Crusher Filling Level Control via Mechanical Loading Feedback
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Solution Overview
Problem
Material comminution systems face overloading issues due to varying material properties, leading to rapid wear and damage of crusher components, particularly when dealing with large feed sizes and high comminution ratios, which existing methods fail to reliably prevent.
Innovation Solution
A method that determines the mechanical loading of the crusher by measuring strain or movement behavior of critical components and adjusts the filling level to prevent overloading, using sensors like strain gauges and acceleration sensors to control the material supply, ensuring components operate within permissible limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the filling level of the crusher is increased to maximize throughput, then productivity increases, but the mechanical loading on the crusher and its components exceeds permissible limits leading to damage and rapid wear
Solution Approach 1:
The system continuously monitors the mechanical loading of the crusher using strain gauges or acceleration sensors and feeds this information back to the control unit. The control unit adjusts the filling level dynamically based on the measured loading, ensuring that the crusher operates within permissible loading limits while maximizing throughput. This closed-loop control prevents overloading and extends component lifespan.
Solution Approach 2:
The filling level is not kept static but is dynamically adjusted based on the actual mechanical loading conditions. The control unit modifies the filling level in real-time according to the measured strain or acceleration values, allowing the system to adapt to varying material properties and loading conditions, thereby optimizing both productivity and reliability.
2Reliability
If the filling level is reduced to prevent overloading, then component wear is reduced, but the throughput of the material comminution system decreases
Solution Approach 1:
The control unit receives continuous feedback on the mechanical loading from sensors and adjusts the filling level accordingly. When loading is within permissible limits, the filling level is maintained high to maximize throughput. When loading approaches dangerous levels, the filling level is reduced to prevent damage. This dynamic feedback control eliminates the need for conservative static filling level settings.
Solution Approach 2:
The system changes the filling level parameter dynamically based on the measured mechanical loading conditions. By adjusting this key operational parameter in real-time, the system optimizes the balance between throughput and component protection, avoiding both overloading and unnecessary throughput reduction.
3Reliability
If strain gauges are installed on the crusher components to measure mechanical loading, then overloading can be detected, but the device complexity and cost increase
Solution Approach 1:
The patent replaces complex strain gauge installations with acceleration sensors that measure the acceleration of the crusher jaw or other moving components. Since mechanical loading is directly related to acceleration, this substitution provides overloading detection with simpler, more robust sensors that are easier to install and maintain, while reducing device complexity.
4Measurement precision
If the mechanical loading is determined using strain gauges, then precise overloading detection is achieved, but the measurement precision requirements increase the complexity of the measurement system
Solution Approach 1:
The patent replaces complex strain measurement systems with acceleration-based measurement. Acceleration sensors are inherently more robust and require less complex signal conditioning and calibration than strain gauges. The relationship between acceleration and mechanical loading is direct and can be processed with simpler electronics, reducing measurement system complexity while maintaining adequate precision for overloading detection.
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 effectively prevents crusher overloading, ensuring high throughput and extending the lifespan of components by dynamically adjusting the filling level based on real-time loading conditions, thereby maintaining efficient and economical operation.
Implementation Method 1
a filling level of the crusher, preferably at a crusher inlet, is determined using a filling level sensor which is configured, for example, as an ultrasonic sensor
Implementation Method 2
the strain of the component subjected to high mechanical loads is determined, for example, by means of a strain gage
Implementation Method 3
the movement behavior of the component subjected to high mechanical loads is determined, for example, by means of an acceleration sensor
Data Source
AI summary
The invention relates to a method for controlling the charging of a crusher, driven by a crusher drive via transmission elements, of a material comminution system, wherein material which is to be crushed is fed to the crusher, a filling level of the crusher is determined using a filling level sensor, and the volume flow of material to be crushed is set and/or regulated according to the filling level determined. The mechanical loading of the crusher or a characteristic variable which is dependent on the mechanical loading of the crusher is determined directly or indirectly, and the filling level of the crusher is set according to the mechanical loading determined, or the characteristic variable which is dependent thereon. The method permits low-wear operation of the material comminution system and of the crusher with, at the same time, a high material throughput rate.