AU2020202399A1 - Control of a crusher - Google Patents

Control of a crusher Download PDF

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Publication number
AU2020202399A1
AU2020202399A1 AU2020202399A AU2020202399A AU2020202399A1 AU 2020202399 A1 AU2020202399 A1 AU 2020202399A1 AU 2020202399 A AU2020202399 A AU 2020202399A AU 2020202399 A AU2020202399 A AU 2020202399A AU 2020202399 A1 AU2020202399 A1 AU 2020202399A1
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AU
Australia
Prior art keywords
yes
gap
crusher
power
wear
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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AU2020202399A
Inventor
John William Long
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Cs Automation Pty Ltd
Original Assignee
Cs Automation Pty Ltd
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Filing date
Publication date
Priority claimed from AU2019901224A external-priority patent/AU2019901224A0/en
Application filed by Cs Automation Pty Ltd filed Critical Cs Automation Pty Ltd
Publication of AU2020202399A1 publication Critical patent/AU2020202399A1/en
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C25/00—Control arrangements specially adapted for crushing or disintegrating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C2/00—Crushing or disintegrating by gyratory or cone crushers
    • B02C2/02—Crushing or disintegrating by gyratory or cone crushers eccentrically moved

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  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Disintegrating Or Milling (AREA)
  • Crushing And Grinding (AREA)

Abstract

A method of controlling a cone crusher includes altering a characteristic gap of the crusher in response to measured performance. The degree by which the gap is altered is subject to change based on learned responses of the crusher. Start Feed on and ACC Active Yes No Close Gap Open Gap No Healthy Healthy Yes Yes Yes Open Gap Open Gap No 4 Conditions Conditions Met Met No Yes |Stop Crusher Feed No Close Gap 4 Conditions Met Crusher Yes Power below Stop Crusher FeedTheol Yes CrusherDelay Timer Power below Threshold Yes Open Crusher Gap Delay Timer Gap Input Yes Close Crusher GapEnbe No Gap ~Feedback >= DelayTimerGap Setpoint Yes Gap Input Enabled Yes Gap NoStop Open Crusher Gap Feedback <= Gap Setpoint Delay Timer Start Crusher Feed Yes Stop Cose Crusher Gap tart Open Gap Lockout Timer Start Crusher Feed St rt Close Gap Lockout 71cTimer Fig. 1

