Abstrict A gyratory crusher includes a control system, an upper frame portion
having a bowl liner, and a crushing head having a mantel such that
a crushing chamber having a gap is formed between the bowl liner
and the mantel. The control system includes detecting means for
detecting a pre-defined bowl float condition of the crusher, adjusting
means for automatically adjusting a width of the gap to thereby
eliminate the bowl float condition, and monitoring means for determining
magnitude and direction of changes in the width of the gap by monitoring
rotation of the bowl liner relative to the upper frame portion.
The control means is adapted to automatically adjust the width of
the gap to operatively compensate for a wearing rate of the bowl
liner and the mantel and to terminate operation of the crusher should
rate of bowl float conditions exceed a pre-determined quantity.
Claims What is claimed and desired to be secured by Letters Patent is
as follows:
1. A gyratory crusher for crushing material, comprising:
(a) a lower frame portion;
(b) an upper frame portion supported by said lower frame portion;
(c) a bonnet threadably supported by said upper frame portion,
said bonnet having a replaceable bowl liner with an upper opening
for receiving the material;
(d) an eccentric member;
(e) a crusher head having a replaceable mantel;
(f) a mounting mechanism structured to pivotally mount said eccentric
member on said lower frame portion about a first axis spaced centrally
and vertically relative to said lower frame member, and to pivotally
mount said crusher head on said eccentric member about a second
axis spaced generally centrally and vertically relative to said
lower frame portion wherein said second axis is angularly offset
from said first axis and intersects said first axis above said crusher
head and wherein a crushing chamber is formed between said bowl
liner and said mantel; said crushing chamber having a gap comprising
a closed side setting at a lower extremity thereof;
(g) electric motor apparatus structured to rotate said eccentric
member about said first axis; and
(h) a control mechanism structured to:
(1) automatically control the width of said gap during operation
of said gyratory crusher by monitoring the magnitude of current
drawn by said electric motor apparatus and by threadably advancing
said bonnet relative to said upper frame portion; and
(2) to operatively detect a pre-defined bowl float condition of
said crusher.
2. The crusher according to claim 1 wherein said control mechanism
includes at least one separation sensor configured to operatively
detect separation of said upper frame portion from said lower frame
portion.
3. The crusher according to claim 2 wherein said at least one
separation sensor is structured to generate a signal that is proportional
to the magnitude of separation of said upper frame portion from
said lower frame portion adjacent to said at least one separation
sensor.
4. The crusher according to claim 1 wherein said control mechanism
is configured to responsively increase said width of said gap upon
detection of said bowl float condition of said crusher.
5. The crusher according to claim 1 wherein said control mechanism
includes a monitoring mechanism configured to operatively control
magnitude and direction of changes in width of said gap by monitoring
rotation of said bonnet relative to said upper frame portion.
6. The crusher according to claim 5 wherein said control means
includes a ring gear mounted to said bonnet and a drive motor mounted
to said frame having a pinion engaging said ring gear, said monitoring
mechanism including a pair of proximity switches configured to operatively
interact with said said pinion.
7. The crusher according to claim 6 wherein said control mechanism
includes a calibrating mechanism structured to determine the spacing
of said bonnet relative to said upper frame portion as said gap
has a minimal width.
8. The crusher according to claim 1 wherein said control mechanism
is configured to operatively compensate for a wearing rate of said
bowl liner and said mantel by responsively displacing said bowl
liner relative to said mantel.
9. The crusher according to claim 1 wherein said control mechanism
is configured to operatively determine an updated wearing rate of
said bowl liner and said mantel.
10. The crusher according to claim 1 wherein said crusher includes
a drive mechanism, and said control mechanism includes a load sensor
responsive to said drive mechanism and wherein said control mechanism
is configured to operatively adjust said width of said gap in response
to changes in signals from said load sensor.
11. The crusher according to claim 1 wherein said control mechanism
is configured to operatively and threadably adjust said bonnet such
that said bonnet is vertically hoistable from said upper frame portion.
12. The crusher according to claim 11 wherein said control mechanism
includes an indicator mechanism structured to operably indicate
whereat said bonnet is vertically hoistable from said upper frame
portion.
13. The crusher according to claim 1 wherein said control mechanism
includes a tracking mechanism structured to track a quantity of
bowl float conditions that occur within a selected time interval.
14. The crusher according to claim 1 wherein said control mechanism
includes a shutdown mechanism structured to shut down said crusher
in the event that a quantity of bowl float conditions occurring
within a selected time interval exceeds a pre-determined quantity
thereof.
15. A control system for a gyratory crusher, wherein said crusher
includes an upper frame portion having a bowl liner and a crushing
head having a mantel such that a crushing chamber having a gap is
formed between the bowl liner and the mantel, said control system
comprising:
a) a detecting mechanism structured to detect a predefined bowl
float condition of the crusher; and
b) an adjusting mechanism structured to automatically adjust a
width of the gap to thereby eliminate said bowl float condition.
16. The control system according to claim 15 wherein said adjusting
mechanism includes a monitoring mechanism structured to determine
magnitude and direction of changes in the width of the gap by monitoring
rotation of the bowl liner relative to the upper frame portion.
17. The control system according to claim 15 wherein said adjusting
mechanism is structured to automatically adjust the width of the
gap to operatively compensate for a wearing rate of the bowl liner
and the mantel.
18. The control system according to claim 15 including a shutdown
mechanism structured to responsively shut down the crusher in the
event that a quantity of bowl float conditions occurring within
a selected time interval exceeds a pre-determined quantity thereof.
