CN115888965A - Working method for measuring load reference value of crusher and control method of crusher - Google Patents

Abstract

The invention discloses a working method for measuring a load reference value of a crusher and a control method of the crusher, wherein a control system in the crusher collects the load of the crusher for a period of time and continuously collects the load for a sufficient time; the average value of the load values is used as a reference value A0, and A0 is a comprehensive load reference value; taking the average value A1 of the load values larger than A0 as a peak load reference value; the average value A2 of the load values smaller than A0 is used as a low-load reference value; the control system automatically records the numerical values and takes the numerical values as the reference values of the load related parameters; the control system counts the number of load values of which the load is greater than or equal to A1 in a certain time period, and calculates an average value N in the whole test data as a peak value number reference value; the number of the load values of which the load is less than or equal to A2 is calculated, and an average value M is calculated in the whole test data and is used as a low-load number reference value; the parameter values are automatically or manually changed after the next operation of the benchmark load test function; the crusher can keep the best performance and the high-efficiency work.

Description

Working method for measuring load reference value of crusher and control method of crusher

Technical Field

The invention relates to a crusher control method, in particular to a working method and a control flow for measuring a crusher load reference value.

Background

The conical crusher (such as a cone crusher and a gyratory crusher) realizes the crushing of mineral aggregates by the change of the gap of a crushing cavity through the rotation of an eccentric shaft, so the load of the conical crusher is characterized by pulsation; the load peak value quantity of the crusher with the pulsating load in unit time can more accurately and quickly reflect the real condition of the load of the crusher; meanwhile, under the working condition of long-time high load of the crusher, the overload of the crusher can be caused by the change of control parameters and external environment at one point; also, it is difficult to avoid that non-crushable objects enter the crusher, and the non-crushable objects enter the crushing cavity, possibly causing damage to the crusher; the rapid recognition of overload is the key to the automatic control of the crusher; in the existing automatic control system of the crusher, a method for measuring a load peak value is mostly adopted to measure and calculate the current load condition of the crusher; in order to automatically adjust the crusher to operate in an optimal state, a peak reference value and a peak quantity reference value of the crusher load are required to be set; because the crushers of different types and models and the crusher of the same model process different materials, the peak values of the load of the crushers are different, and the number of the peak values in unit time is also different; these parameter values are often observed and measured manually, often requiring numerous long adjustments to achieve the desired parameter values.

In patent CN 101316658B, a control method for measuring and recording the maximum number of loads is proposed, but a method for judging the maximum value and a method for measuring the maximum number in a normal working state are not given; the problem that the maximum peak load of the crusher is different when different materials are crushed cannot be solved.

Disclosure of Invention

Aiming at the problems in the prior art, the invention provides a working method for measuring the load reference value of the crusher, by using the method, the reference parameter required by control can be quickly and accurately obtained, and the crushing force or the crushing power of the crusher can be maximized; the control system of the crusher is made to respond more quickly to changes in the crusher load, thereby minimizing the risk of damage to the crushing machinery and avoiding damage to the crushing machinery as much as possible;

when the power or pressure of the crusher, the stress of a crushing mechanism and other instantaneity parameters are measured, the parameters are characterized in that measured values are distributed widely and randomly, parameter values have the characteristics of rapid change and fluctuation, the parameters can represent the instantaneous load characteristics of the crusher, and the load change condition of the crusher can be rapidly obtained by continuously and rapidly detecting the parameters, so that a control system automatically intervenes before faults and damages occur, the faults and damages of the crusher are avoided, and the traditional data acquisition method for obtaining the mean value is long in time period; however, the material entering the crushing chamber is continuously changing, and the excessive reaction and treatment time may cause overload and damage to the crusher.

Maximizing the load of the crusher, representing the load, which may be the crushing power or the crushing means stress or the pressure of the hydraulic system, i.e. maximizing these parameters, in order to achieve a maximum working efficiency of the crusher; the reference parameter is used as an adjusting reference, and if the reference parameter is not suitable, the crusher load can frequently exceed the allowable limit of the crusher, so that the crusher is damaged; when the crusher works under full load, the peak value of the load of the crusher is obtained, the load is recorded, and the load of the crusher is adjusted by taking the peak value as a reference, so that the maximum working efficiency of the crusher is ensured, and the crusher is prevented from being damaged due to overload;

