AU2019273386B2

AU2019273386B2 - Gyratory crusher and control method therefor

Info

Publication number: AU2019273386B2
Application number: AU2019273386A
Authority: AU
Inventors: Nobuyuki Kajita; Takashi Kijima; Jun Kobayashi
Original assignee: Earthtechnica Co Ltd
Current assignee: Earthtechnica Co Ltd
Priority date: 2018-05-21
Filing date: 2019-05-20
Publication date: 2022-11-03
Anticipated expiration: 2039-05-20
Also published as: AU2019273386A1; JP2019202245A; WO2019225557A1; ZA202007104B; JP7010763B2

Abstract

A method for controlling a rotating type crushing machine includes: a step of setting at least one of a supply device and a set adjusting device as a manipulation target, measuring a load index which directly or indirectly represents a crushing load while the manipulation target is operating with a certain manipulated variable, and monitoring that the load index lies within a prescribed steady-state range; if the load index is outside the steady-state range, a step of using a prescribed control algorithm to obtain a new manipulated variable of the manipulation target, on the basis of the difference between a prescribed target value and the measured value of the load index; a step of operating the manipulation target in accordance with the new manipulated variable; a step of generating a response evaluation index of the load index generated by operating the manipulation target; and a step of evaluating the acceptability of the response on the basis of the response evaluation index, and adjusting at least one of the control parameters of the control algorithm if the response is not acceptable.

Description

DESCRIPTION Title of Invention: GYRATORY CRUSHER AND CONTROL METHOD THEREFOR Technical Field

[0001] The present invention relates to gyratory crushers that are used for crushing rocks and ores, and control methods therefor.

Background Art

[0002] To date, gyratory crushers are known in which a mantle having a truncated conical shape and disposed on the inner side of a concave having a conical tubular shape is caused to perform eccentric turning movement and matter to be crushed is seized and crushed between the concave and the mantle. The gap between the two crushing surfaces of the concave and the mantle cyclically varies, and the grain size of the ground product is determined in accordance with the dimension (closed setting) of the setting (opening) at the position where the gap is narrowest. Gyratory crushers are classified into a hydraulic type and a mechanical type depending on the method of changing the setting.

[0003] PTL 1 discloses a hydraulic type gyratory crusher. This gyratory crusher includes a driving motor that drives a mantle to turn, and a hydraulic cylinder that lifts/lowers the mantle with respect to a fixed concave. In this gyratory crusher, when power consumption of an electric motor exceeds a set power, oil is discharged from the hydraulic cylinder for a predetermined time, whereby the mantle is lowered. When power consumption of the electric motor becomes lower than a set power, oil is supplied to a predetermined cylinder for a predetermined time, and the mantle is lifted.

[0004] PTL 2 discloses a hydraulic type gyratory crusher. Operation of this gyratory crusher is controlled in accordance with the mutual relationship between: the supply amount of matter to be crushed to a hopper provided above a crushing chamber, the level amount of the matter to be crushed in the hopper, the hydraulic pressure of a hydraulic cylinder, the current value of an electric motor, and the setting between the two crushing surfaces.

[0005] PTL 3 discloses a hydraulic type gyratory crusher. In this gyratory crusher, the supply amount of matter to be crushed to a hopper is adjusted such that the level, of the matter to be crushed in the hopper, that is detected by a level sensor is maintained at a constant level. In addition, in this gyratory crusher, when a load current of an electric motor detected during operation has reached the upper limit of a set current value, oil is discharged from a hydraulic cylinder until the detected amount of lowering of the hydraulic cylinder reaches a set lifting/lowering value.

[0006] PTL 4 discloses a mechanical type gyratory crusher. This gyratory crusher includes: a mantle; a concave support having a concave fixed to the inner side thereof; and a drive device that includes a screw mechanism and an electric motor, and that rotates the concave support, thereby lifting/lowering the concave with respect to the mantle. In this gyratory crusher, the setting is measured on the basis of the movement amount of the concave that is lifted/lowered by the screw mechanism, and the setting is remotely manipulated on the basis of the measurement value.

Citation List Patent Literature

[0007] PTL 1: Japanese Laid-Open Patent Publication No. S53-137467 PTL 2: Japanese Laid-Open Patent Publication No. S55-5718 PTL 3: Japanese Laid-Open Patent Publication No. H10-272375 PTL 4: Japanese Laid-Open Patent Publication No. H6-154630

Summary

[0008] In order to stably operate a gyratory crusher, it is necessary to maintain a state (choke feed) where a crushing chamber formed between a concave and a mantle is fully filled with matter to be crushed. However, the time required for the matter to be crushed to pass through the crushing chamber differs depending on the properties of the matter to be crushed (e.g., the grain size of the matter to be crushed, attached water amount, etc.), and thus, it is difficult to maintain the choke feed by supplying a constant amount of the matter to be crushed. For such a problem, for example, in PTL 3, the supply amount of the matter to be crushed is adjusted such that the level amount of the matter to be crushed in the hopper is maintained to be constant by a level switch provided to the hopper.

[0009] In a gyratory crusher, even when the choke feed is maintained, the load could vary due to variation in the properties, the water amount, or the like of the matter to be crushed. Further, in the gyratory crusher, overload could be caused due to seizing of foreign matter, a packing phenomenon of the matter to be crushed, or the like. For such a problem, for example, in PTL 2, the magnitude of the load is determined on the basis of hydraulic pressure of a hydraulic cylinder and a current value of the electric motor, and the setting is adjusted on the basis of the determination result. Here, an on/off control in which supply of oil (or discharge of oil) to (from) the hydraulic cylinder for a predetermined time is repeated is performed until a detection value of the setting reaches a target value.

[0010] Although controls for stably operating gyratory crushers have been proposed as described above, it is still difficult to continue stable operation, and eventually, the operation is adjusted, relying on the intuition of experienced operators. The present invention has been made in view of the above-described circumstances. A preferred embodiment of the present invention is to propose a gyratory crusher that can realize continuation of stable operation, and a control method therefor.

[0010a] It is an object of the present invention to overcome and/or alleviate one or more of the disadvantages of the prior art or provide the consumer with a useful or commercial choice.

[0011] The inventors of the present application have examined controlling at least one of the setting of the gyratory crusher and a supply amount of the matter to be crushed, by using a control algorithm including a proportional control (P control), not by an on/off control. Accordingly, a hunting phenomenon characteristic of the on/off control can be avoided. However, appropriate control parameters change due to variation of the properties and water amount of the matter to be crushed. This could cause problems in that response is disturbed during tuning, and that stable response after the tuning cannot be continued, for example.

[0011a] In one aspect, the invention provides a control device of a gyratory crusher, the gyratory crusher including: a concave having a conical tubular shape; a mantle having a truncated conical shape and disposed on an inner side of the concave; an electric motor configured to cause the mantle to perform eccentric turning movement; a hopper configured to feed matter to be crushed, to a crushing chamber formed between the concave and the mantle; a feeder configured to supply the matter to be crushed, to the hopper; a load measuring device configured to measure a load index that directly or indirectly represents a crushing load; and a setting adjustment device configured to, in order to change a setting between the concave and the mantle, cause one of the concave and the mantle to be displaced with respect to another of the concave and the mantle, the control device comprising; a load monitoring unit of which a manipulation target is at least one of the feeder and the setting adjustment device, the load monitoring unit being configured to, in a state where the manipulation target is in operation so as to correspond to a manipulated variable, monitor that the load index measured by the load measuring device is in a predetermined steady-state range, a manipulated variable calculation unit configured to, when the load index is outside the steady-state range, calculate, with respect to the manipulation target, a new manipulated variable on the basis of a deviation between a predetermined target value of the load index and a measurement value, by using a predetermined control algorithm, a response evaluation index generation unit configured to generate a response evaluation index of the load index caused by operation corresponding to the new manipulated variable of the manipulation target, and a tuning unit configured to evaluate, on the basis of the response evaluation index, whether or not response is good, and adjust at least one of control parameters of the control algorithm when the response is not good, wherein the response evaluation index is a deviation integrated value relative to the target value of a response waveform of the load index caused by the operation of the manipulation target over a predetermined parameter adjustment cycle.