19. A gyratory crusher for crushing material, comprising:
(a) a lower frame portion;
(b) an upper frame portion supported by said lower frame portion;
(c) a bonnet adjustably supported by said upper frame portion,
said bonnet having an upper crushing surface and an upper opening
for receiving the material;
(d) an actuator connected to said bonnet for adjusting the position
of said bonnet relative to said upper frame portion;
(e) a crusher head supported by said frame, said crusher head being
operatively connected to a motor, said crusher head being spaced
relative to said bonnet such that a gap is formed therebetween;
and
(f) a controller operatively connected to said actuator for controlling
the width of the gap during operation of said crusher, said controller
including a separation sensor for detecting a bowl float condition,
said controller adjusting the position of said bonnet relative to
said upper frame to thereby eliminate the bowl float condition.
20. The crusher of claim 19 wherein said separation sensor includes
a position sensor for measuring the gap.
21. The crusher of claim 19 wherein said separation sensor includes
a current sensor for monitoring the magnitude of current drawn by
the motor, said separation sensor generating a signal proportional
to the width of the gap.
22. The crusher of claim 19 wherein said bonnet is threadably
mounted to said upper frame.
23. The crusher of claim 22 wherein said actuator includes a ring
gear mounted to said bonnet and a drive motor mounted to said frame
having a pinion engaging said ring gear, said drive motor and said
pinion cooperating to rotate said bonnet.
24. The crusher of claim 23 including a position monitor for monitoring
changes in position of said bonnet relative to said frame due to
said actuator, said position monitor having a pair of proximity
switches operatively interacting with said pinion.
25. The crusher of claim 19 wherein said crusher head is supported
on said frame by hydrostatic thrust bearings, and further including
a lubrication system for supplying lubricant to said thrust bearings,
said lubrication system including a pressure sensor operatively
connected to said controller for terminating operation of said crusher
in response to a malfunction of said lubrication system.
26. The crusher of claim 19 wherein said controller compensates
for a wearing rate of said bowl liner and said crusher head by adjusting
the position of said bonnet relative to said crusher head.
27. The crusher of claim 19 wherein said controller includes a
load sensor operatively connected to the motor, said load sensor
for generating a signal indicative of the load on the motor, and
wherein said controller adjusts the width of the gap in response
to said signal.
Description BACKGROUND OF THE INVENTION
The invention relates generally to controls for a gyratory or cone
crusher.
Gyratory crushers or cone crushers are characterized by crushing
heads having a generally cone-shaped outer surface, which are mounted
to undergo gyratory motion. The cone-shaped crushing head of a gyratory
crusher is generally centered about a cone axis that is angularly
offset from a vertical crusher axis generally centered through the
crusher. The outer surface of the head is protected by a replaceable
mantel.
The crushers are further characterized by a bowl-shaped member,
sometimes referred to as a concave or bonnet, disposed in an inverted
position generally over the cone-shaped crushing head and centered
on the vertical crusher axis. The inner surface of the bowl-shaped
member is protected by a replaceable bowl liner. The outer dimensions
of the head and mantel are smaller than the corresponding inner
dimensions of the bowl liner. The head is mounted such that there
is a space between the mantel and the bowl liner, sometimes referred
to as the "crushing chamber" or "crushing cavity".
The volume of the crushing cavity can be increased by altering the
shape of the exposed surface of the bowl liner and/or the shape
of the exposed surface of the mantel. It can also be increased or
decreased by vertically adjusting the separation between the mantel
and the bowl liner. The bowl-shaped member has an upper opening
through which material to be crushed can be fed into the crushing
cavity.
The smallest distance between the mantel and the bowl liner at
the bottom of the crushing cavity is called the "closed side
setting" or "setting" of the crusher. The width of
the setting determines the size of crushed materials operably produced
by the crusher. The setting can be enlarged to increase the size
of the crushed material produced by the crusher, and can be decreased
to reduce the size of the crushed material produced by the crusher.
The setting can be adjusted by simply raising or lowering the elevation
of the bowl liner relative to the elevation of the cone head. The
setting of some cone crushers is adjusted by raising or lowering
the head. The difference between the width of the closed side setting
and the spacing between the mantel and the bowl liner at the bottom
of the crushing cavity directly opposite from the closed side setting,
sometimes called the "open" side or "open side setting",
is called the "throw" or "stroke" of the crusher.
The small angular offset of the cone axis relative to the vertical
crusher axis is provided by mounting the head on an eccentric element,
or other suitable mounting. The head is caused to gyrate relative
to the bowl-shaped member by rotating that mounting or eccentric
element. As the eccentric element rotates, one side of the head
is caused to approach the bowl liner until it attains the closed
side setting while the opposite side of the head recedes from the
bowl liner until it simultaneously attains the open side setting.
The closed side setting and open side setting operably travel around
the periphery of the lower end of the crushing cavity as the eccentric
element is rotated, each making a complete revolution around the
cone head for each revolution of the eccentric element. The magnitude
of the gyration is determined by the angle that the cone axis is
offset from the crusher axis and by the location of the point at
which those two axes most closely approach or intersect.
State-of-the-art gyratory or cone crushers are generally driven
by a horizontally disposed countershaft which radially extends into
a lower part of a generally cylindrical crusher housing. An inner
end of the countershaft is coupled through a pinion and ring gear
to the eccentric element to rotatably drive the eccentric element.
A motor (either electric or combustion) is used to drive the crusher.
The speed of the motor, the size ratio of the pulleys on the motor
and the crusher, and the gearing of the eccentric element determine
the speed at which the head gyrates, sometimes referred to as the
"gyrational speed". The gyrational speed selected for
each crusher depends on the particular application for which the
crusher is to be used. Increasing or decreasing the gyrational speed
is usually a matter of changing the speed of the motor, changing
the relative sizes of the pulleys on the motor and the crusher,
and/or changing the gear ratios for the eccentric.
The gyratory or gyrating motion of the cone-shaped crushing head
performs a material comminution action on material, such as rock,
ore, coal and other hard substances, as the material is fed through
the bowl opening into the crushing cavity. The material typically
moves by gravity through the annular space between the exposed surface
of the stationary bowl liner and the exposed surface of the cone-shaped
mantel. As the gyrating head approaches the liner, it crushes the
material; as it recedes from the liner, the material falls farther
down the crushing cavity to undergo further crushings during subsequent
revolutions of the eccentric member and as the separation between
the bowl liner and the head gradually decreases from top to bottom.
