Variable Speed Motor Drive for Industrial Roll Crusher
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Solution Overview
Problem
Industrial roll crushers experience high tool wear, downtime, and inconsistent material sizing due to fixed rotational speeds, which limits dynamic adjustment of material product size without redesigning the crusher or tools.
Innovation Solution
A motor drive controller that adjusts the rotational speed of the roll crusher shaft within a range of +/-15% of synchronous speed based on sensor signals, reducing wear, power consumption, and improving sizing consistency by modifying the speed of the breaker motor and conveyor motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed rotational speed is used for the roll crusher shaft, then the structure is simple and reliable, but tool wear is high and material sizing is inconsistent
Solution Approach 1:
The patent applies variable speed control to the roll crusher shaft, transforming it from a fixed-speed system to a dynamic system that can adjust rotational speed within a range of approximately +/-15% of synchronous speed. This dynamic adjustment capability allows the system to optimize material sizing consistency while maintaining structural reliability through proven motor drive technology.
Solution Approach 2:
The patent changes the operational parameter of rotational speed from a fixed value to a variable parameter that can be adjusted within a specific range. By modifying the speed parameter of the motor drive, the system achieves better material sizing consistency without compromising the reliability of the overall structure.
2Device complexity
If fixed rotational speed is used for the roll crusher shaft, then the device complexity is low, but tool life is short and downtime is high
Solution Approach 1:
The patent introduces variable speed control to extend tool life by adjusting the rotational speed of the roll crusher shaft. The dynamic speed adjustment within +/-15% of synchronous speed optimizes the operating conditions to reduce tool wear and extend service life, while the underlying motor drive technology remains relatively simple and proven.
3Use of energy by moving object
If fixed rotational speed is used for the roll crusher shaft, then the power consumption is high, but the ability to dynamically adjust material product size is lost
Solution Approach 1:
The patent implements dynamic speed control to enable real-time adjustment of material product size while optimizing power consumption. The variable speed capability within +/-15% of synchronous speed allows the system to adapt to different material size requirements and operating conditions, improving energy efficiency by matching motor speed to actual processing needs.
Solution Approach 2:
The patent changes the motor speed parameter from fixed to variable, enabling dynamic adjustment of material product size. This parameter change allows the system to optimize power consumption by adjusting speed according to processing requirements, rather than operating at constant high speed regardless of actual needs.
Data Source
AI summary
An industrial machine that includes a breaker motor having a rotational speed, a breaker shaft, a sensor, and a controller. The breaker shaft is mechanically coupled to an output of the breaker motor, and the breaker shaft includes a plurality of tools operable to crush a material. The sensor is configured to generate a signal related to a parameter of the breaker motor. The controller is configured to receive the signal from the sensor, determine a value for the parameter of the breaker motor based on the received signal, compare the value for the parameter of the breaker motor to a threshold value, and generate a control signal for modifying the rotational speed of the breaker motor based on the comparison of the value for the parameter of the breaker motor to the threshold value.