing result and preventing blockages.
Implementation Method 1
the sensor can comprise, for example, an optical or a depth sensor that records the grains in the capturing region and images them in a two-dimensional image
Implementation Method 2
various image processing methods known from the prior art can be used to determine the effective diameter deff
Implementation Method 3
a vibratory conveyor having a drive, wherein bulk material disposed in a capturing region is captured using a sensor
Implementation Method 4
The associated increase in impact energy can prevent motor depression
Data Source
AI summary
A method for controlling a crusher having a crushing tool and a vibratory conveyor (1) having a drive (5), includes capturing bulk material (2) in a capture region (4) using a sensor (3). So that, in the case of grains with an inhomogeneous grain size distribution, even large grains can be crushed with a constant crushing result without a risk of the crusher being damaged, an effective diameter deff, which results from the largest diameter dmax and the direction (9) thereof, transverse to the conveying direction (8) of a grain of the bulk material (2) is determined as the controlled variable in the capture region (4). If the effective diameter deff exceeds a predefined power threshold value, the power of the crushing tool is increased and/or, if the effective diameter deff exceeds a predefined switch-off limit value, the drive (5) is switched off.