This progressive crushing action repeatedly occurs until the crushed
material is discharged from the bottom of the crushing cavity.
A problem with prior art crushers is the inability to automatically
detect and eliminate a bowl float condition. Of course, some of
such bowl float conditions are quickly alleviated by tramp iron
relief systems. If prolonged, however, a bowl float condition can
quickly cause substantial damage to a crusher.
Another problem with prior art crushers is the inability to operatively
and automatically compensate for wearing away of the crushing surfaces
of a bowl liner and a mantel forming a crushing cavity within the
crushers.
A further problem with prior art crushers is the inability to expeditiously
arrange for bowl liners thereof to be vertically hoistable for maintenance
or replacement.
What is needed is a crusher having an automatic control system
or an automatic control system for a crusher wherein a bowl float
condition is automatically detected and eliminated, for automatically
compensating for wearing away of the crushing surfaces of the crusher
as the crusher is being operated, and for automatically adjusting
a bowl liner such that the bowl liner is vertically hoistable from
the crusher.
SUMMARY OF THE INVENTION
An improved gyratory crusher is provided for crushing rock, ore,
coal and other hard substances. The gyratory crusher includes a
lower frame portion, an upper frame portion supported by the lower
frame portion, and a bonnet supported by the upper frame portion.
The bonnet has an upper opening for receiving the material to be
crushed.
The gyratory crusher also includes an eccentric member and a conically
shaped crusher head. The eccentric member is pivotally mounted on
the lower frame portion about a crusher axis spaced centrally and
vertically relative to the lower frame member. The crusher head
is pivotally mounted on the eccentric member about a cone head axis
spaced generally centrally and vertically relative to the lower
frame portion wherein the cone head axis is angularly offset from
the crusher axis and intersects the crusher axis above the crusher
head. A crushing chamber is formed between the crusher head and
the bonnet.
The mounting arrangement of the gyratory crusher also includes
a plurality of hydrostatic bearings for operably supporting the
crusher head, a pair of taper bearings configured to operatively
provide rotational displacement of the eccentric member about the
crusher axis, and a spherical bearing configured to operatively
provide rotational displacement of the crusher head about the cone
head axis. The crusher head is mounted on a main shaft having a
tapped partial bore adapted to threadably receive a mantel stud.
One or more partial bores spaced across the threads of the tapped
partial bore and the threads of the mantel stud are each adapted
to receive a dowel pin as the mantel stud is in threaded engagement
with the tapped partial bore. The dowel pin or pins prevent overtightening
of the self-tightening mantel stud during crushing operations of
the gyratory crusher.
The gyratory crusher also includes a flexible seal that is configured
to operatively protect moving components thereof from dust and grit
generated during crushing operations. An outer edge of the flexible
seal is secured to the crusher head and an inner edge of the flexible
seal is secured to an outer race of a ball bearing seal, the inner
race of which is secured to non-rotating members of the mounting
arrangement.
The gyratory crusher also includes a hydraulic tramp iron relief
system that is configured to automatically allow uncrushable material
to pass through the crushing chamber. The tramp iron relief system
includes channels formed internally within the structure of the
lower frame portion to connect cylinders and accumulators of the
tramp iron relief system in high-pressure hydraulic fluid flow communication.
The gyratory crusher also includes a self-contained lubricating
system configured to operatively lubricate the moving components
and sliding interfaces thereof, and to operably transfer thermal
energy from the moving parts of the mounting arrangement to the
lower frame portion to thereby reduce thermal stress within the
crusher.
A driving arrangement, including a bevel gear centered about the
crusher axis and secured directly to the eccentric member, provides
power for operating the crusher.
The crusher also comprises a control system for automatically controlling
the width of the gap during operation of the crusher. The control
system includes one or more separation sensors configured to operatively
detect separation of the upper frame portion from the lower frame
portion. The separation sensors generate signals that are proportional
to the magnitude of corresponding separations of the upper frame
portion from the lower frame portion adjacent to the respective
separation sensor.
The control system is configured to operatively detect a pre-defined
bowl float condition of the crusher and to responsively increase
the width of the gap upon detection of such a bowl float condition.
The control system is configured to operatively control magnitude
and direction of changes in width of the gap by monitoring rotation
of the bonnet relative to the upper frame portion and to determine
the relative displacement of the bonnet relative to the upper frame
portion as the gap has a minimal width.
The control system is also configured to operatively compensate
for a wearing rate of the bowl liner and the mantel by responsively
displacing the bowl liner relative to said mantel. The control system
provides for periodically recalibrating the relative displacement
of the bonnet relative to the upper frame portion as the gap has
a minimal width to thereby determine an updated or "learned"
wearing rate of the bowl liner and the mantel.
Further, the control means is configured to operatively adjust
the width of the gap in response to changes in amperage drawn as
the crusher is driven by electrically powered drive means and/or
in response to changes in temperature of fluid being circulated
through the crusher. In addition, the control means is configured
to operatively adjust said bonnet such that said bonnet is vertically
hoistable from the upper frame portion to expeditiously facilitate
removal and replacement of inner components of the crusher, and
to track quantity of bowl float conditions occurring within a selected
time interval including shutting down the crusher in the event that
the quantity of bowl float conditions occurring within a selected
time interval exceeds a pre-determined quantity.