the working process of the crusher is stable, and the product quality is excellent; therefore, the adjustment of the crushing, in particular the adjustment of the discharge opening, cannot be carried out frequently; the feeding of the crusher is continuous and large, the properties of the materials have certain differences, so the sizes of the peak values are different, and the load exceeding the reference peak value is frequent; in the parameter acquisition, transformation and operation processes of the control system, the interference of the system exists at the same moment, and the interfered error signals often exceed the reference peak value; the traditional average filtering method and the method of removing the maximum value and the minimum value are not suitable; the time period of the average filtering is too long, so that the requirement of a control system on quick response cannot be met; the method for removing the maximum value and the minimum value can cause the loss of the true value and the wrong judgment because the maximum value and the minimum value can not be determined to be effective values, thereby damaging the crusher; the problem can be effectively solved by adopting the number of the load reference peak values exceeded in a period of time; counting and comparing operations are adopted, so that the occupied resources of the controller are less, the operation speed is high, and the requirement of the crusher on quick adjustment is met; the counting method of a plurality of surpassing reference values effectively filters the interference signals of the system; therefore, the number of the loads exceeding the load reference peak value in the specified time period is a necessary condition for ensuring the stable and reliable operation of the control system under the normal working state, and is a main condition for judging whether the crusher is overloaded or not.

In order to achieve the purpose, the invention adopts the technical scheme that: the working method for measuring the load reference value of the crusher comprises the following specific working methods:

s1: operating the crusher;

s2: a control system of the crusher is switched to a reference load test state;

s3: the control system collects the load of the primary crusher within a period of time;

s4: the crusher continuously operates for a long enough time in a reference load test state, continuously collects the load of the crusher during operation, and records the load value in a control system;

s5: when the crusher stops running or leaves a reference load test state, the control system calculates the average value of all recorded load values as a reference value A0, wherein A0 is a comprehensive load reference value;

s5: calculating the average value of all load values larger than A0, wherein the average value is used as a peak load reference value A1; the average value of the load values smaller than A0 is used as a low-load reference value A2; the control system automatically records the numerical values and takes the numerical values as the reference values of the load related parameters;

s6: counting a certain time period by the control system, wherein the time period is recorded as delta T; the number of load values with the load greater than or equal to A1 is calculated, and an average value is calculated in the whole test data and is used as a peak value number reference value N; the number of load values with the load less than or equal to A2 is calculated, and an average value is calculated in the whole test data and is used as a low-load number reference value M;

s7: the parameters A0, A1, A2, M, N in S3 to S5 are automatically updated after the next benchmark load test function is run, or may be manually changed.

Further, when the crusher works normally, the value greater than A1 is counted by the control system as an effective peak reference value, and the value less than A2 is counted by the control system as an effective low-load value and is used as a parameter for controlling the operation of the crusher.

Further, the operation speed of the control system, the tolerance of the crusher, the property of the crushed material, the type of the crusher and the crushing period are considered when the load of the crusher is collected in the step S3.

Based on the technology, the control process of the crusher is further improved, and the control method of the control system in the crusher comprises the following steps:

sa: the crusher is switched to a normal working state, and the control system continuously detects and records the instantaneous load of the crusher;

sb: comparing the instantaneous load value with a peak load reference value A1, and recording and counting the value greater than A1;

and (C) Sc: counting the number of peak loads with values larger than A1 in the time period T;

sd: comparing the number of the peak loads with a peak number reference value N, and if the number of the peak loads is larger than N, controlling the crusher to reduce the load by the control system;

se: if the number of the peak loads is less than N and the average load value is less than the comprehensive load reference value A0, the control system controls the crusher to increase the load;

sf: if the number of the peak loads is less than N and the average load value is more than or equal to the comprehensive load reference value A0, the control system controls the crusher to keep unchanged;

sg: the crusher circularly executes the steps, and the continuous and efficient operation of the crusher is kept.

Further, the Sd in control system controls the crusher to reduce the load: increasing the discharge opening of the crusher or decreasing the feed rate.

The beneficial effects of the invention are: the control method has the advantages that the peak value reference point is from the actual working process and is the average value of the peak value, so the reference point is close to the maximum load of the crusher, a certain margin is provided, the safety of the crusher is ensured, the operation of the crusher is high-efficient, the control parameters can be changed quickly, the control system can quickly, conveniently and correctly obtain the control parameters under the condition that different materials to be crushed are fed into the crusher (the materials to be crushed can be rocks with different hardness or ores with different water contents, various materials to be crushed such as coal and the like), the control system can control the operation of the crusher at the best performance level according to the control parameters, and the crusher can keep the best performance, provide qualified crushed products and keep high-efficient operation.

Drawings

FIG. 1 is a schematic structural view of the present invention;

FIG. 2 is a schematic structural view of the present invention;

fig. 3 is a schematic structural diagram of the present invention.