Description

Start
Feed on and ACC Active
Yes
No Close Gap Open Gap No Healthy Healthy
Yes Yes
Yes Open Gap Open Gap No 4 Conditions Conditions Met Met
No Yes
No Close Gap |Stop Crusher Feed 4 Conditions Met
Crusher Yes Power below
Stop Crusher FeedTheol
Yes
CrusherDelay Timer Power below Threshold
Yes Open Crusher Gap
Delay Timer
Gap Input Yes
Close Crusher GapEnbe
No Gap ~Feedback>= DelayTimerGap Setpoint Yes Gap Input Enabled Yes
NoStop Open Crusher Gap Gap Feedback <= Gap Setpoint Delay Timer Start Crusher Feed
Yes Stop Cose Crusher Gap tart Open Gap Lockout Timer
Start Crusher Feed
St rt Close Gap Lockout 71cTimer
Fig. 1
AUSTRALIA
Patents Act 1990
COMPLETE SPECIFICATION
Invention title:
"CONTROL OF A CRUSHER"
Applicant:
CS AUTOMATION PTY LTD
Associated provisional applications:
The following statement is a full description of the invention, including the best method of performing it known to me:
"CONTROL OF A CRUSHER"
Field of the Invention
[0001] The present invention relates to crushers, such as cone crushers, used for breaking hard materials such as rock into smaller particles.
Background to the Invention
[0002] Crushing is an important part of processing mined ore, particularly ore found in rocky environments. Mined ore is fed (usually by conveyor) into a hopper, which feeds the ore into a cone crusher. The crusher provides a compression force against the ore, which acts to shatter individual rocks. Crushed ore is then fed from the base of the crusher via an outlet conveyer for further processing.
[0003] A cone crusher features a conical inner body which sits inside a conical chamber. The inner body is arranged to rotate about an eccentric axle, thus acting to oscillate the inner body relative to the wall of the chamber. The movement of the inner body towards the wall of the chamber provides the required compression force on the ore.
[0004] The action of the crusher can be controlled through two principal settings: the power (and speed) of the drive shaft determining the rotation of the inner body, and the size of the gap between the inner body and the chamber wall at the narrowest point.
[0005] These settings are made based on parameters such as the hardness of the rock being crushed. In normal use the settings will be periodically checked and adjusted, for instance in response to wear of the linings on both the inner body and the chamber wall.
Summary of the Invention
[0006] In mineral processing it is usually desirable to maintain a steady rate of ore flow through a processing plant. In one aspect, the present invention seeks to assist this process by continuous monitoring of the rate of crushed ore supplied by a crusher and/or the speed at which ore is fed into a crusher, and adjustment of at least one crusher parameter in response to significant changes to the ore supply rate.
[0007] It is also desirable for the size of ore supplied by a crusher to be consistent over time. In a second aspect, the present invention seeks to improve consistency of crusher operation by predicting crusher wear rates and adjusting the crusher gap settings in response to predicted wear.
[0008] The replacement of crusher wear linings represents a significant period of 'downtime' for the crusher. Such maintenance is usually planned well in advance. While the planning will attempt to schedule lining replacement at the end of lining life, precise prediction of these conditions is impossible. As such, a balance must be met between the possibility of linings failing before scheduled replacement and maximising available lining wear to avoid wastage. In a third aspect, the present invention seeks to control the rate of lining wear by adjustment of at least one crusher parameter.
[0009] According to one aspect of the present invention there is provided a method of controlling a crusher, the crusher having a feeder operating at a feeder speed and an output of crushed material exiting the crusher at an output rate, the crusher having a characteristic gap; the method including the steps of monitoring at least one parameter from the set comprising the feeder speed and the output rate; comparing the monitored parameter to a pre determined desired range; and, in the event that the monitored parameter is outside the pre-determined range, adjusting the characteristic gap by a gap adjustment amount; repeating these steps until the monitored parameter is within the pre-determined desired range; the method further including the steps of calculating the gap adjustment amount to be applied by altering a predetermined base gap adjustment amount by a gap adjustment factor; the gap adjustment factor being determined by taking at least one previous gap adjustment factor and applying to it an amendment factor based on at least one parameter from the set of: average power use compared with desired power use; average throughput compared with desired throughput; average vibration above an expected level; average wear rate compared with a target wear rate; and average feeder speed compared with a target feeder speed.
[0010] The gap adjustment factor may be determined by taking an average of a plurality of previous gap adjustment factors and applying the amendment factor to it.
[0011] The amendment factor is preferably applied as a ratio.
[0012] Preferably the method includes the additional steps of: determining crusher vibration; comparing crusher vibration to a pre-determined desired limit and, in the event crusher vibration exceeds the pre-determined desired limit, opening the characteristic gap of the crusher by the gap adjustment amount; repeating these steps until the crusher vibration is within the pre determined desired limit.
[0013] Ina preferred embodiment, the steps of determining crusher vibration and changing the gap accordingly are done before the steps of monitoring the parameters.