[0011b] In a further aspect, the invention provides a control method for a gyratory crusher, the gyratory crusher including: a concave having a conical tubular shape, a mantle having a truncated conical shape and disposed on an inner side of the concave, an electric motor configured to cause the mantle to perform eccentric turning movement, a hopper configured to feed matter to be crushed, to a crushing chamber formed between the concave and the mantle, a feeder configured to supply the matter to be crushed, to the hopper, and a setting adjustment device configured to, in order to change a setting between the concave and the mantle, cause one of the concave and the mantle to be displaced with respect to another of the concave and the mantle, the control method comprising the steps of: with at least one of the feeder and the setting adjustment device being set as a manipulation target, and in a state where the manipulation target is in operation so as to correspond to a manipulated variable, measuring a load index that directly or indirectly represents a crushing load, and monitoring that the load index is in a predetermined steady-state range; calculating, with respect to the manipulation target, when the load index is outside the steady-state range, a new manipulated variable on the basis of a deviation between a predetermined target value of the load index and a measurement value, by using a predetermined control algorithm; generating a response evaluation index of the load index caused by operation corresponding to the new manipulated variable of the manipulation target; and evaluating, on the basis of the response evaluation index, whether or not response is good, and adjusting at least one of control parameters of the control algorithm when the response is not good, wherein the response evaluation index is a deviation integrated value relative to the target value of a response waveform of the load index caused by the operation of the manipulation target over a predetermined parameter adjustment cycle.

[0012] In another aspect, the invention provides a gyratory crusher comprising: a concave having a conical tubular shape; a mantle having a truncated conical shape and disposed on an inner side of the concave; an electric motor configured to cause the mantle to perform eccentric turning movement; a hopper configured to feed matter to be crushed, to a crushing chamber formed between the concave and the mantle; a feeder configured to supply the matter to be crushed, to the hopper; a load measuring device configured to measure a load index that directly or indirectly represents a crushing load; a setting adjustment device configured to, in order to change a setting between the concave and the mantle, cause one of the concave and the mantle to be displaced with respect to another of the concave and the mantle; and a control device configured to control the setting adjustment device and the feeder, wherein the control device includes a load monitoring unit of which a manipulation target is at least one of the feeder and the setting adjustment device, the load monitoring unit being configured to, in a state where the manipulation target is in operation so as to correspond to a manipulated variable, monitor that the load index measured by the load measuring device is in a predetermined steady-state range, a manipulated variable calculation unit configured to, when the load index is outside the steady-state range, calculate, with respect to the manipulation target, a new manipulated variable on the basis of a deviation between a predetermined target value of the load index and a measurement value, by using a predetermined control algorithm, an operation control unit configured to cause the manipulation target to operate so as to correspond to the new manipulated variable, a response evaluation index generation unit configured to generate a response evaluation index of the load index caused by operation corresponding to the new manipulated variable of the manipulation target, and a tuning unit configured to evaluate, on the basis of the response evaluation index, whether or not response is good, and adjust at least one of control parameters of the control algorithm when the response is not good, wherein the response evaluation index is a deviation integrated value relative to the target value of a response waveform of the load index caused by the operation of the manipulation target over a predetermined parameter adjustment cycle.

[0013] In yet another aspect, the invention provides a control method for a gyratory crusher, the gyratory crusher including: a concave having a conical tubular shape, a mantle having a truncated conical shape and disposed on an inner side of the concave, an electric motor configured to cause the mantle to perform eccentric turning movement, a hopper configured to feed matter to be crushed, to a crushing chamber formed between the concave and the mantle, a feeder configured to supply the matter to be crushed, to the hopper, and a setting adjustment device configured to, in order to change a setting between the concave and the mantle, cause one of the concave and the mantle to be displaced with respect to another of the concave and the mantle, the control method including the steps of: with at least one of the feeder and the setting adjustment device being set as a manipulation target, and in a state where the manipulation target is in operation so as to correspond to a manipulated variable, measuring a load index that directly or indirectly represents a crushing load, and monitoring that the load index is in a predetermined steady-state range; calculating, with respect to the manipulation target, when the load index is outside the steady-state range, a new manipulated variable on the basis of a deviation between a predetermined target value of the load index and a measurement value, by using a predetermined control algorithm; causing the manipulation target to operate so as to correspond to the new manipulated variable; generating a response evaluation index of the load index caused by operation

6a

corresponding to the new manipulated variable of the manipulation target; and evaluating, on the basis of the response evaluation index, whether or not response is good, and adjusting at least one of control parameters of the control algorithm when the response is not good, wherein the response evaluation index is a deviation integrated value relative to the target value of a response waveform of the load index caused by the operation of the manipulation target over a predetermined parameter adjustment cycle.

[0014] According to the gyratory crusher and the control method therefor, when the response to control based on the control algorithm is not good any longer, i.e., when due to disturbance such as change or the like in the properties of the matter to be crushed, a control parameter having been used becomes no longer an appropriate value, the control parameter is automatically adjusted to an appropriate value. Accordingly, even when disturbance has occurred, continuation of stable operation of the gyratory crusher can be realized.

[0015] In the gyratory crusher, the response evaluation index generation unit may create a response waveform of the load index caused by the operation of the manipulation target, and may calculate a positive-side deviation integrated value and a negative-side deviation integrated value relative to the target value of the response waveform over a predetermined parameter adjustment cycle, and the tuning unit may evaluate whether or not the response is good, on the basis of the positive-side deviation integrated value and the negative-side deviation integrated value.

[0016] Similarly, in the control method for the gyratory crusher, the step of generating the response evaluation index may include creating a response waveform of the load index caused by the operation of the manipulation target, and calculating a positive-side deviation integrated value and a negative-side deviation integrated value relative to the target value of the response waveform over a predetermined parameter adjustment cycle, and the step of adjusting at least one of the control parameters may include evaluating whether or not the response is good, on the basis of the positive-side deviation integrated value and the negative-side deviation integrated value.

[0017] Thus, whether or not the value of the control parameter of the control algorithm is an appropriate value can be easily and accurately evaluated.

[0018] In the gyratory crusher and the control method therefor, the control algorithm may be one selected from a group including a proportional (P) control algorithm, a proportional integrating (PI) control algorithm, a proportional-integral-derivative (PID) control algorithm, and a proportional-derivative-feedback (PDF) control algorithm.

6b

[0019] In the gyratory crusher and the control method therefor, the load index may be a value of electric power consumption of the electric motor.

[0020] Alternatively, in the gyratory crusher and the control method therefor, the load index may be crushing pressure applied to the mantle. In this case, the gyratory crusher further includes a hydraulic cylinder configured to be subjected to crushing pressure applied to the mantle, and the load index may be a value of hydraulic pressure of a hydraulic oil of the hydraulic cylinder. Alternatively, the gyratory crusher may further include a thrust bearing configured to support the mantle, and the load index may be a value of oil feeding pressure of a lubricating oil of the thrust bearing.

[0021] As described above, the load index can be selected as appropriate from a plurality of candidates in accordance with a specific configuration of the gyratory crusher, the matter to be crushed, or the like.

[0022] According to the present invention, a gyratory crusher that can realize continuation of stable operation, and a control method therefor can be proposed.

Brief Description of Drawings

[0023] FIG. 1 shows a schematic configuration of a gyratory crusher according to an embodiment of the present invention. FIG. 2 shows a configuration of a control system of the gyratory crusher shown in FIG. 1. FIG. 3 is a flow chart (former part) indicating the flow of a process of a crushing load control according to First Example. FIG. 4 is a flow chart (middle part) showing the flow of the process of the crushing load control according to First Example. FIG. 5 is a flow chart (latter part) showing the flow of the process of the crushing load control according to First Example. FIG. 6 is a graph showing an example of a response waveform of a load index.

FIG. 7 is a flow chart (former part) showing the flow of a process of a crushing load control according to Second Example. FIG. 8 is a flow chart (middle part) showing the flow of the process of the crushing load control according to Second Example. FIG. 9 is a flow chart (latter part) showing the flow of the process of the crushing load control according to Second Example. FIG. 10 shows a schematic configuration of a gyratory crusher according to a modification.

Description of Embodiments

[0024] Next, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows a schematic configuration of a gyratory crusher 1 according to an embodiment of the present invention.

[0025] [Schematic configuration of gyratory crusher 1] As shown in FIG. 1, the gyratory crusher 1 includes: a hopper 2 that stores matter to be crushed; a feeder 4 that supplies the matter to be crushed, to the hopper 2; a mantle 13 and a concave 14 that seize and crush the matter to be crushed having dropped from the hopper 2; an electric motor 8 serving as turning driving means for the mantle 13; a power transmission mechanism 80 that transmits rotational power from the electric motor 8 to the mantle 13; a setting adjustment device 10 that lifts/lowers the mantle 13 with respect to the concave 14; and a control device 9 that governs operation of the gyratory crusher 1.

[0026] The gyratory crusher 1 further includes a frame 3 composed of a top frame 31 and a bottom frame 32. The concave 14 having a conical tubular shape is provided at the inner periphery of the top frame 31. The mantle 13 having a truncated conical shape is disposed on the inner side of the concave 14. A crushing chamber 16 having a vertical cross-section of a wedged shape is formed between the crushing surface of the concave 14 and the crushing surface of the mantle 13 which are opposed to each other with a gap therebetween.

