Crusher Overload Valve Assembly for Fast Crushing Gap Opening
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Solution Overview
Problem
Existing crushers face issues with slow response times during overload situations, leading to potential damage due to inadequate fast opening of the crushing gap, which is not effectively addressed by existing hydraulic systems.
Innovation Solution
The integration of a motion-controlled valve within the movable assembly of the overload triggering device, utilizing an inertia element and a spring element to accelerate the valve opening, allowing for rapid expansion of the crushing gap during overloads, thereby enhancing the reaction time and safeguarding the crusher.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic cylinder with a pressure valve is used for overload protection, then the crusher can be protected against overload situations, but the response time is too slow and components may still be damaged
Solution Approach 1:
The valve is designed to be motion-controlled, opening automatically when the movable assembly moves during an overload event. This dynamic response mechanism eliminates the delay associated with pressure buildup required for conventional pressure valves to open, enabling immediate protection while maintaining system reliability.
Solution Approach 2:
The invention replaces the pressure-based valve opening mechanism with a motion-based triggering mechanism. Instead of relying on pressure differential to open the valve, the system uses the physical movement of the movable assembly during overload to directly actuate the valve, significantly reducing response time.
2Loss of time
If the valve is integrated into the movable assembly, then the response behavior is significantly improved, but the device complexity increases
Solution Approach 1:
The valve is merged with the movable assembly components, specifically utilizing the piston or piston rod as part of the valve structure. This integration reduces the number of separate components and simplifies the overall system architecture while achieving fast motion-controlled response.
Solution Approach 2:
Components of the movable assembly, particularly the piston and piston rod, are designed to serve dual functions: maintaining hydraulic pressure during normal operation and acting as the motion-controlled valve mechanism during overload events. This multi-functionality reduces device complexity despite the enhanced response capability.
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 significantly improves the response behavior and reaction time during overload situations, preventing damage to the crusher components by ensuring a swift opening of the crushing gap, effectively managing non-crushable objects and maintaining operational safety.
Implementation Method 1
The movable assembly is supported in the hydraulic cylinder against a fluid that is pressurized in a pressure chamber of the hydraulic cylinder
Implementation Method 2
utilizing an inertia element and a spring element to accelerate the valve opening
Implementation Method 3
utilizing an inertia element and a spring element to accelerate the valve opening
Data Source
AI summary
The invention relates to a crusher for mineral materials or recycled materials, in particular rotary impact crushers or jaw crushers, 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 a movable assembly of an overload triggering device (30) is coupled to the first or to the second crusher body (11, 14), wherein the movable assembly has a cylinder (25) of a hydraulic cylinder (20) or a piston (23) guided in the cylinder (20), wherein the movable assembly is designed to permit a motion of the coupled crusher body (11, 14) increasing the width of the crushing gap (15) in an evasive motion, wherein a pressure chamber (24) is formed in the hydraulic cylinder (20), which pressure chamber is delimited by a piston (23), and wherein the overload triggering device (30) has a valve (23.8), which, in its open position, establishes a fluid-conveying connection between the pressure chamber (24) and a compensation area (28) and, in the closed valve position, blocks this connection. In order to achieve an efficient protection of the crusher unit 10 against overload situations in such a crusher, provision is made for the valve (28.8) to be formed between two components of the movable assembly that are movable relative to each other.