Crusher Pressure Relief Valve for Fast Overload Gap Response
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Solution Overview
Problem
Existing crushers face challenges in maintaining a constant crushing gap during normal operation while responding quickly to overload situations, especially with varying rock sizes and hardness, leading to potential damage and quality losses.
Innovation Solution
A pressure relief valve design with a piston having a surface area that exerts a closing force, allowing for quick opening in overload situations, and a compensating pressure surface to maintain the crushing gap constant during normal operation, using a hydraulic cylinder connected to the crushing unit with a pressure relief valve that can quickly respond to overloads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a pressure relief valve is designed to open quickly in overload situations, then the response speed is improved, but the closing force required to maintain constant crushing gap during normal operation increases
Solution Approach 1:
The piston is designed with asymmetric surface areas that create dynamic force balance: a large pressure chamber surface area provides strong opening force during overload, while a smaller chamber area surface area provides controlled closing force during normal operation. This dynamic design allows the valve to respond quickly to overloads while maintaining stable crushing gap under normal conditions.
Solution Approach 2:
The invention changes the pressure parameters by introducing a chamber area with lower pressure than the pressure chamber. This pressure differential creates the necessary closing force without requiring excessive force during normal operation, while still enabling rapid opening when overload occurs.
2Stability of the object's composition
If the pressure relief valve setting pressure is increased to prevent normal crusher loads from triggering adjustment, then the crushing gap stability is improved, but the response time to overload situations increases
Solution Approach 1:
The pressure relief valve system is segmented into two distinct pressure zones: a pressure chamber with high pressure for rapid overload response, and a chamber area with lower pressure for stable normal operation. This segmentation allows the valve to maintain high stability during normal crushing while responding quickly to overload conditions.
Solution Approach 2:
The asymmetric piston design creates dynamic response characteristics where the valve remains stable at high pressure during normal operation but can rapidly open when overload pressure is applied, reducing the trade-off between stability and response time.
3Speed
If the piston mass is reduced to improve response behavior, then the response speed is improved, but the closing force required to maintain crushing gap increases
Solution Approach 1:
The invention replaces the need for heavy piston mass with a hydraulic pressure system. The closing force is generated by hydraulic pressure acting on the chamber area surface, substituting mechanical mass with fluid pressure to achieve both rapid response and sufficient closing force.
Solution Approach 2:
By introducing a second pressure zone (chamber area) with lower pressure, the system changes the force generation mechanism. The closing force is achieved through hydraulic pressure differential rather than piston mass, allowing lightweight piston design with fast response.
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
The solution enables the pressure relief valve to open quickly in overload situations, reducing the risk of damage and maintaining consistent crushing gap dimensions during normal operation, improving the response behavior and material quality.
Implementation Method 1
a hydraulic cylinder is coupled to one of the crushing bodies, which is arranged and designed to allow a movement of the coupled crushing body in an evasive movement that increases the width of the crushing gap
Implementation Method 2
a piston of the pressure relief valve is adjustable between a closed position and an open position, wherein in the closed position a fluid-conducting connection between the pressure chamber and a pressure compensation area is blocked and in the open position the fluid-conducting connection is at least partially released
Data Source
Figure 1
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Figure 4
AI summary
The invention relates to a crusher for mineral materials or recycled materials, in particular rotary impact crushers, jaw crushers, cone crushers or roller crushers, with a crushing unit (10) comprising a first crushing element (11), in particular a rotor or a crushing jaw, wherein a second movable crushing element (14), in particular an impact rocker or a crushing jaw, is associated with the first crushing element (11), wherein a crushing gap (15) is formed between the crushing elements (11, 14), wherein a hydraulic cylinder (20) is coupled to one of the crushing elements (11, 14), which is arranged and designed to allow a movement of the coupled crushing element (11, 14) that increases the width of the crushing gap (15) in an evasive movement, wherein a pressure chamber (24) of the hydraulic cylinder (20) is connected to a pressure chamber (41).6) a pressure relief valve (40) is connected to an overload release device (30), wherein a piston (50) of the pressure relief valve (40) is adjustable between a closed position and an open position, wherein in the closed position a fluid-conducting connection between the pressure chamber (41.6) and a pressure equalization area (B) is blocked and in the open position the fluid-conducting connection is at least partially released, and wherein the piston (50) has at least one piston pressure surface (56) by means of which the piston (50) limits the pressure chamber (41.6) in the closed position transversely to the direction of movement of the piston (50). In order to achieve a fast response behavior in such a pressure relief valve (40), it is provided according to the invention that the piston (50) has a surface area (58) on its side facing away from the pressure chamber (41.6) which, in the closed position of the piston (50), forms a chamber area (41.11) limited transversely to the direction of movement of the piston (50) in order to introduce a closing force in the direction of the closing position into the piston (50) under the influence of the pressure in the chamber area (41.11).