Gyratory Crusher Load Measurement via Shell Position Correlation
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Solution Overview
Problem
Current methods for controlling gyratory crushers do not effectively maximize material feed without overloading, as they rely on mean peak pressure calculations, which do not account for uneven material distribution and segregation, leading to inefficient crushing operations.
Innovation Solution
A measuring instrument that includes a first device for measuring instantaneous loads and a second device for measuring the gyrating position of the inner shell relative to the outer shell, with a correlating device to match these measurements, providing an indicating dial to visually represent load distribution and suggesting adjustments for optimal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If mean peak pressure calculations are used to control crusher load, then the crusher can operate at high load, but uneven material distribution and segregation are not detected, leading to inefficient crushing operations
Solution Approach 1:
The patent divides the crusher operation into discrete measurement points around the crushing gap perimeter. Multiple load cells are positioned at different locations to segment the measurement of material distribution, allowing detection of uneven feeding patterns that affect crushing efficiency while maintaining high overall load
Solution Approach 2:
The patent measures load and material distribution at specific local positions around the crushing gap rather than using a single overall measurement. This local quality approach identifies segregation and uneven distribution at specific locations, enabling targeted adjustments to maximize crushing efficiency at each zone while maintaining high crusher load
2Productivity
If material feed rate is increased to maximize throughput, then productivity increases, but the crusher may become overloaded, reducing reliability
Solution Approach 1:
The patent implements a feedback system where load cells continuously measure material distribution and load at multiple positions around the crushing gap. This feedback is processed to detect conditions indicating approaching overload, allowing operators to adjust feed rate before reliability is compromised while maintaining high productivity
Solution Approach 2:
The patent measures and analyzes material distribution patterns before complete overload occurs. By detecting uneven distribution and segregation early in the feeding process, the system enables preliminary adjustments to feed rate and distribution, preventing overload conditions that would reduce reliability while sustaining high productivity
Data Source
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AI summary
A measuring instrument (40) for indicating the load in a gyratory crusher comprises a first measuring device (32, 42) for measuring at least one instanta¬ neous load on the crusher, a second measuring device (44) for measuring the gyrating position of the inner shell (20) relative to the outer shell (22), and a correlating device (48) adapted to match said at least one instanta¬ neous load on the crusher with a corresponding measured gyrating position of the inner shell (20) relative to the outer shell (22).