Crusher Wear Inspection Through a Retractable Sensor Carrier
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Solution Overview
Problem
Accessing the crushing chamber of crushing devices for wear part inspection is difficult and time-consuming, posing safety risks and increasing machine downtime, while existing sensor-based solutions are impractical and require replacing detection devices with wear parts.
Innovation Solution
A detection device is mounted on a carrier that moves between a parked and detection position through an inspection opening, allowing safe and accurate wear part condition assessment without being physically attached to the wear part, using optical or electromagnetic methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the detection device is physically attached to the wear part, then the wear detection is continuous, but the device complexity increases and the detection device must be replaced with every wear part
Solution Approach 1:
A carrier serves as an intermediary between the detection device and the wear part. The carrier holds the detection device and positions it relative to the wear part through the inspection opening, allowing the detection device to remain separate from the wear part while still performing its function. This resolves the contradiction by enabling wear detection without permanent attachment.
Solution Approach 2:
The carrier is designed as a universal platform that can hold and position the detection device for multiple different wear parts. Instead of integrating the detection device into each specific wear part, the same carrier system can service various wear parts, reducing overall system complexity and part numbers.
2Reliability
If the detection device is accessible through the inspection opening, then the operator safety is improved, but the ease of operation deteriorates due to the difficult access to the crushing chamber
Solution Approach 1:
The carrier is designed to be movable between a retracted position (outside the crushing chamber) and an extended position (through the inspection opening into the crushing chamber). This dynamic positioning allows the detection device to access the wear part when needed while maintaining operator safety by keeping the detection device outside the hazardous zone during normal operation.
Solution Approach 2:
The manual access and inspection process is replaced with an automated detection device mounted on the carrier. The actuator automatically positions the detection device through the inspection opening, eliminating the need for operators to manually access the dangerous crushing chamber environment.
3Productivity
If the detection device remains in the crushing chamber, then the wear detection is continuous, but the risk of damage from crushed material and dust increases
Solution Approach 1:
The carrier enables the detection device to dynamically switch between being inside the crushing chamber (for continuous monitoring) and outside the crushing chamber (for protection). The actuator retracts the detection device when not in use, protecting it from damaged by crushed material and dust while maintaining the capability for continuous wear detection when needed.
4Quantity of substance
If manual inspection of wear parts is performed, then the equipment cost is low, but the machine downtime increases and measurement accuracy decreases
Solution Approach 1:
Manual visual inspection is replaced with an automated detection device that uses optical or electromagnetic fields to measure wear part conditions. This substitution eliminates the need for operators to manually access the crushing chamber, significantly reducing machine downtime while providing more accurate and consistent measurements.
Solution Approach 2:
The detection device enables the crushing device to self-monitor its own wear part conditions without requiring external manual inspection. The detection device can automatically detect wear states and provide feedback, allowing the system to self-assess its condition and plan maintenance activities, thereby reducing unplanned downtime.
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 reliable and safe wear detection with reduced risk of damage, minimizing machine downtime and simplifying the inspection process.
Implementation Method 1
the detection device can be, in particular, an optical measuring device, for example, a measuring device comprising a laser scanner or a camera
Implementation Method 2
Electromagnetic distance measurement methods, such as radar or eddy current sensors
Data Source
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AI summary
The invention relates to a crushing device for crushing mineral material or the like, comprising a crushing unit (10) having a crushing chamber (30), wherein a crushing device (11), in particular movable, preferably rotatable or pivotable, is accommodated in the crushing chamber (30), wherein the crushing device (11) carries at least one crushing tool (11.2), in particular a crushing tool, wherein the crushing chamber (30) is limited by means of at least one crushing chamber boundary (31), wherein the crushing chamber boundary (31) has an inner side (31.2) facing the crushing chamber (30) and an outer side (31.1) facing away from the crushing chamber (30), and wherein the crushing chamber boundary (31) has an inspection opening (32).Reliable and operationally safe detection of the wear condition of the crushing device can be achieved if a detection device (50) held by a carrier (40) is provided for determining the wear condition of at least one wear part arranged in the crushing chamber (30), in particular a crushing or crushing tool (11.2), and if the detection device (50) is adjustable through the inspection opening (32), preferably by means of an actuator (80), between a park position and a detection position, wherein the detection device (50) is arranged at least partially in the crushing chamber (30) in the detection position and is arranged outside the crushing chamber (30) in the park position.