Crusher Screen Self-Cleaning Through Temporary Coarse Grain Control
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Solution Overview
Problem
Existing methods for removing blocking-grains in crushers, such as mobile impact crushers, are inefficient, requiring manual intervention and energy-intensive shutdowns due to screen mesh blockages, which reduce the effective screening area and overall efficiency.
Innovation Solution
Measuring material volume and grain size distribution at intervals, and increasing grain size temporarily to generate coarse grain that impacts the screen meshes, clearing blockages without stopping the crusher, and using a neural network for accurate grain size determination at higher conveyor speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tapping bodies are arranged on the screen surface to remove blocking-grains, then screen mesh blockage is reduced, but the available free screening area is reduced and additional energy input is required
Solution Approach 1:
The system uses the material stream itself to clean the screen meshes by detecting blockages and adjusting crushing parameters to generate coarse grain that impacts and removes blocking-grains, eliminating the need for separate tapping bodies
Solution Approach 2:
The patent replaces mechanical tapping bodies with a control system that monitors material properties and dynamically adjusts crushing gap and rotor speed to achieve screen cleaning through material impact
2Reliability
If vibration amplitude of the screen is increased to clean blocking-grains, then screen cleaning is improved, but the impulses transmitted to blocking-grains are too low to allow reliable cleaning
Solution Approach 1:
The system changes operational parameters (crushing gap, rotor speed) to generate appropriate grain sizes that can effectively clean screens without requiring excessive vibration amplitude
Solution Approach 2:
The control system periodically monitors material properties and applies crushing parameter adjustments in cycles to maintain screen cleanliness while optimizing overall crusher efficiency
3Reliability
If manual removal of blocking-grains is performed, then screen mesh blockage is cleared, but machine operation must be temporarily stopped
Solution Approach 1:
The crusher system automatically detects and cleans its own screen meshes by adjusting crushing parameters and using the material stream to impact and remove blocking-grains during continuous operation
Solution Approach 2:
The control system continuously monitors material volume and grain size distribution, and based on this feedback, dynamically adjusts crushing parameters to prevent and clear screen blockages without stopping operation
4Reliability
If shutdown and startup processes are performed for screen cleaning, then blockages are removed, but energy-intensive shutdown and startup processes occur
Solution Approach 1:
The system performs self-cleaning during operation by adjusting crushing parameters to generate coarse grain that impacts and removes blocking-grains, avoiding energy-intensive shutdowns and startups
Solution Approach 2:
The crusher maintains continuous operation and material flow while dynamically adjusting parameters to achieve screen cleaning, eliminating the interruption and energy consumption associated with shutdown-startup cycles
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
Enables continuous crusher operation with reduced downtime and energy consumption, maintaining efficiency by automatically clearing blockages and ensuring reliable grain size detection even at high conveyor speeds.
Implementation Method 1
the grain size created by the crushing tool is increased for a predetermined period of time... coarse grain is specifically generated by the crushing tool... screen meshes are knocked free by the impulse impact of the impinging coarse grain
Data Source
AI summary
In a method for cleaning blinding particles in crushers, material to be crushed is fed via a feed stream (1) to a crushing tool, and from there is separated by a screen (7) into a conveyor stream (8) that passes through the screen (7) and a return stream (10) that is held back by the screen (7) and returned to the feed stream (1), thereby forming a conveyance circuit (9). The method makes an efficient, continuous crusher operation possible, wherein idle times for cleaning blinding particles can be avoided. The particle size distribution and/or the material volume are measured at specified intervals in parts of the conveyance circuit (9) and/or conveyor stream (8), and if the particle size distribution and/or material volume deviate above a predefined limit value, the particle size created by the crushing tool is increased for a predefined time period.