[0014] Preferably the method includes the additional steps of: determining power use by a crusher motor; comparing power use to a pre-determined desired limit and, in the event power use exceeds the pre-determined desired limit, opening the characteristic gap of the crusher by the gap adjustment amount; repeating these steps until the power use is within the pre-determined desired limit.
[0015] In a preferred embodiment, the steps of determining power use and changing the gap accordingly are done before the steps of monitoring the parameters. They may also be done after the steps of determining crusher vibration.
[0016] It is preferred that the monitored parameter is measured over a first pre-determined time period, such that the characteristic gap is only adjusted in response to a monitored parameter being outside the pre-determined limits over the entire first pre-determined time period.
[0017] The method may include the step of determining the time since the last adjustment in the characteristic gap, and only allowing a further adjustment following the expiration of a second pre-determined time period.
[0018] According to a second aspect of the present invention there is provided a method of controlling a crusher, the crusher having a feeder operating at a feeder speed and a motor using power at a crusher power usage, the crusher having a characteristic gap; the method including the steps of providing a pre-determined nominal characteristic gap; providing a discrete set of feeder speeds associated with respective wear rates; providing a discrete set of crusher power usages associated with respective wear rates; monitoring the feeder speed and the crusher power usage; calculating a wear parameter based on feeder speed by linearly interpolating a wear rate between two adjacent feeder speeds within the discrete set of feeder speeds; calculating a wear parameter based on power use by linearly interpolating a wear rate between two adjacent crusher power usages within the discrete set of power usages; calculating an overall wear parameter by adding the wear parameter based on feeder speed to the wear parameter based on power usage, and adjusting the characteristic gap of the crusher by an amount proportional to the overall wear parameter. It will be appreciated that this method will decrease the actual gap as the crusher liners wear, to maintain operation of the crusher at the nominal gap.
[0019] According to a third aspect of the present invention there is provided a method of controlling a crusher, the crusher having a feeder operating at a feeder speed and a motor using power at a crusher power usage, the crusher having a characteristic gap; the crusher having wear linings; the method including the steps of providing a target range of wear lining life span; providing a discrete set of feeder speeds associated with respective wear rates; providing a discrete set of crusher power usages associated with respective wear rates; monitoring the feeder speed and the crusher power usage; calculating a wear parameter based on feeder speed by linearly interpolating a wear rate between two adjacent feeder speeds within the discrete set of feeder speeds; calculating a wear parameter based on power usage by linearly interpolating a wear rate between two adjacent crusher power usages within the discrete set of power usages; calculating an overall wear parameter by adding the wear parameter based on feeder speed to the wear parameter based on power usage; calculating an estimated wear lining life span based on the overall wear parameter, and, in the event that the estimated wear lining life span is outside the target range of wear lining life span, adjusting at least one of the characteristic gap by a gap adjustment amount and the crusher power usage; repeating these steps until the estimated wear lining life span is within the target range of wear lining life span
[0020] Preferably the method further includes the steps of calculating the gap adjustment amount to be applied by altering a predetermined base gap adjustment amount by a gap adjustment factor; the gap adjustment factor being determined by taking at least one previous gap adjustment factor and applying to it an amendment factor based on at least one parameter from the set of: average power use compared with desired power use; average throughput compared with desired throughput; average vibration above an expected level; average wear rate compared with a target wear rate; and average feeder speed compared with a target feeder speed.
[0021] The gap adjustment factor may be determined by taking an average of a plurality of previous gap adjustment factors and applying the amendment factor to it.
[0022] Preferably, the amendment factor is applied as a ratio.
Brief Description of the Drawings
[0023] It will be convenient to further describe the invention with reference to preferred embodiments of the present invention. Other embodiments are possible, and consequently the particularity of the following discussion is not to be understood as superseding the generality of the preceding description of the invention. In the drawings:
[0024] Figure 1 is a flow diagram detailing the logic for adjusting a characteristic gap within a crusher controlled in accordance with the present invention.
[0025] Figure 2 is a flow diagram detailing the logic for adjusting power use of a crusher controlled in accordance with the present invention.
[0026] Figure 3 is a flow diagram detailing the logic for adjusting a characteristic gap within a crusher controlled in accordance with the present invention when in 'power mode'.