In the figure: 0. a crusher; 1. a hydraulic cylinder assembly; 2. a lower frame assembly; 3. a main shaft assembly; 4. a conical lining plate; 5. an upper frame lining plate; 6. an upper frame assembly; 7. a crushing gap; 8. a horizontal drive shaft assembly; 9. a cylinder displacement sensor; 21. a control system; 22. a crushing motor power tester; 23. a hydraulic system; 24. a hydraulic oil pump;

s, the size of a discharge opening.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to the accompanying drawings and examples. It should be understood, however, that the description herein of specific embodiments is only intended to illustrate the invention and not to limit the scope of the invention.

As shown in fig. 1, a crusher 0 includes: the crushing device comprises a hydraulic cylinder assembly 1, a lower rack assembly 2, a main shaft assembly 3, an upper rack assembly 6 and a horizontal driving shaft assembly 8, wherein grooves are formed in the upper rack assembly 6 and the lower rack assembly 2, the upper rack assembly 6 is arranged above the lower rack assembly 2, a crushing cavity is formed between the upper rack assembly 6 and the grooves in the lower rack assembly 2, one end of the main shaft assembly 3 penetrates through the lower rack assembly 2 and extends into the crushing cavity, a cone is arranged on the main shaft assembly 3 extending into the crushing cavity, a conical lining plate 4 is arranged on the surface of the cone, a rack lining plate is arranged on the inner wall of the upper rack assembly 6, a crushing gap 7 is formed between the upper rack lining plate 5 and the conical lining plate 4, a feeding hole is formed in the upper rack assembly 6, and mineral aggregates enter the crushing gap 7 from the feeding hole of the upper rack assembly 6; the hydraulic cylinder assembly 1 is arranged at the lower end of the main shaft assembly 3, the hydraulic cylinder assembly 1 supports and adjusts the main shaft assembly 3 to move up and down, and the size of the capacity of the crushing gap 7 is adjusted; the horizontal driving shaft assembly 8 is arranged on the side surface of the lower frame assembly 2, the horizontal driving shaft assembly 8 drives the main shaft assembly 3 to do pendular motion, so that the crushing gap 7 between the conical lining plate 4 and the upper frame lining plate 5 is continuously changed, mineral aggregate is continuously extruded, and the crushing of the mineral aggregate is completed.

A crushing gap 7 between the upper frame lining plate 5 and the conical lining plate 4 is gradually reduced from top to bottom, the size of the upper end of the crushing gap 7 is large, the size of the lower end of the crushing gap 7 is small, and an outlet at the lower end of the crushing gap 7 is called as a discharge outlet S; the horizontal drive shaft assembly 8 is connected to an external motor.

The crusher 0 further comprises a control system 21, said control system 21 comprising: a controller, a monitoring unit, a detection part consisting of a set of sensors, a power drive part and an electrical control part needed to control the operation of the crusher 0.

The controller generally comprises a CPU, a storage unit input/output interface and the like, generally comprises a PLC, an industrial personal computer and a DCS, and is characterized by having a calculation function and being capable of finishing logic and mathematical operation. The main function of the monitoring unit is a man-machine interaction function, which generally completes the functions of displaying and outputting the running condition of the crusher 0, controlling instructions, inputting parameters and the like, the general input part is composed of a keyboard, a mouse, a touch screen and the like, and the output part comprises a display, a printer, an alarm lamp (bell), a network display and the like.

The detection portion of the control system 21 mainly includes: a cylinder displacement sensor 9 for detecting the displacement of the main shaft, a pressure sensor for detecting the pressure of a hydraulic system 23, a sensor for detecting the energy consumption power of the crusher 0, and a temperature sensor for detecting the temperature of a bearing of the arm support and the temperature of lubricating oil of the crusher 0,

the parameters acquired by the detection part can directly or indirectly express the load of the crusher 0, in the example, the crusher 0 driven by the motor is adopted, so the power of the motor is adopted to represent the load of the crusher 0; the sensor for detecting the energy consumption power of the crusher 0 is a crusher 0 motor power tester, and the function of the sensor is to measure the real-time power of the crushing motor, convert the real-time power into a proper electric signal and input the electric signal into the controller.

The oil cylinder displacement sensor 9 is arranged on the hydraulic cylinder assembly 1 and is used for measuring the displacement of a piston in the hydraulic oil cylinder, so that the displacement of the main shaft assembly 3 is measured, the displacement of the main shaft assembly 3 and the discharge port S have a fixed functional relation, the functional relation depends on the structural parameters of the crusher 0, the functional relation of the crushers 0 with different structures is different, but the functional relation is determined for the crushers 0 with the same structural size.

