AU2012285775B2

AU2012285775B2 - Mobile crushing system and mobile crushing system assembly

Info

Publication number: AU2012285775B2
Application number: AU2012285775A
Authority: AU
Inventors: Wolfgang Genius; Josef Scheid
Original assignee: ThyssenKrupp Industrial Solutions AG
Current assignee: FLSmidth AS
Priority date: 2011-07-19
Filing date: 2012-07-18
Publication date: 2015-09-03
Anticipated expiration: 2032-07-18
Also published as: CN103732327A; BR112014001022B1; WO2013011065A3; AU2012285775B9; AU2012285775A1; EP2734306A2; DE102011051941A1; EP2734306B1; BR112014001022A2; WO2013011065A2

Abstract

The invention relates to a mobile crushing system, comprising a chassis (1), a receiving bin (5a, 5b), a crusher (2), and an apron conveyor (4), which is arranged on a supporting structure (3), for conveying the material to be crushed from the receiving bin (5a, 5b) to the crusher (2), wherein the receiving bin (5a, 5b) is fastened to connection points (8) of the supporting structure (3). According to the invention, the receiving bin (5a, 5b) can be modularly exchanged. According to a first aspect, the apron conveyor (4) extends beyond a bottom of the receiving bin (5b) in a direction opposite the conveying direction (F) by means of section (9) designed to receive the material to be crushed, and the supporting structure (3) has free connection points. According to a further aspect, the receiving bin (5a, 5b) can be removed from the apron conveyor (4) along specified separation surfaces.