[0027] Figure 4 is a flow diagram detailing the logic for adjusting power use of a crusher controlled in accordance with the present invention when in 'power mode'.
[0028] Figure 5 is a flow diagram detailing the logic for adjusting a characteristic gap within a crusher controlled in accordance with the present invention when in 'power mode'.
[0029] Figure 6 is a flow diagram detailing the logic for adjusting power use of a crusher controlled in accordance with the present invention when in 'power mode'.
[0030] Figure 7 is a flow diagram detailing the logic for adjusting a characteristic gap within a crusher controlled in accordance with the present invention when in 'throughput mode'.
[0031] Figure 8 is a flow diagram detailing the logic for adjusting power use of a crusher controlled in accordance with the present invention when in 'throughput mode'.
[0032] Figure 9 is a flow diagram detailing the logic for adjusting a characteristic gap within a crusher controlled in accordance with the present invention when in 'throughput mode'.
[0033] Figure 10 is a flow diagram detailing the logic for adjusting power use of a crusher controlled in accordance with the present invention when in 'rebuild mode'.
[0034] Figure 11 is a flow diagram detailing the logic for adjusting a characteristic gap within a crusher controlled in accordance with the present invention when in 'optimise mode'.
[0035] Figure 12 is a flow diagram detailing the logic for adjusting power use of a crusher controlled in accordance with the present invention when in 'optimise mode'.
Detailed Description of Preferred Embodiments
[0036] The proposed method for controlling a crusher envisages an electronic controller capable of providing a number of different modes in which a crusher may be operated, depending on the requirements at any given time. These modes may be summarised as follows:
[0037] 1. 'Disabled mode', where no control is exercised by the controller.
[0038] 2. 'Power mode', in which a pre-determined optimum value is applied to the power use of a motor associated with a crusher drive shaft. The controller seeks to maintain the crusher at the pre-determined value for power use.
[0039] 3. 'Gap mode', in which a pre-determined characteristic gap is set, and the controller seeks to maintain this gap even as wear linings are reduced.
[0040] 4. 'Throughput mode', in which the controller seeks to maintain an output rate of the crusher within pre-determined limits.
[0041] 5. 'Rebuild mode', in which the controller seeks to match the wear rate of the crusher linings with a pre-determined desired lifespan.
[0042] 6. 'Optimise mode', in which the controller seeks to maximise power and throughput in combination.
[0043] The controller uses as inputs data selected from the following set: Feeder speed (the rate material is supplied to the crusher); Output rate (the rate material exits the crusher, generally measured as load on an output conveyor); Nominal gap (the minimum distance between inner body and chamber wall assuming no wear on crusher wear linings); and crusher power use. Additional inputs used for safety operations include vibration measurement and motor temperature.
[0044] A number of pre-determined settings may be provided to the controller. These include: Base gap (that is, the desired characteristic gap); Base gap adjustment amount (the degree to which a single adjustment will change the characteristic gap in normal operation); Base power (the initial power use); No load power threshold (the minimum power output beneath which the crusher is not operating correctly); Base wear rate (the historical average of the crusher lining wear rate); and Total liner wear (the degree to which crusher linings are preferably worn before replacement).
[0045] The controller is arranged to detect abnormal events in all modes, and to respond accordingly. Such events may occur as follows:
[0046] If vibration exceeds a pre-determined high vibration threshold then the characteristic gap will be opened by a set amount, and the power will reduce.
[0047] If a 'tramp' event occurs, characterised by high vibration and high power use, this is an indication of an un-crushable object within the crusher. A suitable alarm will sound.
[0048] If power use exceeds a maximum threshold then the characteristic gap will be opened by a set amount in order to prevent an electrical trip of the operating circuit.
[0049] If feeder speed remains below a pre-determined limit over a pre determined time frame, the gap will be opened by a set amount. This control is active in power mode and optimise mode.
[0050] If throughput remains below a pre-determined limit over a pre determined time frame, the gap will be opened by a set amount. This control is active in throughput mode and optimise mode.
[0051] The controller includes a pre-determined open gap 'lockout time' and a close gap'lockout time'. This sets a time between successive gap changes, to ensure that excessive adjustment does not occur. The 'lockout' time does not apply to vibration, tramp or excessive power use events.
[0052] Similarly, the controller includes a pre-determined power decrease 'lockout time' and power increase 'lockout time', setting a time between successive power setpoint changes.
[0053] If feeder speed exceeds a pre-determined maximum limit, the gap will be closed by a set amount. This control is active in power mode and optimise mode.
[0054] If throughput remains above a pre-determined limit over a pre determined time frame, the gap will be closed by a set amount. This control is active in throughput mode and optimise mode.
[0055] If the motor approaches its maximum operating temperature the power setpoint will be reduced by a set amount in order to prevent an electrical trip of the operating circuit.
Dynamic gap control