Hydraulic oil is filled into the hydraulic oil cylinder assembly, the piston moves upwards, the main shaft assembly 3 moves upwards, the crushing gap 7 is reduced, the discharge opening S is reduced, and the load of the crusher 0 is increased; hydraulic oil flows out of the hydraulic cylinder assembly, the piston moves downwards, the main shaft assembly 3 moves downwards, the crushing gap 7 is increased, the discharge port S is increased, the load of the crusher 0 is reduced, and the movement of the hydraulic cylinder assembly is driven and controlled by a hydraulic oil pump 24 connected with the outside.

As shown in fig. 2, the hydraulic system 23 includes: the hydraulic oil pump 24, the valve group and the pipeline have the main functions of driving and controlling the hydraulic cylinder assembly 1 to move up and down, so that the main shaft assembly 3 is driven to move up and down, and the change of the gap of the crushing cavity and the discharge port S is completed.

The working method for measuring the 0 load reference value of the crusher comprises the following specific working methods:

s1: operating the crusher 0;

s2: the control system 21 of the crusher 0 goes to the reference load test state;

s3: the control system 21 collects the load of the crusher 0 once during a time period that takes into account the operating speed of the controller, the tolerance of the crusher 0, the properties of the material to be crushed (hardness, brittleness, ductility, etc.), the type of crusher 0, the crushing cycle, etc., and is typically selected to be within 2-5 mS. This time range is only a suggestion beyond which it is also allowed;

s4: the crusher 0 continuously runs for a long enough time in a reference load test state, continuously collects the load of the crusher 0 in the running process, and records the load value in the control system 21;

s5: when the crusher 0 stops running or leaves the reference load test state, the control system 21 calculates the average value of all recorded load values as a reference value A0, wherein A0 is a comprehensive load reference value;

s5: calculating the average value of all load values larger than A0, wherein the average value is used as a peak load reference value A1; the average value of the load values smaller than A0 is used as a low-load reference value A2; the control system 21 automatically records the values and uses the values as reference values of the load related parameters;

s6: the control system 21 counts a certain time period, which is recorded as delta T, and the value of the delta T is generally 50-200mS; the number of the load values of which the load is greater than or equal to A1 is calculated, and the average value is calculated in the whole test data and is used as a peak value number reference value N; the number of the load values of which the load is less than or equal to A2 is calculated, and the average value is calculated in the whole test data and is used as a low-load number reference value M; the results of the detection are shown in FIG. 3;

s7: the above steps are automatically or manually changed after the next operation of the benchmark load test function.

When the crusher 0 works normally, the value greater than A1 is counted by the control system 21 as an effective peak reference value, and the value less than A2 is counted by the control system 21 as an effective low-load value as a parameter for controlling the operation of the crusher 0.

In S3, the load of the crusher 0 is collected in consideration of the operation speed of the control system 21, the tolerance of the crusher 0, the property of the material to be crushed, the type of the crusher 0, and the crushing cycle.

The reference value of the crusher over-iron can be estimated on the basis of the value A1, once the load value which is larger than or equal to the value appears and the load value appears for a specified number of times in a specified short time, the control system can judge that the crusher over-iron exists, the crusher over-iron processing program is started, the fault is prevented from being enlarged, and the crusher is timely protected from being damaged due to over-iron, wherein the over-iron means that the crusher is blocked by non-crushable materials.

The control method of the control system 21 in the crusher 0 comprises the following steps:

sa: the crusher 0 is switched to a normal working state, and the control system 21 continuously detects and records the instantaneous load of the crusher 0;

sb: comparing the instantaneous load value with a peak load reference value A1, and recording and counting the value greater than A1;

and (C) Sc: counting the number of peak loads with values larger than A1 in the time period T;

sd: comparing the number of the peak loads with a peak number reference value N, and if the number of the peak loads is more than N, controlling the crusher 0 to reduce the load by the control system 21;

se: if the number of the peak loads is less than N and the average load value is less than the comprehensive load reference value A0, the control system 21 controls the crusher 0 to increase the load;

sf: if the number of the peak loads is less than N and the average load value is more than or equal to the comprehensive load reference value A0, the control system 21 controls the crusher 0 to keep unchanged;

sg: the crusher 0 circularly executes the steps, and the continuous and efficient operation of the crusher 0 is kept.

In Sd the control system 21 controls the crusher 0 to reduce the load: increasing the discharge opening of the crusher 0 or decreasing the feed rate.

