Crusher Pressure Relief Valve for Fast Overload Gap Control
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Solution Overview
Problem
Existing crushers face challenges in responding quickly to overload situations while maintaining a constant crushing gap during normal operation, leading to potential damage and variability in particle size due to varying rock hardness and size.
Innovation Solution
The design incorporates a piston with a specific surface area distribution that allows for a quick response to overloads by balancing opening and closing forces, using a pressure relief valve with a piston pressure surface and an external pressure equalization surface to maintain a constant crushing gap and reduce the mass of moving components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressure relief valve is designed with a heavy piston to maintain stability during normal operation, then the crushing gap remains constant, but the response time to overload situations increases
Solution Approach 1:
The piston is segmented into two distinct surface areas: a first pressure surface area exposed to pressure chamber pressure and a second pressure surface area exposed to pressure equalization area pressure. This segmentation allows differential force application - the larger first area provides stability during normal operation while the smaller second area enables rapid response to overload conditions when pressure differential increases.
Solution Approach 2:
The design changes the pressure parameters acting on different surfaces of the piston. During normal operation, pressure in both the pressure chamber and pressure equalization area remains relatively balanced. During overload, pressure in the pressure chamber increases sharply while pressure equalization area pressure remains lower, creating a pressure differential that rapidly accelerates the piston despite its mass.
2Loss of time
If the piston mass is reduced to improve response speed, then the response time to overload decreases, but the stability and control of the crushing gap during normal operation deteriorates
Solution Approach 1:
The piston surfaces are designed asymmetrically with respect to pressure exposure. The first pressure surface area is larger than the second pressure surface area, creating an asymmetric force distribution that provides stabilizing force during normal operation while allowing rapid acceleration during overload when the pressure differential overcomes the asymmetric force balance.
3Object-affected harmful factors
If the pressure relief valve opens quickly in overload situations, then damage prevention is improved, but the crushing gap variability during normal operation increases
Solution Approach 1:
The system provides automatic feedback control through the pressure differential mechanism. During normal operation, pressures in the pressure chamber and pressure equalization area remain balanced, providing stable feedback that maintains constant crushing gap. During overload, the sudden pressure increase in the pressure chamber creates a positive feedback differential that rapidly opens the valve to prevent damage, then automatically closes when pressure normalizes, maintaining particle size consistency.
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 solution enables the pressure relief valve to open rapidly in overload situations, preventing damage and maintaining consistent particle size, while reducing the mass and complexity of the piston, thus enhancing the crusher's response and operational efficiency.
Implementation Method 1
a first force acting in the opening direction of the piston, which is computed from a pressure in the pressure chamber and from a first piston pressure surface delimiting the pressure chamber, onto which first piston pressure surface this pressure is applied, and a second force acting in the closing direction of the piston, which is computed from a pressure in the pressure equalization area and from a second piston pressure surface delimiting the pressure equalization area, onto which second piston pressure surface this pressure is applied
Data Source
AI summary
A crusher includes first and second crusher bodies defining a crushing gap. A hydraulic cylinder is coupled to one of the crusher bodies to adjust a width of the crushing gap. A pressure relief valve includes a pressure chamber communicated with the hydraulic cylinder. A pressure relief piston is movable between a closed position and an open position. The pressure relief piston includes at least one piston pressure surface delimiting the pressure chamber in the closed position transversely to the actuation direction of the piston, the pressure relief piston including a surface area at an end facing away from the pressure chamber, which surface area delimits the chamber area transverse to the actuating direction of the piston to transfer a closing force to the pressure relief piston in a closing direction of the closed position when pressure is applied in a chamber area.