PRINCIPAL OBJECTS AND ADVANTAGES OF THE INVENTION
The principal objects and advantages of the present invention include:
providing a gyratory crusher that has an automatic control system
and providing a control system for automatically controlling a gyratory
crusher; providing such a crusher and control system that automatically
controls a width of a close side setting of the crusher during operation
thereof; providing such a crusher and control system that automatically
detects separation of an upper frame portion from a lower frame
portion of the crusher; providing such a crusher and control system
that automatically generates signals that are proportional to the
magnitude of separation of an upper frame portion from a lower frame
portion of the crusher; providing such a crusher and control system
that automatically detects a pre-defined bowl float condition of
the crusher; providing such a crusher and control system that automatically
increases a closed side setting of the crusher upon detection of
a bowl float condition of the crusher; providing such a crusher
and control system that automatically controls magnitude and direction
in changes of a closed side setting of the crusher by monitoring
rotation of a bonnet relative to an upper frame portion of the crusher;
providing such a crusher and control system that automatically determines
displacement of a bonnet relative to an upper frame portion of the
crusher whereat a closed side setting of the crusher is determined
by onset of a bowl float condition of the crusher; providing such
a crusher and control system wherein a bowl liner is automatically
displaced relative to a mantel of a crusher to compensate for a
wearing rate of the crushing surfaces of the bowl liner and the
mantel; providing such a crusher and control system wherein a closed
side setting of the crusher is automatically adjusted in response
to changes in amperage as the crusher is driven by an electrically
powered prime mover; providing such a crusher and control system
wherein a closed side setting of the crusher is automatically adjusted
in response to changes in temperature of a fluid being circulated
through the crusher; providing such a crusher and control system
wherein a bonnet of the crusher is automatically adjusted whereby
access to inner components of the crusher are expeditiously provided;
providing such a crusher and control system wherein a quantity of
bowl float conditions occurring within a selected time interval
are tracked; providing such a crusher and control system wherein
operation of the crusher is automatically terminated in the event
that the quantity of bowl float conditions occurring within a selected
time interval exceeds a pre-determined quantity; and generally providing
such a crusher and control system that are efficient in operation,
capable of long operating life, and particularly well adapted for
the proposed usages thereof.
Other objects and advantages of this invention will become apparent
from the following description taken in conjunction with the accompanying
drawings wherein are set forth, by way of illustration and example,
certain embodiments of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary, side elevational view of a gyratory crusher
having an automatic control system including an elevating arrangement
and cylinders and accumulators of a tramp iron relief system thereof,
in accordance with the present invention.
FIG. 2 is a fragmentary, partially cross-sectional view of the
gyratory crusher having an automatic control system, taken along
line 2--2 of FIG. 1.
FIG. 3 is an enlarged and fragmentary, side elevational view of
the gyratory crusher having an automatic control system, showing
one of the plurality of cylinders of the tramp iron relief system
with portions broken away to reveal details thereof.
FIG. 4 is a further enlarged and fragmentary, side elevational
and cross-sectional view of one of the plurality of cylinders of
the tramp iron relief system of the gyratory crusher having an automatic
control system, taken along line 4--4 of FIG. 3.
FIG. 5 is an enlarged and fragmentary, top plan view of one of
the plurality of accumulators of the tramp iron relief system of
the gyratory crusher having an automatic control system taken along
line 5--5 of FIG. 2 with portions broken away to reveal details
thereof.
FIG. 6 is a fragmentary top plan view of the gyratory crusher having
an automatic control system taken along line 6--6 of FIG. 2 with
a portion cut away to reveal details thereof, showing a thermal
stress relief arrangement thereof.
FIG. 7 is a further enlarged and fragmentary, partially cross-sectional
and side elevational view of a stop pin arrangement of the gyratory
crusher having an automatic control system.
FIG. 8 is an enlarged and fragmentary, partially cross-sectional
and side elevational view of a fluted bowl liner of the gyratory
crusher having an automatic control system.
FIG. 9 is a further enlarged and fragmentary, partially cross-sectional
view of the gyratory crusher having an automatic control system,
showing a mantel stud thereof.
FIG. 10 is a yet further enlarged and fragmentary, partially cross-sectional
view of the gyratory crusher, showing a dust seal arrangement thereof
in the vicinity of a closed side setting of the gyratory crusher
having an automatic control system.
FIG. 11 is a fragmentary view of the gyratory crusher having an
automatic control system, similar to that of FIG. 10 but showing
the dust seal arrangement in the vicinity of an open side setting
of the gyratory crusher.
FIG. 12 is a yet further enlarged and fragmentary view of the gyratory
crusher having an automatic control system, similar to that of FIG.
10 but showing an alternate dust seal arrangement.
FIG. 13 is a schematic representation of a lubricating system of
the gyratory crusher having an automatic control system.
FIG. 14 is a fragmentary and further enlarged plan view of the
elevating arrangements of the gyratory crusher having an automatic
control system.
FIG. 15 is a further enlarged, partial exploded and perspective
view of accumulator attaching means of the gyratory crusher having
an automatic control system.
FIG. 16 is an enlarged and fragmentary, side elevational view of
the gyratory crusher having an automatic control system, showing
a separation sensor thereof.
FIG. 17 is a schematic diagram of a control system of the gyratory
crusher.
FIG. 18 is an enlarged and fragmentary, plan view of the gyratory
crusher having an automatic control system, showing monitoring means
thereof.
FIG. 19 is an enlarged and fragmentary, partially cross-sectional
side elevation view of the gyratory crusher having an automatic
control system, showing indicator means thereof, according to the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments of the present invention are
disclosed herein; however, it is to be understood that the disclosed
embodiments are merely exemplary of the invention, which may be
embodied in various forms. Therefore, specific structural and functional
details disclosed herein are not to be interpreted as limiting,
but merely as a basis for the claims and as a representative basis
for teaching one skilled in the art to variously employ the present
invention in virtually any appropriately detailed structure.
The reference numeral 1 generally refers to a gyratory crusher
in accordance with the present invention, as shown somewhat simplified
to highlight particular features of the present invention in FIGS.