[0027] The hopper 2 is disposed at an upper portion of the top frame 31. The feeder 4 includes, for example, a conveyor (not shown), and the like, and can adjust the supply amount of the matter to be crushed to the hopper 2. An electric motor 41 serving as driving means for the feeder 4 is a variable-speed motor and is driven/controlled by a motor driver 43.

[0028] The mantle 13 is mounted to a mantle core 12 fixed to an upper portion of a main shaft 5. The main shaft 5 is disposed in the frame 3 in a state where the axis of the main shaft 5 is inclined with respect to the vertical direction. The upper end of the main shaft 5 is rotatably supported by an upper bearing 34 provided at an upper end portion of the top frame 31. A lower portion of the main shaft 5 is fitted in an inner bush 51. The inner bush 51 is fixed to an eccentric sleeve 52. The eccentric sleeve 52 is fitted in an outer bush 53 provided at the bottom frame32. A lower portion of the eccentric sleeve 52 is supported by a journal bearing 66 provided at a cylinder tube 63 of a hydraulic cylinder 6. The lower end of the main shaft 5 is supported by a journal bearing 62 provided at a ram 61 of the hydraulic cylinder 6.

[0029] The electric motor 8 is disposed outside the frame 3. The electric motor 8 is provided with a rotation speed sensor 25 that detects the rotation speed of the electric motor 8 and a torque sensor 26 that detects the output torque of the electric motor 8. The electric motor 8 is driven/controlled by a motor driver 88.

[0030] The power transmission mechanism 80 transmits power from the electric motor 8 to the main shaft 5 to which the mantle 13 is fixed. The power transmission mechanism 80 includes: a horizontal shaft 83; a belt (or chain) type transmission mechanism 82 that transmits rotational power from an output shaft 81 of the electric motor 8 to the horizontal shaft 83; the eccentric sleeve 52; and a bevel gear transmission mechanism 84 that transmits rotational power from the horizontal shaft 83 to the eccentric sleeve 52. When the eccentric sleeve 52 rotates upon receiving output of the electric motor 8, the main shaft 5 inserted in the eccentric sleeve 52 turns in an eccentric manner. Accordingly, the mantle 13 performs eccentric turning movement, so-called precession, with respect to the concave 14 of which the position is fixed. Due to the eccentric turning movement of the mantle 13, the setting (opening) between the crushing surface of the mantle 13 and the crushing surface of the concave 14 varies in accordance with the position of the turning of the main shaft 5.

[0031] The gyratory crusher 1 according to the present embodiment includes the hydraulic cylinder 6 serving as the setting adjustment device 10. Due to operation of the hydraulic cylinder 6, the mantle 13 is lifted/lowered with respect to the concave 14, thereby varying the setting (closed setting) at the position where the gap between the two crushing surfaces of the concave 14 and the mantle 13 is narrowest. The hydraulic cylinder 6 also functions as pressure receiving means that receives crushing pressure applied to the mantle 13.

[0032] The hydraulic cylinder 6 includes: the cylinder tube 63; the ram 61 that slides in the cylinder tube 63; a gap setting sensor 23; an oil tank 67; and a hydraulic circuit 7. The gap setting sensor 23 is, for example, a position sensor of a contact type or a non-contact type that detects the position (displacement) of the ram 61. The position in the height direction of the mantle 13 with respect to the concave 14 is determined from the position of the ram 61 detected by the gap setting sensor 23, and the setting is determined on the basis of the relative positional relationship between the concave 14 and the mantle 13.

[0033] A hydraulic chamber 65 of which the volume varies due to displacement of the ram 61 is formed in the cylinder tube 63. The hydraulic circuit 7 is connected to the hydraulic chamber 65. A hydraulic oil of the oil tank 67 is fed through the hydraulic circuit 7 to the hydraulic chamber 65, whereby the ram 61 is lifted. When the hydraulic oil of the hydraulic chamber 65 is discharged through the hydraulic circuit 7 to the oil tank 67, the ram 61 is lowered.

[0034] The hydraulic circuit 7 includes: a communication pipe 71 in communication with a lower portion of the hydraulic chamber 65; an accumulator 72 (or a balance cylinder) provided to the communication pipe 71; an oil feed pipe 73 connected to the communication pipe 71; and an oil discharge pipe 74 connected to the oil feed pipe 73. However, the configuration of the hydraulic circuit 7 is not limited to that of the present embodiment. The oil feed pipe 73 is provided with a strainer 75, a gear pump 76, a check valve 77, and a normally closed shutoff valve 78, in this order, from the upstream side along the flow of the hydraulic oil from the oil tank 67 to the hydraulic chamber 65. The gear pump 76 is driven by a pump motor 68. The pump motor 68 is an electric motor and is driven/controlled by a motor driver 69. The hydraulic chamber 65, the communication pipe 71, or the oil feed pipe 73 is further provided with a pressure sensor 24 that detects the pressure of the hydraulic oil of the hydraulic chamber 65. The oil discharge pipe 74 is connected in the oil feed pipe 73, between the check valve 77 and the shutoff valve 78. The oil discharge pipe 74 is provided with a normally closed shutoff valve 79.

[0035] [Configuration of control system of gyratory crusher 1] FIG. 2 shows a configuration of a control system of the gyratory crusher 1. As shown in FIG. 2, various instruments including the gap setting sensor 23, the pressure sensor 24, the rotation speed sensor 25, and the torque sensor 26 are connected to the control device 9 in a wired or wireless manner so as to be able to transmit/receive (or so as to be able to transmit) signals. In addition, various devices including the motor driver 43 of the electric motor 41 of the feeder 4, the motor driver 88 of the electric motor 8, the motor driver 69 of the pump motor 68, the shutoff valve 78, and the shutoff valve 79 are connected to the control device 9 in a wired or wireless manner so as to be able to transmit/receive signals.

[0036] The control device 9 is a so-called computer, and includes a calculation processing unit such as a CPU, and a storage unit such as a ROM, a RAM, and the like (none of these are shown). The storage unit has stored therein a program executed by the calculation processing unit, various pieces of fixed data, and the like. The calculation processing unit transmits/receives data to/from an external device. The calculation processing unit inputs a detection signal from each of various sensors and outputs a control signal to each control target.

[0037] The control device 9 includes function units which are a load monitoring unit 91, a manipulated variable calculation unit 92, an operation control unit 93, a response evaluation index generation unit 94, and a tuning unit 95. The operation control unit 93 includes: a control unit that controls operation of the feeder 4; a control unit that controls operation of the setting adjustment device 10 (the hydraulic cylinder 6); and a control unit that controls operation of the electric motor 8. In the control device 9, the calculation processing unit reads out software such as the program stored in the storage unit, and executes the software, whereby processes corresponding to the above-described function units are performed. The control device 9 may perform each process through centralized control by a single computer, or may perform each process through decentralized control by cooperation of a plurality of computers. The control device 9 may be implemented as a microcontroller, a programmable logic controller (PLC), or the like.

[0038] [Operation method for gyratory crusher 1] Here, an operation method for the gyratory crusher 1 having the above configuration is described. Before starting operation of the gyratory crusher 1, the control device 9 causes the setting adjustment device 10 to operate such that the setting (closed setting) has an initial set value. The initial set value of the setting is set in advance in accordance with the grain diameter of the matter to be crushed or crushed matter. On the basis of a detection value of the gap setting sensor 23, the control device 9 causes the setting adjustment device 10 to operate such that the setting has the initial set value. When the setting has a value greater than the initial set value, the control device 9 opens the shutoff valve 78, and causes the pump motor 68 to operate, to feed oil to the hydraulic chamber 65. When the setting has a value smaller than the initial set value, the control device 9 opens the shutoff valve 78 and the shutoff valve 79, to discharge oil from the hydraulic chamber 65.

[0039] Subsequently, the control device 9 starts the electric motor 8, and starts the feeder 4. Through operation of the feeder 4, the matter to be crushed is fed through the hopper 2 into the crushing chamber 16, is crushed between the concave 14 and the mantle 13 eccentrically turning, and is collected as a crushed product from a lower part of the bottom frame 32.

[0040] During operation of the gyratory crusher 1 as described above, crushing load varies due to disturbance such as change in the properties or water amount of the matter to be crushed, the level of the matter to be crushed in the hopper 2, or the like. Here, "crushing load" means a load that is applied to the output shaft 81 of the electric motor 8 in association with crushing of the matter to be crushed. When an overload of a predetermined magnitude or greater has occurred in the output shaft 81, rotation of the output shaft 81 is locked, and emergency stop of the electric motor 8 occurs due to activation of an overload protection circuit. Therefore, the gyratory crusher 1 includes a load measuring device that measures a load index I that dire ctly or indirectly represents the crushing load, and the control device 9 monitors the load index I measured during crushing operation, and performs a crushing load control for adjusting at least one of the supply amount, by the feeder 4, of the matter to be crushed and the setting realized by the setting adjustment device, 10 such that the load index I is maintained in a predetermined steady-state range.