Description

WO 2013/011065 A2 MOBILE CRUSHING SYSTEM AND MOB IE CRUSHING SYSTEM ASSEMBLY DESCRIPTION The invention relates to a mobile crushing system comprising a chassis, a hopper, a crusher, and an apron conveyor, which is arranged on a supporting structure, for conveying the material to be crushed from the hopper to the crusher, wherein the hopper is fastened to connection points of the supporting structure. Usually a discharge boom is arranged downstream of the crusher, by means of which discharge boom the crushed material can, for example, be dropped onto a belt system. Mobile crushing systems are often used in the exploitation of minerals such as ores and rock, organic materials such as coal, and for continuous spoil conveyance. In order to make it possible for the spoil, or for the overburden, to be taken away from an extraction area by means of conveyor belts, the corresponding materials must not exceed a particular grain size. It is thus known to dump the materials to be extracted into the hopper of a mobile crushing system by means of a shovel loader or a hydraulic excavator. The invention relates to mobile crushing systems of a considerable size and a considerable empty weight, usually comprising several hundreds of tons. In practical application it is common for mobile crushing systems to be precisely attuned to the intended use. For this reason a host of different parameters are taken account in the design of a crushing system, which parameters then result in an optimally adapted construction. First of all the available space needs to be taken into account. In open cast mining the material of economic value is, for example, removed in a stepped manner (stepped extraction), wherein the individual levels then determine the footprint of the - 2 mobile crushing system and the loading device in the form of a shovel loader or a hydraulic excavator. The nature of the useful material is a further significant aspect, wherein the hardness, the specific weight, as well as the size and shape of the useful material to be fed are to be taken into account. For example, while ores are highly abrasive, organic materials such as coal can be crushed comparatively easily. Tn order to achieve a specified throughput, it is not only necessary for the crusher to be designed for a corresponding quantity of material, but also for the loading device, which is often a shovel loader with cable operation, to comprise a corresponding holding capacity. Matched to this, the shovel volume of the hopper needs to be selected sufficiently generously for it to provide a certain buffer function because dropping of the useful material takes place discontinuously by the loading device. Finally, the entire construction of the crushing system needs to be attuned to the static and dynamic forces experienced during operation. The static forces result from the empty weight of the mobile crushing system and the weight of the fed-in or charged useful material. The dynamic forces result from the intermittent charging of useful material by means of the loading device, wherein the entire volume of a shovel acts with a sudden impact on the hopper. The corresponding impact needs to be absorbed by the supporting structure without there being a danger of the mobile crushing system experiencing damage or excessive vibration. In particular the design needs to take into account different dynamic loads for different throughput rates or different volumes in the individual charges of the loading device. For example, if the design is based on a loading device with a larger shovel, not only is more material placed into the hopper with every charge, but also the loading height for dropping all the material usually - 3 increases. The increased mass and the higher drop height result in a disproportionate increase in the dynamic loads. Against this background, mobile crushing systems are specifically designed to handle a particular useful material and a particular loading device, wherein on the one hand the crushing system is designed to allow reliable continuous operation, and wherein on the other hand over dimensioning, which is cost-intensive during production and during operation, is avoided. Correspondingly, the mobile crushing system cannot be operated with loading devices for which said mobile crushing system is not designed. For example, as a rule, smaller loading devices cannot reach the necessary loading height, while excessively large loading devices stress the mobile crushing system beyond its design limits, and are furthermore associated with the danger of the hopper overflowing. A mobile crushing system with the characteristics described in the introduction is known from WO 02/(-92231 Al. From EP 0 445 366 A2 a mobile processing plant and/or crushing plant is known that comprises a chassis and superstructures, wherein the chassis can be combined in a modular manner with various superstructures. Such a design can relate to a crushing system with a crusher, a supporting structure and a feed hopper, wherein the entire superstructure is placed as a unit on the chassis. A mobile crushing system with the characteristics described in the introduction is known from WO 99/30825 Al. The hopper and the apron conveyor with a very slight incline are arranged on the roof of a vehicle body comprising a drive motor and further devices. Despite a high lifting height, as a result of the arrangement of the apron conveyor and the hopper only a small shovel volume is possible, and consequently this design is disadvantageous - 4 at least in the context of large crushing systems. From DE 28 34 987 Al a mobile crushing system is known in which the hopper with the associated boom and the associated conveyor device is height-adjustable. In particular, the hopper can be held on the boom, so as to be pivotable on a horizontal axis; however, to this effect a stable permanent rotary connection between the hopper and the boom is to be provided. Further mobile crushing systems are known from DE 10 2010 013 154 Al, DE 297 23 701 Ul and US 7 971 817 Bl. It is the object of the present invention to improve the flexibility of operation of a mobile crushing system. Starting from a mobile crushing system with the characteristics described in the introduction, in order to meet this object a first aspect of the present invention provides for the apron conveyor to extend beyond a bottom of 'the hopper in a direction opposite the conveying direction by means of a section designed to receive the material to be crushed, and for the supporting structure to have free connection points. The present invention is based on the design of the mobile crushing system already having taken into account the provision of exchange of the hopper, in practical applications also referred to as a "hopper". If for this purpose hoppers of different holding capacities are provided, in this design they are, however, not arranged in the same position. Instead, the hoppers, depending on their holding capacity, are to be able to be fastened at different positions of the apron conveyor, wherein the hopper with increasing holding capacity is displaced in the direction of the crusher and thus in the direction of the centre of gravity of the entire crushing system in order - 5 to, as a result of shortening the effective lever arm, limit the dynamic loads resulting from the impacts of the intermittent charging with the useful material. in other words, when a hopper with an increased holding capacity is fastened to the supporting structure, said hopper is displaced in the direction of the crusher. The distance, measured along the apron conveyor, between the rotation axis of a lower deflection roller of the apron conveyor and a rear edge of the hopper in this context is preferably at least 1.5 m, preferably at least 2 m. From the state of the art it is known that a short section of the apron conveyor extends beyond the bottom of the hopper, wherein usually the rotation axis of a deflection roller is arranged outside the rear edge of the hopper. However, the entire section of the apron conveyer, which section is provided for receiving the material to be crushed, then extends underneath the hopper, because according to the state of the art an extension of the apron conveyor would merely result in an increase in cost without returning any advantages. In contrast to the above, the present invention accepts that to a certain extent there is a conscious deviation from the concept of optimal configuration, wherein, however, even with different holding capacities of the hoppers permanent reliable operation becomes possible without significant over dimensioning of the individual components. If the hopper is arranged so as to be displaced in the direction of the crusher, according to the first aspect of the present invention there are also unused connection points on the side of the hopper, which side faces away from the crusher. To make it possible to accept different hoppers, on the connection points the undoing of fastening means, the undoing of a positive-l ocking fit, and/or the severance of connection means is provided. It is crucial that such - 6 separability be planned already at the time of designing the mobile crushing system. Against this background, in order to meet the object of the invention, according to a second aspect it is provided that the hopper is attached to the supporting structure by means of a detachable positive-locking and/or non-positive locking connection so that the hopper can be removed from the apron conveyor along predetermined separation surfaces. To this effect, at the connection points the hopper can be screwed to the supporting structure. in addition or as an alternative, at the connection points the hopper can also be supported by the supporting structure by means of a positive-locking fit. The positive-locking fit can, for example, be achieved by retaining lugs, hooks or teeth. Such a positive-locking connection can, for example, be made to engage if the hopper as a separate part is placed from above onto the supporting structure by means of a crane or some comparable lifting device. In order to ensure secure fastening, in this arrangement screw connectors, rive ts or the like can additionally be used. in the above context it must be taken into account that the hopper should be detachable as easily as possible, for which purpose, as a rule, a screw connection is suitable. However, depending on a particular application, a connection by means of pins or rivets can be advantageous because due to the very considerable loads experienced, extremely stable connections are required, and due to the dirty environment screw connections may not be operable without further ado. It may therefore be expedient to provide single-use connection elements such as rivets or pins, which will be replaced whenever the hopper is changed. Usually, partition wal are provided laterally on the apron conveyor, which partition walls prevent material to - 7 be crushed from falling off laterally. To make it possible to arrange different hoppers at different positions of the apron conveyor, according to a preferred embodiment of the invention it is provided that each of the two partition walls laterally arranged on the apron conveyor comprises an interruption, wherein in each case a lower part of the partition walls is connected to the hopper. The length of this lower part then matches the size of the hopper and the different position of the hopper. As explained above, the position of the hopper is varied for different sizes in such a manner that stable operation of the crushing system is always possible. In particular, the hopper, depending on its fill volume and maximum. fill weight, is arranged in such a manner that the centre of gravity is approximately situated in the centre of the chassis, also taking into account the dynamic loads experienced. The chassis can comprise caterpillar tracks or rows of wheels. Particularly preferred is a design in which the chassis comprises two parallel caterpillar tracks that are arranged either parallel to the longitudinal direction of the apron conveyor or across the aforesaid. The design of the chassis as a longitudinal chassis or as a transverse chassis depends on the given situation of extraction. As already described above, the mobile crushing system is preferably provided for use in open-cast extraction and mines. Thus the holding capacity of the hopper is preferably between 100 m3 and 250 m3. The loading height, in other words the upper edge of the hopper, which edge needs to be cleared by a shovel or some comparable loading device, is usually between 7 m and 12 m. However, depending on a particular application, larger or smaller holding capacities or higher or lower loading heights are also imaginable.