[0056] The present invention proposes the degree of adjustment of the characteristic gap to be informed by 'learning' by the machine. In this operation, a gap adjustment amount is calculated from a base value, modified by a gap adjustment factor which varies during operation of the crusher based on observed data.
[0057] Immediately prior to change in the characteristic gap, a new gap adjustment factor is calculated. The calculation is performed by taking the average gap adjustment factor since a base time (generally, since a calibration), and scaling it by a dynamic adjustment ratio.
[0058] The dynamic adjustment ratio is calculated as follows: (a) calculate an Average Power Offset (APO) according to the formula APO- = (PSP - PWR) TPA where PSP is a predetermined Power Set Point (as a fraction of full power), PWR is the measured power (as a fraction of measured power), and TPA is the time since the previous gap adjustment;
(b) calculate an Average Throughput Offset (ATO) according to the formula - TSP) ATO = Y(TON TPA where TON is the measured throughput (as a fraction of maximum throughput), TSP is a predetermined throughput (as a fraction of maximum throughput), and TPA is the time since the previous gap adjustment;
(c) calculate an Average Vibration (AV) according to the formula - TVIB) AV = Y(VIB TPA where VIB is the measured vibration (as a fraction of allowable vibration), TVIB is a predetermined target vibration (as a fraction of allowable vibration), and TPA is the time since the previous gap adjustment. The formula is such that measured vibration below target vibration is recorded as a zero input, rather than a negative one;
(d) calculate an Average Wear Rate (AWR) according to the formula
AWR =>(WR - TWR) TPA where WR is the measured wear rate (as a fraction of maximum allowable wear rate), TWR is a predetermined target wear rate (as a fraction of maximum allowable wear rate), and TPA is the time since the previous gap adjustment;
(e) calculate an Average Feeder Speed (AFS) according to the formula
AFS =>(FS - TFS) TPA where FS is the measured feeder speed (as a fraction of maximum feeder speed), TFS is a predetermined target feeder speed (as a fraction of maximum feeder speed), and TPA is the time since the previous gap adjustment; and
(f) add APO, ATO, AV, AWR and AFS together to obtain the dynamic adjustment ratio.
Power Use Adjustment
[0059] Figure 2 shows the logic circuit used for changing the power set point of the crusher. The main function of this logic circuit is to ensure observance of the power lockout times.
Power Mode
[0060] Figures 3 and 4 show the logic circuits used when the controller is in power mode. In this mode the power set point is maintained within pre determined limits. The controller acts to maintain the required power within these setpoints by control of the characteristic gap (preferably using the dynamic gap control explained above) based on the feeder speed.
Gap Mode
[0061] Figures 5 and 6 show the logic circuits used when the controller is in gap mode. This requires an estimation of the actual gap based on wear of the linings.
[0062] Historic wear rates are provided as two sets of data. The first data set provides a discrete set of power setpoints, and the respective wear rate associated with each setpoint. The second data set provides a discrete set of feeder speed setpoints, and the respective wear rate associated with each setpoint.
[0063] The controller identifies the actual estimated wear rate associated with power use by identifying the two power setpoints in the data set within which the actual power use lies. The controller then uses a linear interpolation between the two associated wear rates to calculate a wear rate associated with power use.
[0064] Similarly, the controller identifies the actual estimated wear rate associated with feeder speed by identifying the two feeder speed setpoints in the data set within which the feed speed lies. The controller then uses a linear interpolation between the two associated wear rates to calculate a wear rate associated with feeder speed.
[0065] The controller calculates total estimated wear rate by adding the power use rate to the feeder speed rate.
[0066] In gap mode, the nominal gap is regularly reduced based on the estimate wear rate, to maintain the actual gap as closely as possible to the base gap.
Throughput Mode
[0067] Figures 7 and 8 show the logic circuits used when the controller is in throughput mode. In this mode the power set point is maintained within pre determined limits. The controller acts to maintain the required power within these setpoints by control of the characteristic gap (preferably using the dynamic gap control explained above) based on the crusher throughput.
Rebuild Mode
[0068] Figures 9 and 10 show the logic circuits used when the controller is in rebuild mode. In this mode wear rate is calculated in the same fashion as for the gap mode, but to a different end. The controller calculates the estimated remaining life of the wear linings based on the current wear rate and previously established total liner wear parameter. If this life is outside a required range (based on schedule replacement) then both the power and the gap are adjusted accordingly: either to increase wear and thus obtain greater efficiency, or to decrease wear to extend the life of the wear liners.
Optimise Mode
[0069] Figures 11 and 12 show the logic circuits used when the controller is in optimise mode. In this mode the power set point and the throughput are maintained within pre-determined limits. The controller acts to maintain the required power and the throughput within these setpoints by control of the characteristic gap (preferably using the dynamic gap control explained above).
[0070] Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.