[0041] The crushing load is expressed as a product of the rotation speed of the output shaft 81 and the output torque. Thus, the crushing load can be measured as a product of a rotation speed detected by the rotation speed sensor 25 and an output torque detected by the torque sensor 26. Since the rotation speed of the output shaft 81 corresponds to the rotation speed of the horizontal shaft 83 and the rotation speed of the eccentric sleeve 52, a rotation speed detected by a rotation speed sensor (not shown) provided to the horizontal shaft 83 or the eccentric sleeve 52 may be used, instead of the rotation speed detected by the rotation speed sensor 25.

[0042] The crushing load has correlation with the driving current of the electric motor 8. Therefore, change in the crushing load can be estimated on the basis of change in the driving current of the electric motor 8. The driving current of the electric motor 8 can be measured as a detection value of a current sensor 88a included in the motor driver 88.

[0043] The crushing load has correlation with electric power consumption of the electric motor 8. Therefore, change in the crushing load can be estimated on the basis of change in the electric power consumption of the electric motor 8. The electric power consumption of the electric motor 8 can be measured as a product of a detection value of the current sensor 88a and a detection value of a voltage sensor 88b, the current sensor 88a and the voltage sensor 88b being included in the motor driver 88.

[0044] The crushing load has correlation with the crushing pressure. Therefore, change in the crushing load can be estimated on the basis of change in the crushing pressure. The crushing pressure can be measured as a pressure of the hydraulic chamber 65 detected by the pressure sensor 24.

[0045] Thus, as the load index I, it is possible to adopt at least one of: the value of the product of the rotation speed and the output torque; the value of the driving current of the electric motor 8; the value of the electric power consumption of the electric motor 8; and the value of the crushing pressure. Then, in accordance with the adopted load index I, an instrument that measures or detects the load index I is selected as the load measuring device.

[0046] [Crushing load control by control device 9] FIG. 3 to FIG. 5 are each a flow chart showing a flow of a process of the crushing load control performed by the control device 9. In the following, with reference to FIG. 3 to FIG. 5, an example of the flow of the process of the crushing load control performed by the control device 9 is described. The crushing load control is started, after the gyratory crusher 1 has been started and then a state where the driving current value and the crushing pressure have become stable at their respective steady-state operation values, i.e., a steady state, has been established.

[0047] <First Example of crushing load control> First, First Example of the crushing load control is described. In the present example, a proportional-integral-derivative (PID) control algorithm is adopted as a control algorithm of the crushing load control. However, the control algorithm of the crushing load control is not limited to this example, and may be one selected from a control algorithm group that includes a proportional (P) control algorithm, a proportional-integrating (PI) control algorithm, a proportional-integral-derivative control algorithm, and a proportional-derivative feedback (PDF) control algorithm.

[0048] In the control device 9, the load index I and a manipulation target are set in advance, and a various numerical values that are used in control and that include a load index target value IT, initial control parameters of the control algorithm, and the like, are set in advance. As described above, the load index I is a measurement value that directly or indirectly represents the crushing load, and may be any one of: the value of the product of the rotation speed and the output torque, the value of the driving current of the electric motor 8, the value of the electric power consumption of the electric motor 8, and the value of the crushing pressure. The manipulation target is at least one of the feeder 4 and the setting adjustment device 10. In the present example, the manipulation target is assumed to be the feeder 4.

[0049] The manipulation target is manipulated with a certain manipulated variable MV by the operation control unit 93 of the control device 9, and is in operation corresponding to the manipulated variable MV (or in a state corresponding to the manipulated variable MV). When having started a crushing load control, the control device 9 obtains a load index I measured by the load measuring device (step Si), and monitors that the load index I is in a predetermined steady-state range (step S2). More specifically, the load monitoring unit 91 of the control device 9 obtains a load index I from the load measuring device, and determines whether or not the load index I is in a range from a predetermined steady-state range lower threshold ILO to a predetermined steady-state range upper thresholdIHI, and whether or not the load index I is lower than a no-load state threshold ILL. When the load index I is in the steady-state range, or when the load index I is lower than the no-load state threshold ILL (YES in step S2), the control device 9 returns to step SIand continues monitoring.

[0050] Meanwhile, when the load index I is outside the steady-state range (NO in step S2), the control device 9 starts measuring a PID control time Ti with a timer (step S3). When the PID control time Ti (i.e., the elapsed time since the start of the time measurement) is less than a predetermined PID control cycle Tis (NO in step S4), the control device 9 returns to step S Iand continues monitoring. Meanwhile, when the PID control time T1 is equal to or greater than the PID control cycle Tis (YES in step S4), the control device 9 resets the PID control time Ti to 0 (step S5), and advances to the next step S6.

[0051] In step S6, the control device 9 calculates a new manipulated variable MVn from the load index I and the load index target valueITby using the control algorithm. More specifically, by using the control algorithm, the manipulated variable calculation unit 92 of the control device 9 calculates a manipulated variable difference AMVn on the basis of three elements of a deviation en between the load index I (control amount) and the load index target valueIT(target value), and the integral and derivative thereof, and calculates a new manipulated variable MVn by adding the manipulated variable difference AMVn to the present manipulated variable MVn-1 .

[0052] Further, the control device 9 compares the new manipulated variable MVn with a predetermined manipulated variable maximum valueMVHI, and when the new manipulated variable MVn is greater than the manipulated variable maximum valueMVHI (YES in step S7), the control device 9 sets the manipulated variable maximum valueMVHIaS a new manipulated variable MVn (step S8). When the new manipulated variable MVn is less than a predetermined manipulated variable minimum value MVLO (YES in step S9), the control device 9 sets the manipulated variable minimum value MVLOas a new manipulated variable MVn (step S10). When the new manipulated variable MVn is an appropriate value that is equal to or greater than the manipulated variable minimum value MVLO and equal to or smaller than the manipulated variable maximum valueMVHI (NO in step S7 and NO in step S9), the new manipulated variable MVn is not replaced by the manipulated variable minimum value MVLO or the manipulated variable maximum valueMVHI. Then, the control device 9 updates the manipulated variable MV with the new manipulated variable MVn (step Sll).

[0053] The control device 9 causes the manipulation target to operate so as to correspond to the new manipulated variable MVn (step S12). More specifically, on the basis of the new manipulated variable MV, the operation control unit 93 of the control device 9 outputs an operation command to the manipulation target, to cause the manipulation target to operate. In a case where the manipulation target is the setting adjustment device 10, the value of the setting is changed so as to correspond to the new manipulated variable MVn of the hydraulic cylinder 6. In a case where the manipulation target is the feeder 4, the supply amount of the matter to be crushed to the hopper 2 is changed so as to correspond to the new manipulated variable MVn of the feeder 4.

[0054] When the manipulation target operates so as to correspond to the new manipulated variable MVn as described above, response to the new manipulated variable MVn appears in the load index I. The response evaluation index generation unit 94 of the control device 9 obtains, from the load measuring device, a load index I caused by the new manipulated variable MVn, creates a response waveform of the load index I (step S13), returns to step S, and continues monitoring.

[0055] The control device 9 generates a response evaluation index by using the response waveform. FIG. 6 is a graph showing an example of the response waveform. The vertical axis of this graph represents the load index I, and the horizontal shaft of this graph represents elapsed time. In the response waveform in FIG. 6, overshoot and hunting have occurred.

[0056] In parallel with step S2, the control device 9 determines whether or not the obtained load index I is greater than the no-load state threshold ILL (step S14). When the load index I is equal to or smaller than the no-load state threshold ILL (NO in step S14), the control device 9 advances the process to step S33, resets a positive-side deviation integrated value Een+ and a negative-side deviation integrated value Een. to 0 (steps S33, S34), and then, returns the process to step S1. Meanwhile, in the control device 9, when the load index I is greater than the no load state threshold ILL (YES in step S14), the response evaluation index generation unit 94 of the control device 9 calculates, with respect to the response waveform of the load index I, a positive-side deviation integrated value Een+ relative to the load index target value IT in a deviation integration time T 2 , and updates the positive-side deviation integrated value Een+ (step S15). In the response waveform in FIG. 6, the positive-side deviation integrated value Een+ is represented by the area of the right-upwardly hatched region. Similarly, the response evaluation index generation unit 94 of the control device 9 calculates a negative-side deviation integrated value Een. relative to the load index target value IT in the deviation integration time T 2 with respect to the response waveform of the load index I, and updates the negative-side deviation integrated value Een. (step S16). In the response waveform in FIG. 6, the negative side deviation integrated value Een. is represented by the area of the right-downwardly hatched region. When the load index I has become lower than the no-load state threshold ILL during a parameter adjustment cycle T2s, the positive-side deviation integrated value Een+ and the negative-side deviation integrated value Een- are reset to 0 (steps S33, S34), the process is then returned to step Si, and generation of the response evaluation index is suspended. Then, when the load index I has become greater than the no-load state threshold ILL again, the process is advanced to step S15, and generation of the response evaluation index is resumed.

