Crusher Feed Opening Adjustment for Power and Wear Control
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Solution Overview
Problem
Current crushers cannot adjust the crushing chamber during operation, leading to inefficiencies in power intake, product distribution, and increased wear on wear parts due to high pressure and energy consumption, particularly when the surface height of material in the feed hopper increases.
Innovation Solution
An adjusting apparatus with movable parts that can adjust the flow area of the feed opening to the crushing chamber, allowing for real-time adjustments based on measured crushing power, pressure, and surface height to optimize material flow and reduce fine material production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the crushing chamber is adjusted by changing wear parts, then the crushing profile can be optimized, but the crusher must be stopped and disassembled, reducing productivity
Solution Approach 1:
The patent applies the dynamics principle by making the crushing chamber adjustable during operation rather than requiring shutdown. The wear parts are designed with movable elements that can be repositioned while the crusher is running, allowing the crushing profile to be optimized without stopping production. This transforms a static structure into a dynamic one that can adapt during operation.
Solution Approach 2:
The crushing chamber is divided into multiple adjustable wear parts that can be independently repositioned. This segmentation allows specific portions of the crushing profile to be optimized without affecting the entire chamber, and enables adjustments to be made in smaller increments during operation rather than requiring complete disassembly.
2Productivity
If the surface height of material in the feed hopper is increased, then the material flow to the crushing chamber is improved, but the pressure increases causing increased wear and higher energy consumption
Solution Approach 1:
The patent implements feedback control by monitoring the power consumption and material flow characteristics, then automatically adjusting the crushing chamber parameters in response. When high material flow is detected causing excessive power consumption and wear, the system adjusts the crushing profile to optimize the balance between productivity and energy usage.
Solution Approach 2:
The crushing chamber parameters such as the gap between wear parts and the crushing profile are dynamically changed based on operating conditions. When material surface height and flow rate increase, the system adjusts these parameters to maintain optimal crushing efficiency while preventing excessive power consumption and wear.
3Reliability
If the crushing chamber is not adjusted during operation, then the structure remains simple and reliable, but the product distribution and power intake cannot be optimized
Solution Approach 1:
The crushing chamber incorporates movable wear parts that can be adjusted during operation without compromising the overall structural stability. The adjustment mechanism is designed to maintain reliability while enabling dynamic adaptation of the crushing profile to optimize product distribution according to varying material properties and production requirements.
Data Source
AI summary
An adjusting apparatus of a feed opening of a crushing chamber of a crusher includes one or more adjusting parts arranged in connection with the feed opening, which one or more adjusting parts is/are movable during crushing for adjusting a flow area of material which is to be crushed and is flowing through the feed opening to the crushing chamber. The front edges of the adjusting parts form a unitary flow opening, the flow area of which is adjustable by moving one or more adjusting parts. An adjusting system includes the adjusting apparatus for a feed opening of a crushing chamber of a crusher. A method for adjusting a pressing crusher or a crushing plant suitable for mineral material crushing. A method for avoiding a start peak of a crusher. A method for limiting power intake and/or crushing pressure of a crusher.