Crusher Wear Assessment With Quality Indicators
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Solution Overview
Problem
Existing rock processing machines, particularly crushing apparatuses, suffer from excessive wear due to physical-abrasive interaction with mineral rock, leading to unpredictable operational capacity and potential machine damage from inaccurate wear predictions based on historical data.
Innovation Solution
A rock processing machine equipped with a data processing apparatus that provides wear information along with quality indicators, utilizing various data collection bases to assess wear accurately, including wear sensors and adjustable tool configurations, enabling precise wear prediction and operational capacity estimation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If wear information is ascertained based on historical wear data from identical working tool configurations, then wear prediction capability is improved, but reliability deteriorates when historical data is unavailable or inaccurate
Solution Approach 1:
The patent introduces a data processing apparatus that acts as an intermediary between raw sensor data and wear predictions. This apparatus collects data from multiple sources (sensors, operational parameters, material properties) and processes them through algorithms to generate reliable wear information even when historical data is limited, thereby resolving the contradiction between information availability and prediction accuracy
Solution Approach 2:
The system is designed to handle multiple data collection bases (historical data, real-time sensor data, operational parameters, material properties) through a single unified data processing apparatus. This multi-functional approach allows the system to adapt to different data availability scenarios and maintain reliable wear predictions across various operating conditions
2Measurement precision
If multiple data collection bases are utilized for wear assessment, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple data collection bases (sensors, operational parameters, material properties, historical data) into a single integrated data processing apparatus. This merging approach consolidates what would otherwise be separate complex systems into one unified platform, achieving high measurement precision while managing device complexity through integration rather than multiplication of components
Solution Approach 2:
The data processing apparatus is designed as a universal system that can process diverse data types from multiple collection bases through standardized algorithms. This multi-functional design allows the same apparatus to handle different data sources and processing requirements, achieving comprehensive wear assessment without proportionally increasing system complexity
3Productivity
If wear information is provided without quality indicators, then productivity is maintained, but reliability deteriorates due to unpredictable wear limits
Solution Approach 1:
The patent implements feedback by providing quality indicators alongside wear information. These indicators (such as confidence levels, data completeness metrics, and prediction uncertainty measures) give operators feedback on the reliability of wear predictions, enabling them to make informed decisions about maintenance timing while maintaining optimal productivity
Solution Approach 2:
The data processing apparatus acts as an intermediary that not only calculates wear information but also assesses the quality and reliability of this information through multiple data collection bases. This intermediary function adds a layer of quality evaluation that enhances both productivity and reliability by providing trustworthy wear predictions
Data Source
AI summary
A rock processing machine comprises: a material feeding apparatus having a material buffer for loading starting material to be processed; at least one working apparatus of at least one crushing apparatus and/or at least one screening apparatus; at least one conveyor apparatus for conveying material; a data processor including a data memory; a display connected to the data processor in data-transmitting fashion. The data processor ascertains, from data retrievable from the data memory which are based on at least one data collection basis, wear information regarding the wear of a working tool configuration of the at least one working apparatus, ascertains for the wear information, starting from at least one data collection basis, on which at least a portion of the data used for ascertaining the wear information is based, quality information regarding the wear information, and output the wear information and quality information via the display.