[0057] The control device 9 starts measuring the deviation integration time T 2 (step S17). When the deviation integration time T 2 (i.e., the elapsed time since the start of the time measurement) is less than a predetermined parameter adjustment cycle T2s (NO in step S18), the control device 9 returns to step S Iand repeats the process. Meanwhile, when the deviation integration time T 2 is equal to or greater than the parameter adjustment cycle T 2 s (YES in step S18), the control device 9 sets the deviation integration time T 2 to 0 (step S19), advances to the next steps S20, S25, S27, and starts control parameter tuning.

[0058] The tuning unit 95 of the control device 9 compares the positive-side deviation integrated value Een+ in the parameter adjustment cycle T2s with a predetermined first positive side threshold Ei+ (step S20), and compares the negative-side deviation integrated value Een. in the parameter adjustment cycle T 2 s with a predetermined first negative-side threshold Ei. (step S21). When the positive-side deviation integrated value Een+ is greater than the first positive side threshold Ei+ (YES in step S20) and the negative-side deviation integrated value Een. is smaller than the first negative-side threshold Ei. (YES in step S21), the tuning unit 95 detects hunting and generates a new proportional gain Kpn obtained by decreasing a proportional gain Kp by a predetermined first proportional gain adjustment amount (step S22). Here, when the new proportional gain Kpn is smaller than a predetermined proportional gain minimum value KpLO (YES in step S23), the tuning unit 95 sets the proportional gain minimum value KpLO as a new proportional gain Kpn (step S24). Then, the tuning unit 95 updates the proportional gain Kp with the new proportional gain Kpn (step S32), sets the positive-side deviation integrated value Een+ and the negative-side deviation integrated value Een- to zero (steps S33, S34), and returns the process to step S1.

[0059] The tuning unit 95 compares the negative-side deviation integrated value Een. with a second negative-side threshold E2 - (step S25). When the negative-side deviation integrated value Een. is smaller than the second negative-side threshold E2 - (YES in step S25) and the positive-side deviation integrated value Een+ is substantially 0 (YES in step S26), the tuning unit detects that the steady-state deviation is excessive, and generates a new proportional gain Kpn obtained by increasing the proportional gain Kp by a predetermined second proportional gain adjustment amount (step S29). Here, when the new proportional gain Kpn is greater than a predetermined proportional gain maximum value KpHI (YES in step S30), the tuning unit 95 sets the proportional gain maximum value KpHIaS a new proportional gain Kpn (step S31). Then, the tuning unit 95 updates the proportional gain Kp with the new proportional gain Kpn (step S32), and advances the process to step S33.

[0060] The tuning unit 95 compares the positive-side deviation integrated value len+ with a second positive-side threshold E 2+(step S27). When the positive-side deviation integrated value le,+ is smaller than the second positive-side threshold E2 + (YES in step S27) and the negative-side deviation integrated value Een. is substantially 0 (YES in step S28), the tuning unit detects that the steady-state deviation is excessive and generates a new proportional gain Kpn obtained by increasing the proportional gain Kp by a predetermined second proportional gain adjustment amount (step S29). Here, when the new proportional gain Kpn is greater than the predetermined proportional gain maximum value KpHI (YES in step S30), the tuning unit 95 sets the proportional gain maximum value KpHIaS a new proportional gain Kpn (step S31). Then, the tuning unit 95 updates the proportional gain Kp with the new proportional gain Kpn (step S32), and advances the process to step S33.

[0061] When the positive-side deviation integrated value Een+ is smaller than the first positive-side threshold E 1+ (NO in step S20), or when the negative-side deviation integrated value Een. is greater than the first negative-side threshold Ei (NO in step S21), the tuning unit 95 of the control device 9 determines that hunting has not occurred. When the negative-side deviation integrated value Een-is greater than the second negative-side threshold E 2 - (NO in step S25), or when the positive-side deviation integrated value Een+ is not substantially 0 (NO in step S26), the tuning unit 95 determines that the negative-side steady-state deviation is not excessive. When the positive-side deviation integrated value Een+ is smaller than the second positive-side threshold E2+ (NO in step S27), or when the negative-side deviation integrated value Een. is not substantially 0 (NO in step S28), the tuning unit 95 determines that the positive-side steady-state deviation is not excessive. When the determination that hunting has not occurred (NO in step S20 or NO in step S21) or the negative-side steady-state deviation is not excessive (NO in step S25 or NO in step S26), and the determination that the positive-side steady-state deviation is not excessive (NO in step S27 or NO in step S28) are established, the tuning unit 95 advances the process to step S33 without updating the proportional gain Kp.

[0062] In the above-described crushing load control, the proportional gain Kp is adjusted by the tuning unit 95. However, at least one of a derivative gain Kd and an integral gain Ki may be adjusted in addition to the proportional gain Kp.

[0063] <Second Example of crushing load control> Next, Second Example of the crushing load control is described. In First Example described above, at least one of the feeder 4 and the setting adjustment device 10 is set as the manipulation target. In contrast, in Second Example, the feeder 4 and the setting adjustment device 10 are set as the manipulation targets. One, out of the feeder 4 and the setting adjustment device 10, of which the manipulated variable is preferentially changed is defined as a first manipulation target, and the other is defined as a second manipulation target.

[0064] In the flow of the process of the crushing load control according to Second Example, steps S6 to SlIin the flow of the process of the crushing load control according to First Example are different, and the other steps are substantially the same. In the following, the flow of the process of the crushing load control according to Second Example are described with reference to FIG. 7 to FIG. 9. For contents that overlap with the process of the crushing load control according to the above-described First Example, First Example should be referred to, and description of the contents is not repeated.

[0065] The first manipulation target is manipulated with a certain manipulated variable MV1 by the operation control unit 93 of the control device 9, and is in operation corresponding to the manipulated variable MV1. The second manipulation target is manipulated with a certain manipulated variable MV2, and is in operation corresponding to the manipulated variable MV2. When having started a crushing load control, the control device 9 obtains a load index I measured by the load measuring device (step S41), and monitors that the load index I is in a predetermined steady-state range (or no-load state) (step S42). When the load index I is in the steady-state range (or no-load state) (YES in step S42), the load monitoring unit 91 of the control device 9 returns to step S41 and continues monitoring.

[0066] Meanwhile, when the load index I is outside the steady-state range (NO in step S42), the control device 9 starts measuring a PID control time T Iwith a timer (step S43). When the PID control time Ti (i.e., the elapsed time since the start of the time measurement) is less than a predetermined PID control cycle Tis (NO in step S44), the control device 9 returns to step S41 and continues monitoring. Meanwhile, when the PID control time Ti is equal to or greater than the PID control cycle Tis (YES in step S44), the control device 9 resets the PID control time Ti to 0 (step S45), and advances to the next step S46.

[0067] In step S46, with respect to the first manipulation target, the manipulated variable calculation unit 92 of the control device 9 calculates a new manipulated variable MV1n in accordance with the control algorithm from the load index I and the load index target value IT. Further, the control device 9 compares the new manipulated variable MV1n with a predetermined manipulated variable maximum valueMV1HI, and when the new manipulated variable MV1 is greater than the manipulated variable maximum valueMV1HI (YES in step S47), the control device 9 calculates a new manipulated variable MV2n in accordance with the control algorithm from the load index I and the load index target valueITwith respect to the second manipulation target (step S61).

[0068] The control device 9 compares the new manipulated variable MV2n with a predetermined manipulated variable minimum value MV2LO, and when the new manipulated variable MV2n is less than the manipulated variable minimum value MV2LO (YES in step S62), the control device 9 sets the manipulated variable minimum value MV2LO as a new manipulated variable (step S63). Then, with respect to the second manipulation target, the control device 9 updates the manipulated variable MV2 with the new manipulated variable MV2n (step S67).

[0069] In step S47, when the new manipulated variable MV1n is equal to or smaller than the manipulated variable maximum valueMV1HI (NO in step S47), the control device 9 compares the new manipulated variable MV1n with a manipulated variable minimum value MVLO, and when the new manipulated variable MV1n is less than the manipulated variable minimum value MV1LO (YES in step S48), the control device 9 calculates a new manipulated variable MV2n in accordance with the control algorithm from the load index I and the load index target valueIT with respect to the second manipulation target (step S64).

[0070] The control device 9 compares the new manipulated variable MV2n with a predetermined manipulated variable maximum value MV2HI, and when the new manipulated variable MV2n is greater than the manipulated variable maximum value MV2HI (YES in step S65), the control device 9 sets the manipulated variable maximum value MV2HIaS a new manipulated variable MV2n (step S66). Then, the control device 9 updates the manipulated variable MV2 with the new manipulated variable MV2n with respect to the second manipulation target (step S67).

