Crusher Overload Valve Control for Adaptive Gap Protection
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Solution Overview
Problem
Existing crushers, particularly rotary impact crushers, face inefficiencies and safety issues due to the inability to distinguish between critical and uncritical overload situations, leading to unnecessary stress and damage during crushing operations.
Innovation Solution
The implementation of an overload triggering device with a high-pressure valve that differentiates between uncritical and critical overload situations by adjusting the crushing gap width, using a pressure valve that opens at a lower pressure for minor load peaks and a high-pressure valve that opens at a significantly higher pressure for non-crushable objects, ensuring efficient and safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single pressure valve is used to detect overload situations, then the crusher can respond to overload conditions, but it cannot distinguish between critical and uncritical overloads, leading to unnecessary stress and damage
Solution Approach 1:
The single pressure valve is segmented into two distinct pressure valves: a first pressure valve with a lower opening pressure for uncritical overloads and a second pressure valve with a higher opening pressure for critical overloads. This segmentation allows the system to differentiate between different overload severity levels and respond appropriately, preventing unnecessary damage while maintaining reliability.
2Adaptability or versatility
If the crushing gap is constantly adjusted to respond to varying loads, then the crusher can adapt to different material conditions, but the grain size of crushed material varies undesirably
Solution Approach 1:
The system applies different response strategies to different overload conditions: the first pressure valve triggers a controlled, minimal adjustment for uncritical overloads to maintain grain size consistency, while the second pressure valve triggers a more significant adjustment only when necessary for critical overloads. This localized quality approach ensures adaptability without compromising manufacturing precision.
3Productivity
If the crusher operates with a fixed crushing gap for optimal performance, then crushing efficiency is maximized, but the system cannot respond to overload situations
Solution Approach 1:
The system maintains a fixed crushing gap configuration under normal operating conditions to maximize crushing efficiency. The two pressure valves remain closed, preserving the optimized gap setting. When overload conditions occur, the appropriate pressure valve opens dynamically, allowing controlled adjustment of the crushing gap to protect the system, thus maintaining both productivity and reliability.
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 allows for precise control of the crushing gap, preventing damage from non-crushable objects while maintaining optimal crushing performance under varying loads, enhancing both efficiency and safety by quickly adjusting the gap width in response to different overload conditions.
Implementation Method 1
a hydraulic cylinder (20) which can be used to adjust the position of the crusher body (14) and thus the width of the crushing gap (15)
Implementation Method 2
the triggering pressure required to open the pressure valve being lower than the triggering pressure required to open the high-pressure valve
Data Source
AI summary
The invention relates to a crusher, in particular a rotary impact crusher, cone crusher or jaw crusher, having a crusher unit (10), which has a movable first crusher body (11), in particular a rotor or a crusher jaw, wherein a second crusher body (14), in particular an impact rocker or a crusher jaw, is assigned to the first crusher body (11), wherein a crushing gap (15) is formed between the crusher bodies (11, 14), wherein an overload triggering device (30) is coupled to the first crusher body or to the second crusher body, which overload triggering device has a hydraulic cylinder (20) and which overload triggering device is designed to permit a motion of the coupled crusher body (11, 14) increasing the width of the crushing gap (15), wherein the hydraulic cylinder (20) has a pressure chamber (24), which is delimited by means of a piston (23), and wherein the overload triggering device (30) has a pressure valve (31) which, in its open position, establishes a fluid-conveying connection between the pressure chamber (24) and a low-pressure area and, in the closed valve position, blocks this connection. The productivity and operational safety of such a crusher can then be increased if provision is made that the overload triggering device (30) has a high-pressure valve (40), which, as a result of an overload situation, in its open position establishes a fluid-conveying connection between the pressure chamber (24) of the hydraulic cylinder (20) and a low-pressure area and, after the overload situation has ended, is moved into a closed position to block this connection, and in that the triggering pressure required to open the pressure valve (31) is lower than the triggering pressure required to open the high-pressure valve (40).