Claims (15)

  1. Claims 1. A method of controlling a crusher, the crusher having a feeder operating at a feeder speed and an output of crushed material exiting the crusher at an output rate, the crusher having a characteristic gap; the method including the steps of monitoring at least one parameter from the set comprising the feeder speed and the output rate; comparing the monitored parameter to a pre-determined desired range; and, in the event that the monitored parameter is outside the pre-determined range, adjusting the characteristic gap by a gap adjustment amount; repeating these steps until the monitored parameter is within the pre-determined desired range; the method further including the steps of calculating the gap adjustment amount to be applied by altering a predetermined base gap adjustment amount by a gap adjustment factor; the gap adjustment factor being determined by taking at least one previous gap adjustment factor and applying to it an amendment factor based on at least one parameter from the set of: average power use compared with desired power use; average throughput compared with desired throughput; average vibration above an expected level; average wear rate compared with a target wear rate; and average feeder speed compared with a target feeder speed.
  2. 2. A method of controlling a crusher as claimed in claim 1, wherein the gap adjustment factor is determined by taking an average of a plurality of previous gap adjustment factors and applying the amendment factor to it.
  3. 3. A method of controlling a crusher as claimed in claim 1 or claim 2, wherein the amendment factor is applied as a ratio.
  4. 4. A method of controlling a crusher as claimed in any preceding claim, wherein the method includes the additional steps of: determining crusher vibration; comparing crusher vibration to a pre-determined desired limit and, in the event crusher vibration exceeds the pre-determined desired limit, opening the characteristic gap of the crusher by the gap adjustment amount; repeating these steps until the crusher vibration is within the pre-determined desired limit.
  5. 5. A method of controlling a crusher as claimed in claim 4, wherein the steps of determining crusher vibration and changing the gap accordingly are done before the steps of monitoring the parameters.
  6. 6. A method of controlling a crusher as claimed in any preceding claim, wherein the method includes the additional steps of: determining power use by a crusher motor; comparing power use to a pre-determined desired limit and, in the event power use exceeds the pre-determined desired limit, opening the characteristic gap of the crusher by the gap adjustment amount; repeating these steps until the power use is within the pre-determined desired limit.
  7. 7. A method of controlling a crusher as claimed in claim 6, wherein the steps of determining power use and changing the gap accordingly are done before the steps of monitoring the parameters.
  8. 8. A method of controlling a crusher as claimed in claim 7 when dependent on claim 4, wherein the steps of determining power use and changing the gap accordingly are done after the steps of determining crusher vibration.
  9. 9. A method of controlling a crusher as claimed in any preceding claim, wherein the monitored parameter is measured over a first pre-determined time period, such that the characteristic gap is only adjusted in response to a monitored parameter being outside the pre-determined limits over the entire first pre-determined time period.
  10. 10. A method of controlling a crusher as claimed claim 9, wherein the method includes the step of determining the time since the last adjustment in the characteristic gap, and only allowing a further adjustment following the expiration of a second pre-determined time period.