[0071] In step S38, when the new manipulated variable MV1n is equal to or greater than the manipulated variable minimum value MV1LO (NO in step S48), the control device 9 updates the manipulated variable MV1 with the new manipulated variable MV1n with respect to the first manipulation target (step S49).

[0072] The control device 9 causes the first manipulation target and the second manipulation target to operate at the new manipulated variables MV1n, MV2n (step S50).

[0073] When the first manipulation target and the second manipulation target operate so as to correspond to the new manipulated variables MV1, MV2n as described above, the responses of the new manipulated variables MV1, MV2n appear in the load index I. The response evaluation index generation unit 94 of the control device 9 obtains, from the load measuring device, the load index I caused by the new manipulated variable MV1n, MV2, creates a response waveform of the load index I (step S51), returns to step S41, and continues monitoring.

[0074] The control device 9 generates a response evaluation index by using the response waveform. In parallel with step S42, the control device 9 determines whether or not the obtained load index I is greater than the no-load state threshold ILL (step S52). When the load index I is equal to or smaller than the no-load state threshold ILL (NO in step S52), the control device 9 advances the process to step S78, resets the positive-side deviation integrated value Een+ and the negative-side deviation integrated value Een. to 0 (steps S78, S79), and then returns the process to step Si. Meanwhile, when the load index I is greater than the no-load state threshold ILL (YES in step S52), the response evaluation index generation unit 94 of the control device 9 calculates, with respect to the response waveform of the load index I, a positive-side deviation integrated value Een+ relative to the load index target valueITin the deviation integration time T 2 , and updates the positive-side deviation integrated value Een+ (step S53). Similarly, with respect to the response waveform of the load index I, the response evaluation index generation unit 94 of the control device 9 calculates a negative-side deviation integrated value Een. relative to the load index target valueITin the deviation integration time T 2, and updates the negative side deviation integrated value Een- (step S54).

[0075] The control device 9 starts measuring the deviation integration time T 2 (step S55). When the deviation integration time T 2 is less than a predetermined parameter adjustment cycle T 2 s (NOin step S56), the control device 9 returns the process to step S41. Meanwhile,when the deviation integration time T 2 is equal to or greater than a predetermined parameter adjustment cycle T 2 s (YES in step S56), the control device 9 sets the deviation integration time T 2 to 0(step S57), then advances to the subsequent steps S72, S57, S59, and starts control parameter tuning.

[0076] The tuning unit 95 of the control device 9 compares the positive-side deviation integrated value Een+ in the parameter adjustment cycle T2swith a predetermined first positive side threshold Ei+ (step S72), and compares the negative-side deviation integrated value Een. in the parameter adjustment cycle T 2swith a predetermined first negative-side threshold Ei. (step S73). When the positive-side deviation integrated value Een+ is greater than the first positive side threshold Ei+ (YES in step S72) and the negative-side deviation integrated value Een. is smaller than the first negative-side threshold Ei. (YES in step S73), the tuning unit 95 detects hunting and generates a new proportional gain Kpn obtained by decreasing a proportional gain Kp by a predetermined first proportional gain adjustment amount (step S74). Here, when the new proportional gain Kpn is smaller than a predetermined proportional gain minimum value KpLO (YES in step S75), the tuning unit 95 sets the proportional gain minimum value KpLO as a new proportional gain Kpn (step S76). Then, the tuning unit 95 updates the proportional gain Kp with the new proportional gain Kpn (step S77), sets the positive-side deviation integrated value le,+ and the negative-side deviation integrated value Een. to zero (steps S78, S79), and returns the process to step S41.

[0077] The tuning unit 95 compares the negative-side deviation integrated value Een. with a second negative-side threshold E2 - (step S81). When the negative-side deviation integrated value len. is smaller than the second negative-side threshold E2 - (YES in step S81) and the positive-side deviation integrated value Een+ is substantially 0 (YES in step S82), the tuning unit detects that the steady-state deviation is excessive, and generates a new proportional gain Kpn obtained by increasing the proportional gain Kp by a predetermined second proportional gain adjustment amount (step S85). Here, when the new proportional gain Kpn is greater than a predetermined proportional gain maximum value KpHI (YES in step S86), the tuning unit 95 sets the proportional gain maximum value KpHI as a new proportional gain Kpn (step S87). Then, the tuning unit 95 updates the proportional gain Kp with the new proportional gain Kpn (step S77), and advances the process to step S78.

[0078] The tuning unit 95 compares the positive-side deviation integrated value Een+ with a second positive-side threshold E 2 + (step S83). When the positive-side deviation integrated value Een+ is smaller than second positive-side threshold E 2 + (YES in step S83) and the negative side deviation integrated value Een. is substantially 0 (YES in step S84), the tuning unit 95 detects that the steady-state deviation is excessive, and generates a new proportional gain Kpn obtained by increasing the proportional gain Kp by a predetermined second proportional gain adjustment amount (step S85). Here, when the new proportional gain Kpn is greater than the predetermined proportional gain maximum value KpHI (YES in step S86), the tuning unit 95 sets the proportional gain maximum value KpHI as a new proportional gain Kpn (step S87). Then, the tuning unit 95 updates the proportional gain Kp with the new proportional gain Kpn (step S77), and advances the process to step S78.

[0079] When the positive-side deviation integrated value Een+ is smaller than the first positive-side threshold E 1+ (NO in step S72), or when the negative-side deviation integrated value Een. is greater than the first negative-side threshold Ei. (NO in step S73), the tuning unit 95 determines that hunting has not occurred. When the negative-side deviation integrated value Een. is greater than the second negative-side threshold E2 - (NO in step S81), or when the positive-side deviation integrated value Een+ is not substantially 0 (NO in step S82), the tuning unit 95 determines that the negative-side steady-state deviation is not excessive. When the positive-side deviation integrated value Een+ is smaller than the second positive-side threshold E2 + (NO in step S83), or when the negative-side deviation integrated value Een. is not substantially 0 (NO in step S84), the tuning unit 95 determines that the positive-side steady-state deviation is not excessive. When the determination that the hunting has not occurred (NO in step S72 or NO in step S73) or the negative-side steady-state deviation is not excessive (NO in step S81 or NO in step S82), and the determination that the positive-side steady-state deviation is not excessive (NO in step S83 or NO in step S84) are established, the tuning unit 95 advances the process to step S78 without updating the proportional gain Kp.

[0080] As described above, the gyratory crusher 1 according to the present embodiment includes: the concave 14 having a conical tubular shape; the mantle 13 having a truncated conical shape and disposed on the inner side of the concave 14; the electric motor 8 configured to cause the mantle 13 to perform eccentric turning movement; the hopper 2 configured to feed matter to be crushed, to the crushing chamber 16 formed between the concave 14 and the mantle 13; the feeder 4 configured to supply the matter to be crushed, to the hopper 2; the load measuring device configured to measure a load index I that dire ctly or indirectly represents a crushing load; the setting adjustment device 10 configured to, in order to change the setting between the concave 14 and the mantle 13, cause one of the concave 14 and the mantle 13 to be displaced with respect to another of the concave 14 and the mantle 13; and the control device 9 configured to control the setting adjustment device 10 and the feeder 4.

[0081] The control device 9 includes: the load monitoring unit 91 of which a manipulation target is at least one of the feeder 4 and the setting adjustment device 10, the load monitoring unit 91 being configured to, in a state where the manipulation target is in operation so as to correspond to a manipulated variable, monitor that the load index I measured by the load measuring device is in a predetermined steady-state range; the manipulated variable calculation unit 92 configured to, when the load index I is outside the steady-state range, calculate, with respect to the manipulation target, a new manipulated variable on the basis of a deviation between a predetermined target value IT of the load index I and a measurement value, by using a predetermined control algorithm; the operation control unit 93 configured to cause the manipulation target to operate so as to correspond to the new manipulated variable; the response evaluation index generation unit 94 configured to generate a response evaluation index of the load index I caused by operation corresponding to the new manipulated variable of the manipulation target; and the tuning unit 95 configured to evaluate, on the basis of the response evaluation index, whether or not response is good, and adjust at least one of control parameters of the control algorithm when the response is not good.

[0082] A control method for the gyratory crusher 1 according to the present embodiment includes the steps of: with at least one of the feeder 4 and the setting adjustment device 10 being set as a manipulation target, and in a state where the manipulation target is in operation so as to correspond to a manipulated variable, measuring a load index I that directly or indirectly represents a crushing load, and monitoring that the load index I is in a predetermined steady-state range; calculating, with respect to the manipulation target, when the load index I is outside the steady-state range, a new manipulated variable on the basis of a deviation between a predetermined target value IT of the load index I and a measurement value, by using a predetermined control algorithm; causing the manipulation target to operate so as to correspond to the new manipulated variable; generating a response evaluation index of the load index I caused by operation corresponding to the new manipulated variable of the manipulation target; and evaluating, on the basis of the response evaluation index, whether or not response is good, and adjusting at least one of control parameters of the control algorithm when the response is not good.