- 8 An object of the invention also relates to a mobile crushing system assembly comprising a chassis, a first hopper, a crusher and an apron conveyor, which is arranged on a supporting structure, for conveying the material to be crushed to the crusher, wherein the hopper is fastened to connection points of the supporting structure. According to a first improvement, in such a mobile crushing system assembly comprising two hoppers both hoppers can be identical in terms of their design. The modular interchangeability can be used to effect a change in the case of the hopper requiring service or maintenance, and consequently operation of the mobile crushing system requires only a short interruption. In practical use a change in wear plates is necessary from time to time, which wear plates are arranged as protective devices within the hoppers. Hitherto this required expensive maintenance measures for which the entire mobile crushing system had to be shut down for a considerable period of time. However, according to the present invention, the hopper can be exchanged for another hopper within a shorter period of time, wherein maintenance of the wear plates can then take place separately, if need be in a workshop, without this resulting in operational downtime. Changing hoppers is, for example, possible with the use of a crane or the like. In relation to open-casr extraction or a mine with a mobile crushing system or with several mobile crushing systems of identical design it is thus possible to have an additional hopper ready as a replacement. In the case of maintenance work this additional hopper is exchanged against a waiting hopper, wherein after completion of maintenance the additional bin is again available as a replacement for the same or for some other mobile crushing system.

