Crusher Feed Control Using Material Flow Prediction
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Solution Overview
Problem
Existing material processing devices, particularly crushing and screening plants, face inefficiencies due to inadequate control of material feed, leading to mechanical overloads, wear, and reduced separation efficiency, which can be addressed by predicting and regulating the feed based on material characteristics and volume flow.
Innovation Solution
Determine material characteristics and volume flow using sensors and artificial neural networks (ANNs) to control the conveyor speed, adjusting parameters like crushing gap and rotor speed to prevent overloads and underloads, ensuring optimal processing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the crusher is overfilled to increase processing capacity, then productivity increases, but mechanical loads and wear increase excessively
Solution Approach 1:
The system determines material characteristics and volume flow in advance before the material reaches the crusher, allowing the conveying speed to be adjusted proactively to prevent overload situations before they occur
Solution Approach 2:
The system continuously monitors material characteristics and volume flow, using this feedback to dynamically adjust the conveying speed to maintain optimal crusher filling level and avoid excessive mechanical loads
2Reliability
If the crusher is underfilled to reduce mechanical loads, then reliability improves, but the desired quality of the end product is no longer achieved
Solution Approach 1:
The system predicts material volume flow and characteristics in advance, allowing the conveying speed to be adjusted to ensure the crusher receives the optimal amount of material to maintain quality without excessive loading
Solution Approach 2:
The system dynamically adjusts the conveying speed parameter based on determined material characteristics and volume flow to maintain optimal crusher filling level for both quality and reliability
3Productivity
If the layer thickness on the screen lining increases to handle more material, then productivity increases, but the separation efficiency decreases noticeably
Solution Approach 1:
The system determines material characteristics and volume flow before material reaches the screening plant, allowing proactive adjustment of conveying speed to maintain optimal layer thickness on the screen lining
Solution Approach 2:
The system uses continuous monitoring of material parameters to dynamically adjust conveying speed, ensuring the screen lining maintains optimal layer thickness for both productivity and separation efficiency
Data Source
AI summary
The invention relates to a method for controlling and/or regulating the feed of material to be processed, in particular rock material, to a crushing and/or screening plant of a material processing device, wherein a conveyor device is used to guide the material to be processed to the crushing and/or screening plant, wherein a characteristic of the material to be processed is determined, and/or wherein a volume flow of the material to be processed is determined, and wherein a conveying speed of the conveyor device is controlled and/or regulated taking into account the characteristic and/or the volume flow of the material to be processed. The invention also relates to a material processing device designed to perform such a method.