1 through 15. The crusher 1 includes frame means 3 head mounting
means 5 adjusting means 7 lubricating means 9 thermal stress
relief means 11 dust seal means 13 and a tramp iron relief system
15.
The frame means 3 includes a lower frame portion 21 and an upper
frame portion 23. A "V-seat" arrangement 25 as shown
in FIG. 7 is peripherally situated between the lower frame portion
21 and the upper frame portion 23 similar to that disclosed in
U.S. Pat. No. 4773604 entitled "Seat Member for Gyratory
Rock Crusher Bowls" and issued Sep. 27 1988. A bowl, concave
or bonnet 31 is mounted on the upper frame portion 23 by threads
33. A bowl liner 35 having an exposed surface 37 is replaceably
mounted on the bonnet 31 by liner connectors 39. The bowl liner
35 is a wear item that is replaceable while the crusher 1 is shut
down during maintenance periods. The upper frame portion 23 the
bonnet 31 and the bowl liner 35 which may be collectively referred
to herein as an upper assembly 41 are all centered about a vertically
oriented crusher axis 51 located centrally through the crusher
1. The bowl liner 35 has the general shape of a hollow truncated
pyramid with a generally circularly shaped upper opening 53 and
a wider, generally circularly shaped lower opening 55. The upper
opening 53 provides a material feed or intake opening for the crusher
1.
Partially located within the bowl liner 35 and extending through
the lower opening 55 into the space encompassed by the bowl liner
35 is a crusher head or cone head 61 of the crusher 1. The cone
head 61 is generally conically shaped. A mantel 63 replaceably
mounted on the cone head 61 provides a conical upwardly facing
crushing surface 65 for the cone head 61. The cone head 61 is centered
about a generally vertically oriented cone head axis 67 which is
disposed and supported at an angle of deviation, as indicated by
the numeral 69 in FIG. 2 with respect to the crusher axis 51. The
cone head axis 67 and the crusher axis 51 intersect at an apex of
gyration or apex 71 that lies centrally above the crusher 1. During
the operation of the crusher 1 the cone head 61 gyrates about the
apex 71 with respect to the bonnet 31.
The head mounting means 5 includes a main shaft 81 centered about
the cone head axis 67 for receiving the cone head 61 as shown
in FIG. 2. An upper end 83 of the main shaft 81 has a tapped partial
bore 85 for threadably receiving a mantel stud 87 as shown in FIG.
9.
The mantel stud 87 has an inner threaded portion 89 for mating
with the partial bore 85 and an outer threaded portion 91 for mating
with a mantel nut 93 as hereinafter described. The handedness of
the inner threaded portion 89 and the outer threaded portion 91
is such that the mantel stud 87 and the mantel nut 93 are self-tightening.
The threads of the inner threaded portion 89 and the outer threaded
portion 91 have an appropriate pitch, such as four threads per inch
for the outer threaded portion 91 and six threads per inch for the
inner threaded portion 89.
At least one, preferably two or more, partial bores 95 axially
aligned with the cone head axis 67 are located across the mated
threads of the partial bore 85 and the inner threaded portion 89
for receiving a respective dowel pin 97 therein. The dowel pins
97 are adapted to prevent over-tightening of the mantel stud 87
during the crushing operation and to thereby facilitate subsequent
removal or replacement of the mantel stud 87 thereby allowing low-cost
replacement of a corresponding thread system that holds a mantel
bolt 99 without having to remove or replace the main shaft 81.
The mantel 63 is attached to the cone head 61 by placing the mantel
63 on the cone head 61 and placing a mantel washer or "torch
ring" 111 over the outer threaded portion 91. The mantel nut
93 is threadably advanced along the outer threaded portion 91. The
mantel nut 93 has outwardly tapered shoulders 113 which, in conjunction
with the torch ring 111 and an appropriately sized and shaped orifice
115 through the mantel 63 centers and secures the mantel 63 to
the cone head 61. A mantel cap 117 is secured to the mantel nut
93 by the bolt 99 to protect the mantel nut 93 and the torch ring
111 from material falling through the upper opening 53.
The head mounting means 5 also includes an eccentric member 131
mounted within an encasement portion 133 of the lower frame portion
21. Rotational movement of the eccentric member 131 relative to
the encasement portion 133 is provided by a pair of taper bearings
135 137 centered about the crusher axis 51 as shown in FIG. 11.
A cavity 139 formed within the eccentric member 131 is configured
to provide the angular offset 69. Rotational movement of the cone
head 61 relative to the eccentric member 131 is provided by a spherical
bearing 141 centered about the cone head axis 67. A bushing 143
and a spacer 145 about the main shaft 81 appropriately locate the
spacing of the spherical bearing 141 relative to the main shaft
81. Counterweight 147 can be attached to the eccentric member 131
to balance the gyratory forces, as needed.
To provide adequate mounting for the taper bearings 135 137 while
also providing added support for the substantial stress forces generated
during the crushing operating, the cone head 61 is mounted in abutting
engagement with a plurality of hydrostatic bearings 161 mounted
on thrust seats 163 equidistantly spaced around the crusher axis
51. A bottom surface 165 of the cone head 61 is spherically shaped
with the center of curvature thereof located at the apex 71 whereby
the abutting engagement between the hydrostatic bearings 161 and
the surface 165 form a sliding interface as the cone head 61 gyrates
during the crushing operation.
The thrust seats 163 are mounted on and jointly supported by an
upper side 167 of the encasement portion 133 and the taper bearings
135 137. The primary purpose for partially supporting the cone
head 61 by the taper bearings 135 137 is to "load" the
taper bearings 135 137. In so doing, the eccentric member 131 is
precisely located, both axially and radially, relative to the encasement
portion 133. Selected ones of a plurality of shims 169 having different
thicknesses provide the desired loading of the taper bearings 135
137.
