Integrated Motor Crusher Drive Eliminates Belt Vibration
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Solution Overview
Problem
Existing mineral crushers face issues with space inefficiency, vibration, noise, and maintenance due to belt-based power transmission systems, which also lead to increased structural stress and risk of blockages during demanding crushing events.
Innovation Solution
A direct drive system where the rotor is rigidly coupled with the rotating crusher element, eliminating the need for external belts and pulleys, and integrating the motor within the crusher element to reduce vibrations and enhance energy efficiency, allowing the rotor's mass to contribute to peak forces and inertia.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If belt-based power transmission is used, then the motor can be positioned separately from the crusher unit, but the system occupies substantial space and increases the overall size of the crusher
Solution Approach 1:
The motor is integrated directly into the crusher unit, merging two previously separate components into a single compact assembly. This eliminates the need for belt-based power transmission and reduces the overall volume occupied by the crusher system.
2Power
If belt-based power transmission is used, then power can be transmitted from the motor to the crusher, but the system requires protective covering around belts and belt wheels to prevent user injuries
Solution Approach 1:
The hazardous belt-based power transmission components are completely removed from the system. Power is transmitted directly through the integrated motor-crus her assembly, eliminating the need for protective coverings around belts and belt wheels.
3Ease of operation
If belt-based power transmission is used, then the motor can be mounted on a separate motor bed or subframe, but the resonant vibration causes noise and substantial stress in various structures
Solution Approach 1:
The motor and crusher unit are merged into a single integrated assembly, eliminating the separate motor bed and subframe structures. This integration reduces resonant vibration and noise by removing the intermediate mounting structures that amplify vibrations.
4Power
If belt-based power transmission is used, then power can be transmitted to the crusher unit, but the system easily excites resonant vibration through the body to associated material conveyors
Solution Approach 1:
The belt-based power transmission system is extracted and removed from the design. Direct integration of the motor into the crusher unit eliminates the intermediate transmission components that excite resonant vibrations in the body and associated conveyors.
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
This configuration reduces vibrations, noise, and maintenance needs while improving energy efficiency and compactness, enabling effective crushing without external power transmission components and enhancing the crusher's ability to handle peak loads and blockages.
Implementation Method 1
allowing the rotor's mass to contribute to peak forces and inertia
Data Source
Figure 1a~1c
Figure 2~3
Figure 4a~4b
AI summary
A mineral material crusher (30, 200; 500, 510) comprising: a body (11, 211; 511); a rotating crusher element (13, 215; 513);a drive shaft arrangement (212,215) configured to support the rotating crusher element to the body and to rotate the rotating crusher element; and a motor comprising a rotor (218; 516) for driving the drive shaft arrangement; the motor is formed inside the rotating crusher element; the drive shaft arrangement being configured to form for the rotor a rotating axle that is rigidly coupled with the rotating crusher element and capable of leading torque from the rotor to the rotating crusher element for rotating the crusher element around the drive shaft. A method comprising: supporting and rotating by a drive shaft arrangement (212,215) a rotating crusher element (13, 215; 513) of a mineral material crusher (30, 200; 500, 510) by a motor comprising a rotor (218; 16) for driving the drive shaft arrangement; forming the motor inside the rotating crusher element; forming by the drive shaft arrangement for the rotor a rotating axle that is rigidly coupled with the rotating crusher element and capable of leading torque from the rotor to the rotating crusher element for rotating the crusher element around the drive shaft.