Variable Speed Gyratory Crusher Control System
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Solution Overview
Problem
Gyratory crushers have large discharge hoppers due to uncontrolled feed rates and constant conveyor operation, leading to increased costs and energy consumption, as the hopper size must accommodate high flow rates, necessitating a reduction in hopper size to optimize operational efficiency.
Innovation Solution
A variable speed drive and control system for the gyratory crusher, incorporating a variable frequency drive coupled to the eccentric, a camera for particle size detection, and sensors for material level monitoring, dynamically adjusts the rotational speed and crushing gap to optimize discharge flow rates, allowing for a smaller discharge hopper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the discharge hopper size is reduced to lower costs, then the cost of the rock crushing system decreases, but the ability to accumulate material during high flow rates deteriorates
Solution Approach 1:
The patent applies dynamics by implementing a variable speed drive system that allows the gyratory crusher to dynamically adjust its operating speed based on feed conditions and discharge requirements. This enables the system to optimize material flow rates in real-time, ensuring that material accumulation in the discharge hopper remains within acceptable limits even with a smaller hopper capacity, thereby reducing hopper size while maintaining reliable operation
Solution Approach 2:
The patent implements feedback control through sensors that monitor material flow rates, crusher performance, and hopper fill levels. This feedback information is used by the control system to continuously adjust the crusher speed via the variable speed drive, maintaining optimal material flow and preventing overflow even with reduced hopper capacity, thus resolving the contradiction between smaller hopper size and material accumulation capability
2Productivity
If the gyratory speed is increased to improve crushing efficiency, then the productivity increases, but the energy consumption increases
Solution Approach 1:
The patent applies dynamics by replacing fixed-speed operation with variable speed control. The gyratory crusher can now dynamically adjust its operating speed to match actual production requirements and feed conditions, allowing the system to operate at optimal speeds that balance productivity and energy consumption rather than running at constant high speed regardless of conditions
Solution Approach 2:
The patent implements parameter changes by allowing the operating speed parameter to vary within a defined range based on process conditions. The variable speed drive enables continuous adjustment of the gyratory speed parameter, allowing optimization of the relationship between crushing efficiency and energy consumption by selecting the most appropriate speed for each operating condition
3Loss of energy
If the discharge hopper size is reduced to optimize operational efficiency, then energy consumption decreases, but the ability to accommodate uncontrolled feed rates deteriorates
Solution Approach 1:
The patent applies dynamics through variable speed control that allows the crusher to adapt its operating characteristics in real-time. This dynamic adjustment capability enables the system to handle variations in feed rates effectively, maintaining stable material flow to the discharge hopper and preventing overflow even with reduced hopper capacity, thus allowing smaller hopper size while maintaining adaptability
Solution Approach 2:
The patent implements feedback control that monitors material flow conditions and hopper fill level continuously. This feedback mechanism enables the control system to adjust crusher speed in response to feed rate variations, ensuring that material accumulation remains within the reduced hopper capacity limits, thereby maintaining adaptability to uncontrolled feed rates despite smaller hopper size
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
The system reduces the size of the discharge hopper by optimizing the gyratory crusher's operation, lowering costs and energy consumption while maintaining efficient crushing performance.
Implementation Method 1
The variable frequency drive includes an electric motor and a variable frequency controller
Implementation Method 2
The mainshaft includes an eccentric that is positioned around a portion of the mainshaft such that the eccentric creates rotation of the mainshaft within the gyratory crusher
Implementation Method 3
a camera is positioned to detect the particle size of the material fed into the dump hopper
Data Source
AI summary
A system and method for controlling the operation of a gyratory rock crusher is shown and described. The gyratory rock crusher includes a variable frequency drive that allows the eccentric speed of the gyratory crusher to be modified based upon sensed parameters of the rock crushing system. The speed of the eccentric rotation can be dynamically adjusted to compensate for the size of the material particles being crushed and the availability of the material. The use of the variable frequency drive increases the operating efficiency of the gyratory crusher by controlling the discharge flow rate of the crushed material from the crusher and thus allows for a reduction in the size of the discharge hopper. The rotational speed of the eccentric is controlled to be below the critical speed for the gyratory crusher.