  11. 11. A method of controlling a crusher, the crusher having a feeder operating at a feeder speed and a motor using power at a crusher power usage, the crusher having a characteristic gap; the method including the steps of providing a pre-determined nominal characteristic gap; providing a discrete set of feeder speeds associated with respective wear rates; providing a discrete set of crusher power usages associated with respective wear rates; monitoring the feeder speed and the crusher power usage; calculating a wear parameter based on feeder speed by linearly interpolating a wear rate between two adjacent feeder speeds within the discrete set of feeder speeds; calculating a wear parameter based on power use by linearly interpolating a wear rate between two adjacent crusher power usages within the discrete set of power usages; calculating an overall wear parameter by adding the wear parameter based on feeder speed to the wear parameter based on power usage, and adjusting the characteristic gap of the crusher by an amount proportional to the overall wear parameter. It will be appreciated that this method will decrease the actual gap as the crusher liners wear, to maintain operation of the crusher at the nominal gap.
  12. 12. A method of controlling a crusher, the crusher having a feeder operating at a feeder speed and a motor using power at a crusher power usage, the crusher having a characteristic gap; the crusher having wear linings; the method including the steps of providing a target range of wear lining life span; providing a discrete set of feeder speeds associated with respective wear rates; providing a discrete set of crusher power usages associated with respective wear rates; monitoring the feeder speed and the crusher power usage; calculating a wear parameter based on feeder speed by linearly interpolating a wear rate between two adjacent feeder speeds within the discrete set of feeder speeds; calculating a wear parameter based on power usage by linearly interpolating a wear rate between two adjacent crusher power usages within the discrete set of power usages; calculating an overall wear parameter by adding the wear parameter based on feeder speed to the wear parameter based on power usage; calculating an estimated wear lining life span based on the overall wear parameter, and, in the event that the estimated wear lining life span is outside the target range of wear lining life span, adjusting at least one of the characteristic gap by a gap adjustment amount and the crusher power usage; repeating these steps until the estimated wear lining life span is within the target range of wear lining life span
  13. 13. A method of controlling a crusher as claimed in claim 12, wherein the method further includes the steps of calculating the gap adjustment amount to be applied by altering a predetermined base gap adjustment amount by a gap adjustment factor; the gap adjustment factor being determined by taking at least one previous gap adjustment factor and applying to it an amendment factor based on at least one parameter from the set of: average power use compared with desired power use; average throughput compared with desired throughput; average vibration above an expected level; average wear rate compared with a target wear rate; and average feeder speed compared with a target feeder speed.
  14. 14. A method of controlling a crusher as claimed in claim 13, wherein the gap adjustment factor is determined by taking an average of a plurality of previous gap adjustment factors and applying the amendment factor to it.
  15. 15. A method of controlling a crusher as claimed in claim 13 or claim 14, wherein the amendment factor is applied as a ratio.
    CS AUTOMATION PTY LTD By its Patent Attorneys ARMOUR IP
    P2309AU01
    Start
    Feed on and 2020202399
    ACC Active
    Yes
    No No Close Gap Open Gap Healthy Healthy
    Yes Yes
    Yes Open Gap Open Gap No Conditions Conditions Met Met
    No Yes
    Stop Crusher Feed No Close Gap Conditions Met
    Crusher Yes Power below Threshold Stop Crusher Feed
    Yes
    Delay Timer Crusher Power below Threshold
    Open Crusher Gap Yes
    Delay Timer
    Yes Gap Input Enabled Close Crusher Gap
    No Gap Feedback >= Delay Timer Gap Setpoint Yes Gap Input Enabled Yes
    Stop Open Crusher Gap
    Gap No Feedback <= Gap Setpoint Delay Timer Start Crusher Feed
    Yes Stop Close Crusher Gap Start Open Gap Lockout Timer
    Start Crusher Feed
    Start Close Gap Lockout Timer
    Fig. 1
    Start 2020202399
    Feed on and ACC Active
    Yes
    No Increase Power Decrease Power No Conditions Conditions Healthy Healthy
    Yes Yes
    No No Increase Power Decrease Power Conditions Met Conditions Met
    Yes Yes
    Delay Timer Delay Timer
    No No Delay Timer Delay Timer Complete Complete
    Yes Yes
    Increase Power Decrease Power
