Crusher Pressure Relief Valve for Fast Overload Gap Opening
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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 in high-speed variants, leading to potential damage from non-breakable materials and variability in grain size due to changing rock forces.
Innovation Solution
The design incorporates a pressure relief valve with a piston that has reduced piston pressure surfaces, allowing for easier control and mass reduction of accelerated components, enabling quicker response to overloads and maintaining a consistent crushing gap during normal operation by adjusting the projection of piston pressure surfaces within a specific plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pressure relief valve with a piston is used to respond to overload situations, then the crusher can quickly open the crushing gap to prevent damage, but the piston mass and associated component mass increase, slowing down the response speed
Solution Approach 1:
The pressure chamber is segmented such that the piston does not delimit the entire pressure chamber transversely to the actuating direction. Instead, the piston pressure surface projects into the pressure chamber but only delimits a portion of it, creating a smaller effective pressure area on the piston. This segmentation reduces the piston mass and inertial resistance, enabling faster response to overload conditions while maintaining sufficient force through the concentrated pressure application.
2Speed
If the piston pressure surface area is reduced to decrease component mass and improve response speed, then the response to overload improves, but the force available to trigger the pressure relief valve decreases
Solution Approach 1:
The pressure chamber geometry is optimized locally in the region where the piston pressure surface acts. The pressure chamber is designed with enhanced pressure generation capability in the specific zone corresponding to the reduced piston pressure surface area. This local quality enhancement ensures that despite the reduced area, the concentrated pressure force remains sufficient to quickly trigger the pressure relief valve when overload occurs.
3Reliability
If an elastic gas spring is used to support the impact rocker, then the crushing gap can adjust to overload, but the elastic gas spring causes constant variation in crushing gap width during normal operation, degrading material quality
Solution Approach 1:
The elastic gas spring is extracted from the system and replaced with a hydraulic cylinder combined with a pressure relief valve. The hydraulic cylinder provides rigid, controllable support for the crushing body, eliminating the constant elastic variations that degraded material quality. The pressure relief valve is added as a separate overload protection mechanism, separating the normal operation support function from the overload response function, thereby maintaining crushing gap consistency during normal operation while providing reliable overload protection.
4Reliability
If the pressure relief valve is designed to respond quickly to overload, then damage from non-breakable materials is prevented, but the pressure increase during rapid crushing gap opening must be limited, requiring careful valve dimensioning
Solution Approach 1:
The pressure relief valve is designed with dynamic characteristics optimized for rapid response. The valve opening area, spring preload, and damping characteristics are tuned to open quickly upon detecting overload pressure, preventing damage from non-breakable materials. Simultaneously, the valve geometry and flow passages are designed to limit excessive pressure buildup during the rapid opening process, balancing protection capability with pressure control.
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 enhances the crusher's response to overload situations, reduces the risk of damage from non-breakable materials, and maintains consistent grain size by ensuring the pressure relief valve remains closed during normal operation, improving the overall efficiency and reliability of the crushing process.
Implementation Method 1
a hydraulic cylinder is coupled to one of the crushing bodies, which is arranged and designed to permit 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 in a cylinder 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
Figure 2~3
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 (43) 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 (43) has at least one piston pressure surface (43.2) by means of which the piston (43) limits the pressure chamber (41.6) in the closed position transversely to the direction of movement of the piston (43). In such a crusher, the overload release device responds quickly in the event of an overload if it is provided that in the closed state of the pressure relief valve the projection of the piston pressure surface (43.2) or the piston pressure surfaces (43.2) of the piston (43) into a projection plane transverse to the direction of movement of the piston (43), preferably into the closing plane, only a part of the pressure chamber (41.6) is limited transversely to the direction of movement of the piston (43). At the same time, the crushing gap (15) is kept as constant as possible during crushing operation in normal operation.