By precisely mounting and locating the eccentric member 131 relative
to the encasement portion 133 with the taper bearings 135 137
a gear 181 such as a spiral bevel gear, can be centered about the
crusher axis 51 and attached directly to the eccentric member 131
thereby eliminating the more complicated, more expensive and higher
maintenance gear arrangements of the prior art arrangements. A drive
train or drive pinion arrangement 183 meshed with the gear 181
and connected to a sheave 185 or other suitable means, provides
means for powering the crusher 1.
The crushing operation is effected by the spacing between the cone
head 61 and the bonnet 31 or, more particularly, the spacing between
the mantel 63 and the bowl liner 35. A releasable clamping arrangement
187 jams the opposing threads 33 against each other to prevent relative
rotation of the threads 33 except when desired. Preferably, the
clamping arrangement 187 is activated by appropriately spaced hydraulic
cylinders 189. For emergency or transporting purposes, the clamping
arrangement may be activated by utilizing bolts and nuts 190. It
should be understood that the bolts and nuts 190 are not used when
using control system 421 as hereinafter described.
Wear occurring on the respectively exposed mantel surface 65 and
the bowl liner surface 37 tends to increase the spacing therebetween.
Consequently, the adjusting means 7 which provides periodic corrective
adjustments of the spacing between the mantel 63 and the bowl liner
35 includes the threads 33 which permit continuous adjustment of
the axial position of the bonnet 31 in a step-less up or down displacement
by rotating the bonnet 31 about the crusher axis 51 with respect
to the upper frame portion 23 using the the ring gear 191 and
a pair of drive motors 193 as shown in FIG. 1.
The adjusting means 7 also includes a plurality, four for example,
of vertically oriented cleats 195 secured to a wall 197 of the bonnet
31. The ring gear 191 has a corresponding plurality of vertically
oriented grooves 199. The ring gear 191 cleats 195 and grooves
199 are configured whereby the ring gear 191 can be displaced vertically
alongside the wall 197 but cannot be horizontally rotated relative
to the wall 197 due to interaction between the cleats 195 and the
grooves 199 as shown in FIG. 14.
The drive motors 193 are mounted on the lower frame portion 21.
A plurality of rollers 201 supporting the ring gear 191 are also
mounted on the lower frame portion 21 whereby the ring gear 191
is maintained in gearing engagement with the drive motors 193.
To adjust the separation between the mantel 63 and the bowl liner
35 the hydraulic cylinders 189 are bled whereby the jamming pressure
between the opposing threads 33 is reduced allowing the drive motors
193 to displace the mating surfaces of the threads 33 relative to
each other. Then, the drive motors 193 are activated whereby the
ring gear 191 is horizontally rotated. If it is desired to increase
the separation between the bowl liner 35 and the mantel 63 the
drive motors 193 are operated in unison to cause the upper bonnet
31 to be threadably advanced upwardly. Conversely, if it is desired
to decrease the separation between the bowl liner 35 and the mantel
63 the drive motors 193 are operated in unison in the opposite
direction to cause the upper frame portion 23 to be threadably advanced
downwardly. After attaining the desired separation between the bowl
liner 35 and the mantel 63 forces exerted by the clamping arrangement
187 are increased to maintain the newly established separation.
Included conical angles of the bowl liner 35 and the mantel 63
are configured to provide an annular space or crushing chamber 211
between the bowl liner surface 37 and the mantel surface 65 the
width thereof generally decreasing downwardly. An annular gap 213
at the lower opening 55 between the bowl liner 35 and the mantel
63 constitutes an annular material discharge opening 215 from the
crushing chamber 211. During operation of the crusher 1 material
is fed into the crushing chamber 211 through the upper opening 53
which material is gravitationally urged downwardly through the annular
crushing chamber 211 and is reduced in size through repeated crushing
contacts between the adjacent surfaces 37 and 65 of the bowl liner
35 and the mantel 63.
The maximum size of material that can be crushed by the crusher
1 is determined by the spacing between the uppermost ends of the
bowl liner surface 37 and the mantel surface 65 as indicated by
the phantom circle designated by the numeral 217 in FIG. 8. If desired,
a plurality of flutes 219 may be formed in the bowl liner surface
37 as shown in FIG. 8 whereby occasional oversized material may
be received by the crushing chamber 211 to thereby increase the
maximum opening of the crushing chamber 211 without increasing the
size of the crusher 1.
The lubricating means 9 of the crusher 1 is self-contained and
includes a first pumping arrangement 231 for circulating oil through
the crusher 1 for lubricating the various moving parts thereof.
Oil for the first pumping arrangement 231 is contained in an oil
pan 233. The first pumping arrangement 231 as schematically illustrated
in FIG. 13 draws oil from the oil pan 233 by a lubricating portion
235 of a pump 237 and directs that oil by an oil line 239 through
a high-pressure filter 241 a pressure transducer 243 and a flow
divider 245. If a failure should occur whereby oil pressure should
unexpectedly drop at the pressure transducer 243 such as a broken
oil line, the pressure transducer 243 is adapted to signal shut-down
controls 247 which immediately shut-down operation of the crusher
1. If, instead, oil pressure in the oil line 239 should exceed a
certain pre-determined level, oil will be bled from the oil line
239 by a relief valve 249 and routed back to the oil pan 233.
The flow divider 245 distributes oil flowing therethrough separately
to each of the hydrostatic thrust bearings 161 and to the drive
pinion arrangement 183 from where the oil gravitationally returns
to the oil pan 233 as indicated by the arrow designated by the
numeral 251 in FIG. 13. The flow divider 245 also distributes oil
to the drive train 183 as indicated by the dashed line designated
by the numeral 252.
Monitoring means 253 monitors the volume of oil being 3 processed
through the flow divider 245. If oil flow to the hydrostatic thrust
bearings 161 or the drive pinion arrangement 183 as evidenced by
a reduction in volume of oil flow therethrough as determined by
the monitoring means 253 the monitoring means 253 will signal the
shut-down controls 247 to immediately shut-down operation of the
crusher 1.