[0083] According to the gyratory crusher 1 and the control method therefor, when the response to control based on the control algorithm is not good any longer, i.e., when due to disturbance such as change or the like in the properties of the matter to be crushed, a control parameter having been used becomes no longer an appropriate value, the control parameter is automatically adjusted to an appropriate value. Accordingly, even when disturbance has occurred, continuation of stable operation of the gyratory crusher 1 can be realized.

[0084] In the gyratory crusher 1 according to the present embodiment, the response evaluation index generation unit 94 creates a response waveform of the load index I caused by the operation of the manipulation target, and calculates a positive-side deviation integrated value Een+ and a negative-side deviation integrated value Een. relative to a target value IT of the response waveform over a predetermined parameter adjustment cycle T2s, and the tuning unit 95 evaluates whether or not response is good, on the basis of the positive-side deviation integrated value Een+ and the negative-side deviation integrated value Een.

[0085] Similarly, in the control method for the gyratory crusher 1 according to the present embodiment, the step of generating the response evaluation index includes creating a response waveform of the load index I caused by the operation of the manipulation target, and calculating a positive-side deviation integrated value Een+ and a negative-side deviation integrated value Een. relative to a target value IT of the response waveform over a predetermined parameter adjustment cycle T2, and the step of adjusting at least one of the control parameters includes evaluating whether or not the response is good, on the basis of the positive-side deviation integrated value le,+ and the negative-side deviation integrated value le.

[0086] Since the response is evaluated with this method, whether or not the value of the control parameter of the control algorithm is an appropriate value can be easily and accurately evaluated.

[0087] In the gyratory crusher 1 and the control method therefor, the load index I may be a value of electric power consumption of the electric motor 8. The load measuring device in this case is the current sensor 88a and the voltage sensor 88b provided to the motor driver 88.

[0088] Alternatively, in the gyratory crusher 1 and the control method therefor, the load index I may be crushing pressure applied to the mantle 13. The gyratory crusher 1 further includes the hydraulic cylinder 6 configured to be subjected to crushing pressure applied to the mantle 13. The load measuring device in this case is the pressure sensor 24 that detects hydraulic pressure of the hydraulic oil of the hydraulic cylinder 6.

[0089] As described above, the load index I to be used in control can be selected as appropriate from a plurality of candidates in accordance with a specific configuration of the gyratory crusher 1, the matter to be crushed, or the like.

[0090] [Modification] Next, a modification of the above embodiment is described. FIG. 10 shows a schematic configuration of a gyratory crusher 1A according to a modification. The gyratory crusher 1 according to the above embodiment includes the setting adjustment device 10 of a hydraulic type, whereas the gyratory crusher 1A according to the present modification includes a setting adjustment device 1OA of a mechanical type. Except for this difference, both gyratory crushers have substantially the same structure. Thus, in the description of the gyratory crusher 1A according to the modification, members that are the same as or similar to those in the gyratory crusher 1 according to the above-described embodiment are denoted by the same reference signs, and description thereof is omitted or simplified.

[0091] As shown in FIG. 10, the gyratory crusher 1A includes a hopper 2 that feeds matter to be crushed, to a crushing chamber 16; a feeder 4 that supplies the matter to be crushed, to the hopper 2; a mantle 13 and a concave 14 that seize and crush the matter to be crushed having dropped from the hopper 2; an electric motor 8 serving as turning driving means for the mantle 13; a power transmission mechanism 80 that transmits rotational power from the electric motor 8 to the mantle 13; a setting adjustment device 1OA that lifts/lowers the concave 14 with respect to the mantle 13; and a control device 9 that governs operation of the gyratory crusher 1.

[0092] The gyratory crusher 1 further includes a frame 3 composed of a top frame 31 and a bottom frame 32. A concave support 35 having a cylindrical shape is disposed at the inner periphery of the top frame 31. The concave 14 is fixed to the inner periphery of the concave support 35. The hopper 2 is fixed to an upper portion of the concave support 35.

[0093] An inside screw 31a is formed at the inner peripheral surface of the top frame 31, an outside screw 35a is formed at the outer peripheral surface of the concave support 35, and these screws are engaged with each other. External gear teeth 35b are formed at the concave support , and the external gear teeth 35b are meshed with a driving gear 45. The driving gear 45 rotates by receiving rotational power of an electric motor 46. The electric motor 46 is supported by the top frame 31. Operation of the electric motor 46 is controlled by a motor driver 47 connected to the control device 9.

[0094] The setting adjustment device 10A is composed of the inside screw 31a of the top frame 31, the outside screw 35a and the external gear teeth 35b of the concave support 35, the driving gear 45, the electric motor 46, and the motor driver 47. In the setting adjustment device A, when the driving gear 45 rotates, the concave support 35 rotates with respect to the top frame31. When the concave support 35 rotates, the concave support 35 is lifted/lowered with respect to the top frame 31 due to the engagement of the inside screw 31a of the top frame 31 and the outside screw 35a of the concave support 35, whereby the setting is changed.

[0095] The top frame 31 or the concave support 35 is provided with a gap setting sensor 23A of a contact type or a non-contact type that detects displacement of the concave support 35 with respect to the top frame 31. The control device 9 can obtain a setting from a detection value of the gap setting sensor 23A. On the basis of the value of the setting detected by the gap setting sensor 23A, the control device 9 causes the setting adjustment device 10A to operate.

[0096] The mantle 13 is mounted to a mantle core 12 fixed to an upper portion of a main shaft 5. The main shaft 5 is disposed in the frame 3 in a state where the axis of the main shaft 5 is inclined with respect to the vertical direction. A lower portion of the main shaft 5 is fitted in an inner bush 51. The inner bush 51 is fixed to an eccentric sleeve 52. The eccentric sleeve 52 is fitted in an outer bush 53 provided at the bottom frame 32. A lower portion of the eccentric sleeve 52 is supported by a journal bearing 66. The mantle core 12 is supported by a thrust bearing (hydrostatic bearing) 55 provided to the bottom frame 32. An oil film due to a lubricating oil is formed between the mantle core 12 and the thrust bearing 55. A lubrication circuit 7A of the thrust bearing 55 is provided with a pressure sensor 24A that detects oil feeding pressure of the lubricating oil. When crushing pressure is applied to the mantle 13, an even higher pressure is required in order to send out the lubricating oil between the mantle core 12 and the thrust bearing 55, and the oil pressure of the lubricating oil to be supplied to the thrust bearing 55 is increased. Therefore, the oil feeding pressure of the thrust bearing 55 detected by the pressure sensor 24A is a measurement value that indirectly represents the crushing load, and may be used as a load index I.

[0097] Similar to the gyratory crusher 1 described above, the gyratory crusher 1A having the above-described configuration includes a load measuring device that measures a load index I that directly or indirectly represents a crushing load, and the control device 9 monitors the load index I measured during crushing operation, and performs a crushing load control for adjusting the supply amount, by the feeder 4, of the matter to be crushed such that the load index I is maintained in a predetermined steady-state range. However, in the gyratory crusher 1A of a mechanical type, since it is necessary to fix, under pressure, the setting adjustment device 10A during crushing operation, it is difficult to change the setting during the crushing operation. Thus, the above-described First Example is adopted as the crushing load control method, and the feeder 4 is selected as the manipulation target.

[0098] While the preferred embodiment of the present invention has been described above, the details of specific structures and/or functions of the above embodiment may be modified without deviating from the scope of the present invention, and such modifications can be included in the present invention.

