Drone-Mounted Laser Measurement for Gyratory Crusher Gap Width
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Solution Overview
Problem
Current methods for measuring the gap width between the mantle and concave in gyratory crushers are either unsafe, time-consuming, or require shutting down the crusher, making it difficult to accurately determine wear and schedule maintenance.
Innovation Solution
A system using a drone-mounted camera and calibration laser emitter that generates point cloud data to measure the gap width without shutting down the crusher, allowing for quick and safe determination of the closed-side and open-side settings, enabling accurate prediction of mantle life and optimization of crusher operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement with lead ball is used, then CSS measurement is achieved, but operator safety is compromised and measurement time increases
Solution Approach 1:
The patent replaces the manual mechanical measurement system (lead ball and rope) with an automated optical measurement system using laser emitter, camera, and image processing. The laser traces the gap and the camera captures images for automated analysis, eliminating the need for operators to physically enter the crusher chamber and handle lead balls, thereby resolving the safety contradiction while maintaining measurement capability
Solution Approach 2:
The patent introduces a laser trace as an intermediary element between the measurement system and the CSS gap. The laser creates a visible trace that represents the gap width, allowing remote optical measurement without direct physical contact with the hazardous environment, thus improving operator safety while enabling precise measurement
2Measurement precision
If 3D laser imaging is used, then CSS measurement is achieved, but crusher shutdown is required and measurement time increases
Solution Approach 1:
The patent implements periodic measurement capability where the laser and camera system can quickly capture CSS data at specific intervals or on-demand without requiring continuous crusher shutdown. The system can perform measurements during scheduled maintenance windows or when the crusher is temporarily idle, minimizing production impact while maintaining measurement accuracy
Solution Approach 2:
The patent replaces the complex 3D laser imaging system requiring crusher shutdown with a simplified laser trace and 2D image capture system that can operate with the crusher stationary but not necessarily shut down. This substitution reduces measurement time and allows for quicker data acquisition, improving crusher availability
3Measurement precision
If frequent CSS monitoring is implemented, then wear prediction accuracy is improved, but measurement time and operational disruption increase
Solution Approach 1:
The patent establishes preliminary calibration procedures where the laser and camera system are pre-configured with reference measurements and calibration data. This preliminary setup enables rapid subsequent measurements without requiring full recalibration each time, allowing frequent monitoring while minimizing the time penalty for each measurement event
Solution Approach 2:
The patent replaces time-consuming manual measurement procedures with automated laser tracing and digital image analysis. The automated system quickly captures measurements and processes images to determine CSS values, reducing measurement time from potentially hours to minutes, thereby enabling frequent monitoring without significant operational disruption
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 rapid, risk-free measurement of gap widths during crusher operation, extending mantle life, maintaining production quality, and reducing downtime, while allowing for precise planning of maintenance and maximizing crusher throughput.
Implementation Method 1
a laser emitter, the laser emitter positioned to mark a laser trace traversing the gap and at least intersecting the concave liner
Implementation Method 2
a camera mounted on the drone, the camera to capture an at least one image of the laser trace and an outer edge of the concave liner
Data Source
AI summary
A gyratory crusher and system for determining a close-side setting or an open-side setting is provided including a point cloud generator mounted proximate the crusher; a drone; a laser emitter mounted on the drone to mark the first trace on the mantle at a predetermined position of the gap; a camera mounted on the drone to capture a series of image of the first trace as the mantle of the gyratory crusher rotates; and a computer in communication with the camera, the point cloud generator and the drone, the computer comprising a memory and a processor, the memory providing instructions to process the image to provide a gap width and to determine at least one of a close-side setting or an open-side setting from the gap width.