- 9 According to an alternative improvement of the invention, the first hopper and the second hopper have different hol ding capacities and/or different loading heights. This makes possible a degree of adaptation to different loading devices. For example, if the loading device experiences a breakdown as a result of a defect and can only be replaced with a loading device of some other conveyance volume, a correspondingly matched hopper can be used. According to a particularly preferred embodiment, the second hopper has a greater holding capacity and a higher loading height than the first hopper, wherein then, for reasons of stability, the installation position of the second hopper is offset in the direction of the crusher relative to the installation position of the first hopper. As a result of this displacement or offset, in the case of the larger hopper a shorter lever acting by way of the chassis results, and consequently the significantly larger dynamic forces can be absorbed. The base components of the mobile crushing system, in other words the chassis, the apron conveyor, the crusher and the usually provided discharge boom, are then selected and aligned relative to each other in such a manner that, taking into account the static and dynamic forces, reliable operation is possible with different configurations. This concept differs from the usual approach in the design of mobile crushing systems. The crusher itself is preferably a roller crusher with rollers that are driven to rotate in opposite directions. However, other embodiments of the crusher are not excluded from the scope of the invention. Below, the invention is explained with reference to a drawing that shows but one exemplary embodiment. The following are shown: - 10 Fig. 1 a mobile crushing system assembly comprising a first hopper and a second hopper, which hoppers are mutually exchangeable, Fig . 2 the mobile crushing system according to Fig. 1 comprising the first hopper detachable arranged thereon, Fig. 3 the mobile crushing system according to Fig. 1 comprising the hopper detachable arranged thereon. Fig. 1 shows a mobile crushing system assembly comprising a chassis 1, a crusher 2 and an apron conveyor 4 arranged on a supporting structure 3. According to the invention, the mobile crushing system assembly comprises a first hopper 5a and a second hopper 5b, which are mutually exchangeable as modules. To this effect the two hoppers 5a, 5b are detachable fastened to the supporting structure 3 so that the hoppers 5a, 5b can be removed from the apron conveyor 4 along a predetermined separation surface. In the exemplary embodiment shown the fill volume of the second hopper 5b is greater than that of 'the first hopper 5a. As a result of the greater holding capacity the second hopper 5b can also be loaded with the use of a larger shovel 12b. During operation the larger volume of the second hopper 5b results in greater static loads as a result of the intrinsic weight of the crushing system and as a result of the weight of the fill material fed in. However, the changes relating to the dynamic loads are more severe still, because the larger second hopper 5b can also be loaded with the use of a larger shovel 12b (see Fig. 3). The pulse transmitted during the loading action to the - 11 supporting structure 3 by the second hopper 5b is greatly increased as a result of the greater overall weight of each filling action and as a result of the higher drop height. in order to be able to absorb the dynamic loads, the second hopper 5b is to be arranged at a shorter distance from the crusher 2 when compared to the distance to the first hopper Sa, and thus at a shorter distance from the centre of gravity of the entire device. In the design of the crushing system the lever arms that can act on both sides of the chassis 1 are to be taken into account. As a result of the displacement of the second hopper 5b in the direction of the crusher 2 the latter is also arranged so as to be higher on the apron conveyor 4. As a result of the higher arrangement on the apron conveyor the drop height is also reduced, or matched to the higher drop height of the larger shovel 12b. This also contributes to limiting the dynamic loads. Thus in the smaller first hopper 5a it is provided to arrange said hopper 5a further away from the crusher 2 and thus from the centre of gravity, thus extending the lever arm. In relation to the apron conveyor 4, which extends upwards at an incline, the first hopper 5a is thus arranged lower, and consequently the loading height h, in other words the height of the upper edge of the hopper 5a, which height has to be bridged by a shovel 12a, is considerably reduced. According to a concrete exemplary embodiment the first hopper 5a comprises a holding capacity of 153 m 3 , with said hopper 5a being designed for a shovel 12a with a loading volume of 61 m. In contrast to this, the second hopper 5b comprises a holding capacity of 190 M 3 , with said hopper 5b being designed for a shovel 12b with a volume of 75 M 3 . To make it possible to arrange the first hopper Sa and the second hopper 5b at different positions, partition walls 6 arranged on each side of the apron conveyor 4 comprise an interruption 7, wherein in each case a lower cart 6' of the - 12 partition walls 6 is connected to the hopper 5a, 5b and is removable with the aforesaid. Fig. 2 shows the mobile crushing system, ready for operation, with the first hopper 5a, wherein the hopper 5a is detachable fastened to the supporting structure 3. Fastening can be effected by means of a posit ive-locking or non-positive-locking connection. According to Fig. 2, on connection points 8 of the supporting structure 3 the hopper 5a is fastened by means of screw connections. In addition, support of the connection by means of a positive locking arrangement can be provided, as a result of which, in particular, the placement of the hoppers 5a, 5b onto the supporting structure can be facilitated. Fig. 3 shows a mobile crushing system in which the first hopper 5a has been replaced by the second hopper 5b. In order to compensate for the higher static and dynamic loads, the second hopper 5b is arranged so as to be closer to the crusher 2 and thus closer to the centre of gravity. The lower part 6' of the partition walls 6, which lower part 6' is fastened to the crusher 2, is of a correspondingly shorter design, wherein also the apron conveyor 4 with a section 9 provided for receiving the material to be crushed along the direction F of conveyance extends beyond a bottom of the hopper 5b. Thus in the configuration according to Fig. 3 a considerable part of the apron conveyor 4 remains unused in order to overall make possible a flexible use with different hoppers 5a, 5b. With the usual dimensioning of the mobile crushing system the distance a, measured along the apron conveyor 4, between the rotation axis D of a bottom deflection roller 10 and a rear edge .11 of the second hopper 5b is at least 1.5 im, in the concrete exemplary embodiment said distance is 2.4 m. Because the second hopper 5b is arranged so as to be displaced in the direction of the crusher 2, one of the connection points 8, to which the first hopper 5a according - 13 to Fig. 2 is fastened, is free in an arrangement of the second hopper 5b. The crushing system assembly according to the invention, with a first hopper 5a and a second hopper 5b makes it possible for operation using loading devices with different shovel sizes to take place. According to Fig. 2 the only sketchily indicated loading device comprises a shovel 12a with a fill volume of 61 m 3 . This shovel is designed in such a manner that it can overcome the loading height h, which in the exemplary embodiment is 8.50 m. In the design according to Fig. 2 the first hopper 5a is arranged in such a manner that with maximum loading the static and dynamic forces that act on both sides of the chassis I approximately cancel each other out, or at least that a predetermined maximum load is not exceeded. In particular, excessive vibration as a result of dynamically changing forces must be prevented. The arrangement according to Fig. 2 with the first hopper 5a cannot readily be used with a loading device comprising a larger shovel. This is because in the case of a larger shovel the dynamic load would increase as a result of the greater mass and as a result of the increased drop height, and consequently there would be a danger of the crushing system being overloaded. Furthermore, it is possible that the volume of the first hopper 5a may not be adequate. According to Fig. 3, for operation with a larger shovel 12b the second hopper 5b is provided, which in terms of its size and its arrangement matches greater loads. Since the second hopper 5b is arranged so as to be closer in the direction of the crusher, overloading can be prevented even in the case of a greater drop weight and a greater drop height. Thus, during the design phase various configurations are - 14 taken into account. in advance, wherein a balance is achieved between the parts arranged on both sides of the centre of gravity. In the design process it must be taken into account that in the mobile crushing system the hopper 5a, 5b is arranged on one side of the centre of gravity, and the crusher 2 as well as a discharge boom 13 (merely indicated in the figures) are arranged on the other side of the centre of gravity.