Pressurized oil is conveyed from the flow divider 245 to the interface
between the hydrostatic bearings 161 and the bottom surface 165
of the cone head 61 by oil channels 255 for lubrication purposes.
The oil is sufficiently pressurized whereby the cone head 61 is
slightly elevated and supported on a thin film of oil on each of
the hydrostatic bearings 161. Oil sprays outwardly from the interface
between the hydrostatic bearings 161 and the bottom surface 165
of the cone head 61 and, as it cascades downwardly, lubricates the
other moving parts of the head mounting means 5 there below. Spring
loaded wiper rings 257 cause oil sprayed radially outwardly from
the hydrostatic bearings 161 to be directly downwardly onto a seal
bearing 259. Weep holes 261 drain oil from the seal bearing 259
and other pockets for gravitational return to the oil pan 233.
The thermal stress relief means 11 is also self-contained and includes
a second pumping arrangement 281. The second pumping arrangement
281 draws oil from the oil pan 233 by a cooling portion 283 of the
pump 237 and directs that oil through oil line 285 and a filter
287. If the oil temperature should be lower than a pre-determined
temperature, a bypass valve 289 diverts the oil from the oil line
285 to the oil pan 233. When the oil in oil line 285 reaches or
exceeds that pre-determined temperature, oil is no longer diverted
by the bypass valve 289 but, instead, is directed through half-collars
291 abutting a wall 293 of the lower frame portion 21 and into the
oil pan 233. The half collars 291 as shown in FIG. 6 and the oil
circulated therethrough are adapted to elevate the temperature of
the wall 293 to a temperature more closely approximately the temperatures
in the head mounting means 5 to reduce thermal stresses within the
lower frame portion 21 of the crusher 1.
Actually, the thermal relief means 11 serves a dual purpose. In
addition to relieving the thermal stress, the thermal relief means
11 also serves as a cooling means for the lubricating oil. In addition
to the thermal energy conducting inwardly through the wall 293 to
relieve the thermal stress caused by crushed material impacting
with and cooling the wall 293 thermal energy also radiates and
convects outwardly from the half collars 291 to the ambient atmosphere
to cool the lubricating oil.
The dust seal means 13 is adapted to isolate inner moving components,
such as the interface between the hydrostatic bearings 161 and the
bearings 135 137 and 141 from abrasive contamination arising from
the ubiquitous dust and grit generated during the crushing process.
The dust seal means 13 includes a flexible seal 301 having an outer
edge 303 secured to a lower extremity 305 of the cone head 61 and
an inner edge 307 secured to an outer race 309 of the seal 259
an inner race 311 of which is secured to the thrust seats 163. Bearing
balls 312 are captured between the inner race 311 and the outer
race 309 in peripheral grooves thereof.
To provide the flexibility needed to compensate for the oscillatory
displacement of the cone head 61 due to the gyratory motion thereof,
the flexible seal 301 generally has a single-wall construction with
a corrugation-like cross-sectional configuration, as shown in FIG.
10. As the separation between the mantel 63 and the bowl liner 35
at a particular point along the gap 213 approaches the closed side
setting, the corrugations or fingers 313 widen to compensate for
the corresponding increasing separation between the lower extremity
305 and the seal bearing 301. Similarly, as the separation between
the mantel 63 and the bowl liner 35 approaches the open side setting,
the fingers 313 become narrower to compensate for the corresponding
decreasing separation between the lower extremity 305 and the seal
bearing 301.
To compensate for rotation of the cone head 61 relative to the
bowl liner 35 during a crushing operation, the outer race 309 rotates
with the cone head 61 peripherally relative to the inner race 311.
Alternatively, the dust seal means 13 may include a flexible seal
321 having a double-wall construction that forms a bladder 323 therebetween,
as shown in FIG. 12. For some applications, it may be desirable
to pressurize the bladder 323 such as between one to five pounds
per square inch.
The tramp iron relief system 15 includes a lower radial member
331 secured to and spaced radially outwardly from an upper end 333
of the wall 293 of the lower frame portion 21. A peripheral groove
335 is formed in an outer edge 337 of the lower radial member 331.
A plurality of equidistantly spaced partial bores 341 extend radially
inwardly from the groove 335 as shown in FIG. 2. For example, the
tramp iron relief system 15 may include eight of the partial bores
341.
In addition, a port 343 is provided from each of the partial bores
341 through a lower surface 345 of the lower radial member 331
as shown in FIG. 3. The ports 343 are spaced outwardly from the
wall 293 whereby a cylinder 347 can be connected to and suspended
downwardly from a respective one of each of the ports 343. If desired,
the cylinders 347 may be connected to the ports 343 by inserts 349
as shown in FIG. 3 preferably constructed of a dissimilar metal,
such as brass or other suitable material to minimize or eliminate
galling when removing the cylinders 347 from the ports 343. The
cylinders 347 are spaced in close proximity to the wall 293.
The tramp iron relief system 15 also includes a skirt 351 secured
to the lower radial member 331 as shown in FIG. 4. The skirt 351
extends downwardly from the lower radial member 331 to provide some
protection for the cylinders 347. If desired, a groove 353 may be
provided along an inner peripheral surface of the skirt 351 to complement
and provide greater flow capacity for hydraulic fluid being conveyed
along the groove 335.
A piston rod 355 extends downwardly from each of the cylinders
347 and connects to a respective one of a plurality of rocker arm
arrangements 357. Each of the rocker arm arrangements 357 has an
extension 359 extending through a respective one of a plurality
of guides 361. A pair of opposing pull rods 371 extend upwardly
from each end of a respective one of the rocker arm arrangements
357 through corresponding openings 373 in the lower radial member
331 and through additional corresponding openings 375 in an upper
radial member 377 secured to and spaced radially outwardly from
the wall 197 of the upper frame portion 23. Split keepers 379 connected
to upper ends of each of the pull rods 371 provide means for hydraulically
providing substantial hold-down forces between the upper frame portion
23 and the lower frame portion 21.