    Start Increase Power Start Decrease Power Lockout Timer Lockout Timer
    Fig. 2
    Start Start 2020202399
    Vibration Power Mode Yes Yes Vibration Selected Adjust No High Enabled
    Yes No No
    Yes Vibration Above Limit Power Draw Yes High
    No No
    Power Draw Power Draw Yes Below Limit Above Limit Tramp Detected
    Yes Yes
    No Increase Power Decrease Power Conditions Met Conditions Met
    Yes Close Gap Lockout Time Active Fig. 4
    No
    Yes Open Gap Lockout Time Active
    No
    Power Mode Selected
    Yes
    No Feeder Feeder No Speed Above Speed Below Limit Limit
    Yes Yes
    Delay Timer Delay Timer
    No No Delay Timer Delay Timer Complete Complete
    Yes Yes
    Close Gap Conditions Met Open Gap Conditions Met
    Fig. 3
    Start Start 2020202399
    Vibration Gap Mode Yes Yes Vibration Selected Adjust No High Enabled
    Yes No No
    Yes Vibration Above Limit Power Draw Yes High
    No No
    Power Draw Power Draw Yes Below Limit Above Limit Tramp Detected
    Yes Yes
    No Increase Power Decrease Power Conditions Met Conditions Met
    Yes Close Gap Lockout Time Active Fig. 6
    No
    Yes Open Gap Lockout Time Active
    No
    Gap Mode Selected
    Yes
    No Estimated Estimated No Gap Above Gap Below Limit Limit
    Yes Yes
    Delay Timer Delay Timer
    No No Delay Timer Delay Timer Complete Complete
    Yes Yes
    Close Gap Conditions Met Open Gap Conditions Met
    Fig. 5
    Start Start
    Throughput 2020202399
    Vibration Yes Yes Mode Vibration Adjust Selected No High Enabled
    Yes No No
    Yes Vibration Above Limit Power Draw Yes High
    No No
    Power Draw Power Draw Yes Below Limit Above Limit Tramp Detected
    Yes Yes
    No Increase Power Decrease Power Conditions Met Conditions Met
    Yes Close Gap Lockout Time Active
    Fig. 8 No
    Yes Open Gap Lockout Time Active
    No
    Throughput Mode Selected
    Yes
    No No Throughput Throughput Above Limit Below Limit
    Yes Yes
    Delay Timer Delay Timer
    No No Delay Timer Delay Timer Complete Complete
    Yes Yes
    Close Gap Conditions Met Open Gap Conditions Met
    Fig. 7
    Start Start
    Rebuild 2020202399
    Vibration Yes Yes Mode Vibration Adjust Selected No High Enabled
    Yes No No
    Yes Vibration Above Limit Power Draw Yes High
    No No Estimated Wear Estimated Wear Rate Below Rate Above Yes Limit Limit Tramp Detected
    Yes Yes
    No Increase Power Decrease Power Conditions Met Conditions Met
    Yes Close Gap Lockout Time Active
    Fig. 10 No
    Yes Open Gap Lockout Time Active
    No
    Rebuild Mode Selected
    Yes
    No Estimated Estimated No Wear Rate Wear Rate Above Limit Below Limit
    Yes Yes
    Delay Timer Delay Timer
    No No Delay Timer Delay Timer Complete Complete
    Yes Yes
    Close Gap Conditions Met Open Gap Conditions Met
    Fig. 9
    Start 2020202399
    Vibration Yes Yes Vibration Adjust High Enabled
    No No
    Power Draw Yes High
    No
    Yes Tramp Detected
    No
    Yes Close Gap Lockout Time Active
    No
    Yes Open Gap Lockout Time Active
    No
    Optimise Mode Selected
    Yes
    No No Power Throughput Throughput Throughput Above Limit Above Limit Below Limit Below Limit
    Yes Yes Yes Yes
    Delay Timer Delay Timer Delay Timer Delay Timer
    No No No No Delay Timer Delay Timer Delay Timer Delay Timer Complete Complete Complete Complete
    Yes Yes Yes Yes
    Close Gap Conditions Met Open Gap Conditions Met
    Fig. 11
    Start
    Optimise 2020202399
    Mode Selected No
    Yes
    Yes Vibration Above Limit
    No
    Power Draw Power Draw Below Limit Above Limit
    Yes Yes
    Increase Power Decrease Power Conditions Met Conditions Met
    Fig. 12
AU2020202399A 2019-04-10 2020-04-06 Control of a crusher Pending AU2020202399A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2019901224A AU2019901224A0 (en) 2019-04-10 Controlling operation of a crusher
AU2019901224 2019-04-10

Publications (1)

Publication Number Publication Date
AU2020202399A1 true AU2020202399A1 (en) 2020-10-29

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Family Applications (1)

Application Number Title Priority Date Filing Date
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Country Status (1)

Country Link
AU (1) AU2020202399A1 (en)

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