Claims

1. A mobile crushing system comprising a chassis (1), a hopper (5a, 5b) , a crusher (2) , and an apron conveyor (4) , which is arranged on a supporting structure (3), for conveying the material to be crushed from the hopper (5a, 5b) to the crusher (2), wherein the hopper (5a, 5b) is fastened to connection points (8) of the supporting structure (3), characterised in that the apron conveyor (4), by means of a section (9) designed to receive the material to be crushed, extends beyond a bottom of the hopper (5b) in a direction opposite the conveying direction (F), and in that the supporting structure (3) has free connection points (8).

2. The mobile crushing system according to claim 1, characterised in that the distance (a), measured along the apron conveyor (4) , between the rotation axis (D) of a deflection roller (10) of the apron conveyor (4) and a rear edge (11) of the hopper (5b) is at least 1.5 m.

3. The mobile crushing system according to the preamble of claim 1, characterised in that the hopper (5a, 5b) is attached to the supporting structure (3) by means of a positive-locking and/or non-positive-locking connection so that the hopper (5a, 5b) can be removed from the apron conveyor (4) along predetermined separation surfaces.

4. The mobile crushing system according to any one of claims 1 to 3, characterised in that at both sides of the apron conveyor (4) are arranged partition walls (6) each featuring interruptions (7), whereas in each case a lower part (6') of the partition walls (6) is connected to the hopper. -16

5. The mobile crushing system according to any one of claims 1 to 4, characterised in that at the connection points (8) the hopper (5a, 5b) is screwed to the supporting structure (3).

6. The mobile crushing system according to any one of claims 1 to 5, characterised in that at the connection points (8) the hopper (5a, 5b) is supported by the supporting structure (3) by means of a positive locking fit.

7. The mobile crushing system according to any one of claims 1 to 6, characterised in that the holding capacity of the hopper (5a, 5b) is between 100 m 3 and 250 M 3 .

8. The mobile crushing system according to any one of claims 1 to 7, characterised in that the loading height (h) of the hopper (5a, 5b) is between 7 m and 12 m.

9. A mobile crushing system assembly comprising a chassis (1), a first hopper (5a), a crusher (2), and an apron conveyor (4), which is arranged on a supporting structure (3), for conveying the material to be crushed to the crusher (3), wherein the hopper (5a) is fastened to connection points (8) of the supporting structure (3) , characterised by a second hopper (5b), wherein the first hopper (5a) and the second hopper (5b) are mutually exchangeable as modules.

10. The mobile crushing system assembly according to claim 9, characterised in that the first hopper (5a) and the second hopper (5b) have different holding capacities and/or different loading heights (h).

11. The mobile crushing system assembly according to claim 10, characterised in that the second hopper (5b) has a greater holding capacity and a higher loading height (h) than the first hopper (5a), wherein the installation position of the second hopper (5b) is offset in the direction of the crusher (2) relative to the installation position of the first hopper (5a).