Recycling Plant Screen Vibration Control via Crushing Roll Current
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing treatment plants for recycling or disposing of construction and processing residues face challenges such as frequent shutdowns due to oversized materials, requiring specialized personnel for operation, and resulting in reduced productivity and increased costs.
Innovation Solution
A control method for a treatment plant that includes a crushing roll and a screen, where amperometric sensors measure current consumption to prevent excessive loading, slowing down the screen and conveyor belt to avoid shutdowns, and using control circuits to manage the flow and reduce personnel intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the crushing roll operates continuously without shutdown, then productivity is improved, but material accumulation and excessive loading occur leading to operational failures
Solution Approach 1:
The patent implements a feedback control system using amperometric sensors to continuously monitor current consumption of the crushing roll. When the current exceeds a predetermined threshold indicating excessive loading, the system automatically reduces the vibration amplitude of the screen to decrease material feed rate, and when current is within normal range, restores normal operation. This closed-loop feedback mechanism prevents material accumulation and operational failures while maintaining continuous processing, thereby resolving the contradiction between productivity and reliability.
Solution Approach 2:
The system performs preliminary detection of excessive loading conditions through current monitoring before actual material accumulation and shutdown occur. By detecting current threshold exceedance in advance, the control system proactively adjusts the screen vibration amplitude to prevent harmful material buildup, thus maintaining continuous operation and preventing operational failures before they happen.
2Reliability
If specialized personnel continuously monitor the plant operation, then operational reliability is improved, but operational costs and device complexity increase
Solution Approach 1:
The patent implements a self-service automated control system where the treatment plant monitors and adjusts its own operation without human intervention. Amperometric sensors continuously monitor crushing roll current consumption, and the control system automatically adjusts screen vibration amplitude based on detected conditions. This self-monitoring and self-adjusting mechanism eliminates the need for specialized personnel to continuously monitor operations, reducing operational complexity and costs while maintaining reliability.
Solution Approach 2:
The patent replaces the mechanical system of human personnel monitoring and manual intervention with an automated electronic control system. Amperometric sensors, control circuits, and automated vibration amplitude adjustment substitute for human operators, transforming the monitoring function from a manual process to an automated electromechanical system, thereby reducing device complexity related to personnel requirements while maintaining operational reliability.
3Reliability
If the screen vibration amplitude is reduced to prevent excessive loading, then operational reliability is improved, but processing speed and productivity decrease
Solution Approach 1:
The patent implements dynamic adjustment of screen vibration amplitude based on real-time crushing roll loading conditions. Rather than maintaining a fixed low vibration amplitude that would continuously reduce productivity, the system dynamically modulates vibration amplitude in response to detected current levels. When loading is normal, full vibration amplitude maintains high processing speed; when excessive loading is detected, vibration amplitude is temporarily reduced to prevent operational failures. This dynamic adaptation resolves the contradiction by optimizing both reliability and productivity according to actual operating conditions.
Solution Approach 2:
The patent changes the operational parameter of screen vibration amplitude dynamically based on crushing roll current consumption. By adjusting this parameter in response to detected loading conditions, the system prevents excessive loading (improving reliability) while minimizing the duration and magnitude of amplitude reduction (maintaining productivity). The parameter change is temporary and condition-dependent, allowing the system to balance reliability and productivity rather than sacrificing one for the other.
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 approach increases productivity by minimizing shutdowns, reduces the need for specialized personnel, and lowers operational costs by maintaining continuous operation and efficient material processing.
Implementation Method 1
a measurement step, preferably but not necessarily by means of appropriate amperometric sensors, of the current absorbed by the crushing roll (2)
Data Source
Figure 1~2
Figure 3~4
AI summary
A control method of a treatment plant (1) for elements to be recycled or disposed of, comprising a crushing roll (2) for a reduction in size of the elements to be recycled or disposed of, a screen (4) operatively arranged upstream of the crushing roll (2) to allow passage thereto only of elements having a larger size than predetermined sizes. The method includes: a measuring step of the current absorbed by the crushing roll (2); a comparing step of the measured current value to a first predetermined value; a reducing step of the vibrations of the screen (4), if the measured current exceeds the first predetermined value.