The above example shows only one operating condition of the crusher 0, and for other operating conditions, the load of the crusher 0 may be reduced in other ways, such as reducing the feeding amount of the crusher 0.

The present example only illustrates the procedure and the constitution of the invention in relation to a crusher 0, and the invention is not limited to any particular type of crusher 0, but it can be applied to any other type of crusher 0, which is constituted by a crushing chamber, such as a single-cylinder cone crusher, a multi-cylinder cone crusher 0, a jaw crusher 0, a hammer crusher 0, etc., where the invention refers to a crusher 0, mainly the size of the crushing gap 7 and the size of the discharge opening, can be adjusted or where the above mentioned parameters of the crusher 0 can be measured and can be adjusted.

The power type of the crusher 0 of the present invention may be of various types, such as hydraulic, electric or mechanical, without any limitation of the power type of the crusher 0.

The invention is not limited by any particular measurement or sensing technique, and alternatively any type of sensor may be used, provided that they are able to reflect sufficient information of the crusher 0 characteristics and the crusher 0 parameters.

The invention is not limited to any particular material to be crushed, and any material that can be crushed may be referred to as a mineral material, such as rock, ore, pebbles, bricks, asphalt, concrete, ceramics, glass, and the like.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs, and the terms used herein in the specification of the present invention are for the purpose of describing particular embodiments only and are not intended to limit the present invention.

The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents or improvements made within the spirit and principle of the present invention should be included in the scope of the present invention.

Claims (6)

1. The working method for measuring the load reference value of the crusher is characterized in that: the specific working method comprises the following steps:

s1: operating the crusher;

s2: a control system of the crusher is switched to a reference load test state;

s3: the control system collects the load of the primary crusher within a period of time;

s4: the crusher continuously operates for a long enough time in a reference load test state, continuously collects the load of the crusher during operation, and records the load value in a control system;

s5: when the crusher stops running or leaves a reference load test state, the control system calculates the average value of all recorded load values as a reference value A0, wherein A0 is a comprehensive load reference value;

s5: calculating the average value of all load values larger than A0, wherein the average value is used as a peak load reference value A1; the average value of the load values smaller than A0 is used as a low-load reference value A2; the control system automatically records the numerical values and takes the numerical values as the reference values of the load related parameters;

s6: the control system counts a certain time period, and the time period is recorded as delta T; the number of load values with the load greater than or equal to A1 is calculated, and an average value is calculated in the whole test data and is used as a peak value number reference value N; the number of load values with the load less than or equal to A2 is calculated, and an average value is calculated in the whole test data and is used as a low-load number reference value M;

s7: and updating and changing the parameters, namely, the parameters A0, A1, A2, M and N in the steps S3 to S5 are automatically updated after the benchmark load test function is operated next time, and can also be manually changed.

2. A working method for measuring a crusher load reference value according to claim 1, characterized in that: when the crusher works normally, the value greater than A1 is counted by the control system as an effective peak value reference value, and the value smaller than A2 is counted by the control system as an effective low-load value and is used as a parameter for controlling the operation of the crusher.

3. A working method for measuring a load reference value of a crusher as claimed in claim 1, characterized in that: in the step S3, the conditions of the operation speed of a control system, the tolerance of the crusher, the property of the crushed material, the type of the crusher and the crushing period need to be considered when the load of the crusher is collected.

4. A crusher control method having an operating method for measuring a crusher load reference value according to claim 1, characterized in that: the control method comprises the following steps:

sa: the crusher is switched to a normal working state, and the control system continuously detects and records the instantaneous load of the crusher;

sb: comparing the instantaneous load value with a peak load reference value A1, and recording and counting the value greater than A1;

and (Sc): counting the number of peak loads with values larger than A1 in a time period T;

sd: comparing the number of the peak loads with a peak number reference value N, and if the number of the peak loads is larger than N, controlling the crusher to reduce the load by the control system;

se: if the number of the peak loads is less than N and the average load value is less than the comprehensive load reference value A0, the control system controls the crusher to increase the load;

sf: if the number of the peak loads is less than N and the average load value is more than or equal to the comprehensive load reference value A0, the control system controls the crusher to keep unchanged;

sg: the crusher circularly executes the steps, and the continuous and efficient operation of the crusher is kept.

5. The crusher control method according to claim 4, characterized in that: sd, the control system controls the crusher to reduce the load: increasing the discharge opening of the crusher increases or decreases the amount of feed.

6. The crusher control method according to claim 4, characterized in that: the control system in Se controls the crusher to increase the load: increasing the discharge opening of the crusher reduces or increases the amount of feed.

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