Reference Signs List

[0099] 1, 1A gyratory crusher 2 hopper 3 frame 4 feeder 5 main shaft 6 hydraulic cylinder 7 hydraulic circuit 7A lubrication circuit 8 electric motor 9 control device 10, 1OA setting adjustment device 12 mantle core 13 mantle 14 concave 16 crushing chamber

23, 23A gap setting sensor 24, 24A pressure sensor rotation speed sensor 26 torque sensor 31 top frame 32 bottom frame 34 upper bearing concave support 41 electric motor 43 motor driver driving gear 46 electric motor 47 motor driver 51 inner bush 52 eccentric sleeve 53 outer bush thrust bearing 61 ram 62 journal bearing 63 cylinder tube hydraulic chamber 66 journal bearing 67 oil tank 68 pump motor 69 motor driver 71 communication pipe 72 accumulator 73 oil feed pipe 74 oil discharge pipe strainer 76 gear pump 77 check valve 78 shutoff valve 79 shutoff valve power transmission mechanism 81 output shaft 82 belt type transmission mechanism 83 horizontal shaft 84 bevel gear transmission mechanism 88 motor driver 88a current sensor 88b voltage sensor 91 load monitoring unit 92 manipulated variable calculation unit 93 operation control unit 94 response evaluation index generation unit tuning unit

Claims

CLAIMS 1. A gyratory crusher including: a concave having a conical tubular shape; a mantle having a truncated conical shape and disposed on an inner side of the concave; an electric motor configured to cause the mantle to perform eccentric turning movement; a hopper configured to feed matter to be crushed, to a crushing chamber formed between the concave and the mantle; a feeder configured to supply the matter to be crushed, to the hopper; a load measuring device configured to measure a load index that directly or indirectly represents a crushing load; a setting adjustment device configured to, in order to change a setting between the concave and the mantle, cause one of the concave and the mantle to be displaced with respect to another of the concave and the mantle; and a control device configured to control the setting adjustment device and the feeder, wherein the control device includes a load monitoring unit of which a manipulation target is at least one of the feeder and the setting adjustment device, the load monitoring unit being configured to, in a state where the manipulation target is in operation so as to correspond to a manipulated variable, monitor that the load index measured by the load measuring device is in a predetermined steady-state range, a manipulated variable calculation unit configured to, when the load index is outside the steady-state range, calculate, with respect to the manipulation target, a new manipulated variable on the basis of a deviation between a predetermined target value of the load index and a measurement value, by using a predetermined control algorithm, an operation control unit configured to cause the manipulation target to operate so as to correspond to the new manipulated variable, a response evaluation index generation unit configured to generate a response evaluation index of the load index caused by operation corresponding to the new manipulated variable of the manipulation target, and a tuning unit configured to evaluate, on the basis of the response evaluation index, whether or not response is good, and adjust at least one of control parameters of the control algorithm when the response is not good.
2. The gyratory crusher according to claim 1, wherein the response evaluation index generation unit creates a response waveform of the load index caused by the operation of the manipulation target, and calculates a positive-side deviation integrated value and a negative-side deviation integrated value relative to the target value of the response waveform over a predetermined parameter adjustment cycle, and the tuning unit evaluates whether or not the response is good, on the basis of the positive-side deviation integrated value and the negative-side deviation integrated value.
3. The gyratory crusher according to claim 1 or 2, wherein the control algorithm is one selected from a group including a proportional control algorithm, a proportional-integrating control algorithm, a proportional-integral-derivative control algorithm, and a proportional-derivative-feedback (PDF) control algorithm.
4. The gyratory crusher according to any one of claims I to 3, wherein the load index is a value of electric power consumption of the electric motor.
5. The gyratory crusher according to any one of claims 1 to 3, further including a hydraulic cylinder configured to be subjected to crushing pressure applied to the mantle, wherein the load index is a value of hydraulic pressure of a hydraulic oil of the hydraulic cylinder.
6. The gyratory crusher according to any one of claims 1 to 3, further including a thrust bearing configured to support the mantle, wherein the load index is a value of oil feeding pressure of a lubricating oil of the thrust bearing.
7. A control method for a gyratory crusher, the gyratory crusher including a concave having a conical tubular shape, a mantle having a truncated conical shape and disposed on an inner side of the concave, an electric motor configured to cause the mantle to perform eccentric turning movement, a hopper configured to feed matter to be crushed, to a crushing chamber formed between the concave and the mantle, a feeder configured to supply the matter to be crushed, to the hopper, and a setting adjustment device configured to, in order to change a setting between the concave and the mantle, cause one of the concave and the mantle to be displaced with respect to another of the concave and the mantle, the control method including the steps of: with at least one of the feeder and the setting adjustment device being set as a manipulation target, and in a state where the manipulation target is in operation so as to correspond to a manipulated variable, measuring a load index that directly or indirectly represents a crushing load, and monitoring that the load index is in a predetermined steady-state range; calculating, with respect to the manipulation target, when the load index is outside the steady-state range, a new manipulated variable on the basis of a deviation between a predetermined target value of the load index and a measurement value, by using a predetermined control algorithm; causing the manipulation target to operate so as to correspond to the new manipulated variable; generating a response evaluation index of the load index caused by operation corresponding to the new manipulated variable of the manipulation target; and evaluating, on the basis of the response evaluation index, whether or not response is good, and adjusting at least one of control parameters of the control algorithm when the response is not good.
8. The control method for the gyratory crusher according to claim 7, wherein the step of generating the response evaluation index includes creating a response waveform of the load index caused by the operation of the manipulation target, and calculating a positive-side deviation integrated value and a negative-side deviation integrated value relative to the target value of the response waveform over a predetermined parameter adjustment cycle, and the step of adjusting at least one of the control parameters includes evaluating whether or not the response is good, on the basis of the positive-side deviation integrated value and the negative-side deviation integrated value.
9. The control method for the gyratory crusher according to claim 7 or 8, wherein the control algorithm is one selected from a group including a proportional control algorithm, a proportional-integrating control algorithm, a proportional-integral-derivative control algorithm, and a proportional-derivative-feedback control algorithm.
10. The control method for the gyratory crusher according to any one of claims 7 to 9, wherein the load index is a value of electric power consumption of the electric motor.
11. The control method for the gyratory crusher according to any one of claims 7 to 9, wherein the load index is crushing pressure applied to the mantle.
12. A control device of a gyratory crusher, the gyratory crusher including: a concave having a conical tubular shape; a mantle having a truncated conical shape and disposed on an inner side of the concave; an electric motor configured to cause the mantle to perform eccentric turning movement; a hopper configured to feed matter to be crushed, to a crushing chamber formed between the concave and the mantle; a feeder configured to supply the matter to be crushed, to the hopper; a load measuring device configured to measure a load index that directly or indirectly represents a crushing load; and a setting adjustment device configured to, in order to change a setting between the concave and the mantle, cause one of the concave and the mantle to be displaced with respect to another of the concave and the mantle, the control device comprising; a load monitoring unit of which a manipulation target is at least one of the feeder and the setting adjustment device, the load monitoring unit being configured to, in a state where the manipulation target is in operation so as to correspond to a manipulated variable, monitor that the load index measured by the load measuring device is in a predetermined steady-state range, a manipulated variable calculation unit configured to, when the load index is outside the steady-state range, calculate, with respect to the manipulation target, a new manipulated variable on the basis of a deviation between a predetermined target value of the load index and a measurement value, by using a predetermined control algorithm, a response evaluation index generation unit configured to generate a response evaluation index of the load index caused by operation corresponding to the new manipulated variable of the manipulation target, and a tuning unit configured to evaluate, on the basis of the response evaluation index, whether or not response is good, and adjust at least one of control parameters of the control algorithm when the response is not good.
13. The control device of the gyratory crusher according to claim 12, wherein the response evaluation index generation unit creates a response waveform of the load index caused by the operation of the manipulation target, and calculates a positive-side deviation integrated value and a negative-side deviation integrated value relative to the target value of the response waveform over a predetermined parameter adjustment cycle, and the tuning unit evaluates whether or not the response is good, on the basis of the positive-side deviation integrated value and the negative-side deviation integrated value.
14. A control method for a gyratory crusher, the gyratory crusher including: a concave having a conical tubular shape, a mantle having a truncated conical shape and disposed on an inner side of the concave, an electric motor configured to cause the mantle to perform eccentric turning movement, a hopper configured to feed matter to be crushed, to a crushing chamber formed between the concave and the mantle, a feeder configured to supply the matter to be crushed, to the hopper, and a setting adjustment device configured to, in order to change a setting between the concave and the mantle, cause one of the concave and the mantle to be displaced with respect to another of the concave and the mantle, the control method comprising the steps of: with at least one of the feeder and the setting adjustment device being set as a manipulation target, and in a state where the manipulation target is in operation so as to correspond to a manipulated variable, measuring a load index that directly or indirectly represents a crushing load, and monitoring that the load index is in a predetermined steady-state range; calculating, with respect to the manipulation target, when the load index is outside the steady-state range, a new manipulated variable on the basis of a deviation between a predetermined target value of the load index and a measurement value, by using a predetermined control algorithm; generating a response evaluation index of the load index caused by operation corresponding to the new manipulated variable of the manipulation target; and evaluating, on the basis of the response evaluation index, whether or not response is good, and adjusting at least one of control parameters of the control algorithm when the response is not good.
15. The control method for the gyratory crusher according to claim 14, wherein the step of generating the response evaluation index includes creating a response waveform of the load index caused by the operation of the manipulation target, and calculating a positive-side deviation integrated value and a negative-side deviation integrated value relative to the target value of the response waveform over a predetermined parameter adjustment cycle, and the step of adjusting at least one of the control parameters includes evaluating whether or not the response is good, on the basis of the positive-side deviation integrated value and the negative-side deviation integrated value.

Kabushiki Kaisha Earthtechnica Patent Attorneys for the Applicant SPRUSON&FERGUSON