The tramp iron relief system 15 also includes a plurality of accumulators
385. For example, the crusher 1 may have one of the accumulators
385 positioned in every other space between the cylinders 347. Each
of the accumulators 385 are connected in flow communication with
the groove 335 similarly to that provided by the ports 343 and
the partial bores 341 for the cylinders 347 and, preferably, by
inserts similar to the inserts 349. An appropriately spaced input
port 387 is provided for injecting hydraulic fluid into the tramp
iron relief system 15 from an external hydraulic source 388 as
schematically shown in FIG. 1.
Each of the accumulators 385 are affixed to the wall 293 by accumulator
attaching means, comprising a pair of opposing locators 389 and
an interconnecting hanger 391. Each of the locators 389 is spaced
outwardly from the wall 293 by standoffs 392. The locators have
a pair of slots in a base 393 thereof that allows a cylindrical
edge 394 thereof to be placed and affixed in abutting engagement
with the respective accumulator 385 as shown in FIGS. 5 and 15.
The hanger 391 has a threaded connector 395 at each end thereof
to clamp the accumulator 385 against the cylindrical edges 394.
One of the distinct advantages provided by the present invention
is the elimination of all external plumbing of a hydraulic system
for tramp iron relief purposes.
In an application in accordance with the present invention, hydraulic
fluid is injected into the system to pressurize the hydraulics of
the tramp iron relief system 15 to a selected pressure; for example,
2000-2400 psi or other suitable pressure as appropriate to clamp
the upper frame portion 23 to the lower frame portion 21 particularly
across the V-seat arrangement 25.
The closed side setting is adjusted by displacing the bowl liner
35 upwardly or downwardly as needed by clockwise or counterclockwise
rotation of the elevating ring gear 191 as appropriate. The first
pumping arrangement 231 is activated to provide lubricating oil
to the hydrostatic thrust bearings 161 and the drive pinion arrangement
183. The second pumping arrangement 281 is activated to provide
oil to the half collars 291 after the oil reaches or surpasses a
pre-determined temperature. Drive means, such as a prime mover 397
as schematically indicated in FIG. 2 is drivingly engaged with
the sheave 185 to initiate gyration of the cone head 61 relative
to the bowl liner 35.
Rock, ores or other material are dropped through the upper opening
53 of the bowl liner 35 and are crushed between the mantel 63 and
the bowl liner 35 as the material being crushed is gravitationally
urged through the crushing chamber 211 to be discharged through
the gap 213 thereof. As the crushing operation progresses, the temperature
of the oil increases until the pre-determined temperature setting
of the bypass valve 289 is reached or exceeded. Then, the bypass
valve 289 directs the oil passing through the second pumping arrangement
281 to and through the half collars 291.
The trajectory of crushed material being discharged from the gap
213 which is generally much cooler than the oil, bearings and other
moving parts of the crusher 1 causes the crushed material to impact
with the wall 293 thereby cooling the wall 293. Due to the temperature
difference between the cooled wall 293 and that of the moving components
of the crusher 1 prior art crushers endure thermal stresses in
addition to the substantial physical stresses inherent in the crushing
process. In the present invention, however, the oil circulated through
the half collars 291 warms the wall 293 thereby counteracting the
cooling effect of the crushed material impacting with the wall 293.
As a result, thermal stresses in the crusher 1 of the present invention
are substantially reduced from those of prior art crushers.
As non-crushable material that is too large to be processed through
the crushing chamber 211 sometimes referred to as "tramp iron",
is dropped into the crushing chamber 211 a portion of the bowl
liner 35 and the association portion of the upper frame portion
23 are forced upwardly from the cone head 61 causing the corresponding
portion of the V-seat arrangement 25 to separate. As the upper frame
portion 23 is forced upwardly, corresponding ones of the pull rods
371 which are secured to the upper radial member 377 by the split
keepers 379 and the rods 355 connected to the pull rods 371 by
the rocker arm arrangements 357 are also forced upwardly.
As the rods 355 are forced upwardly, pistons 399 push hydraulic
fluid thereabove into the enclosed peripheral groove 335. The hydraulic
fluid flows along the groove 335 to each of the plurality of accumulators
385 connected in flow communication with the groove 335. As the
added pressure in the hydraulic fluid is conveyed to the accumulators
385 compressed bladders 401 within the accumulators 385 are further
compressed to temporarily store the added mechanical energy caused
by the tramp iron passing through the crushing chamber 211.
Immediately after the tramp iron has worked its way through the
crushing chamber 211 and dropped from the gap 213 thereby relieving
the upwardly thrusting forces previously exerted by the tramp iron,
the extra pressure stored in the bladders 401 is dissipated as the
upper frame portion 23 which was forced upwardly, returns to its
rest position about the V-seat arrangement 25 also returning the
pistons 399 the piston rods 355 the rocker arm arrangements 357
and the pull rods 371 to their rest positions. As the V-seat arrangement
25 is disturbed, such as during passage of tramp iron or "bowl
float", stop pins 403 prevent rotation of the upper frame portion
23 relative to the lower frame portion 21. Sleeves or inserts 405
are readily removable to facilitate replacement of worn parts interacting
with the stop pins 403 and of the pins 403 themselves to thereby
minimize maintenance costs.
"Bowl float" is well known in the art to indicate the
condition wherein the upper frame portion 23 is repeatedly lifted
from and bounced or vibrated against the lower frame portion 21.
Bowl float generally occurs when a non-crushable object is fed into
the crusher 1 or when the crusher 1 is operated with a closed side
setting that is too small. In the crusher of the present invention,
bowl float can rapidly cause substantial damage to the crusher 1
particularly in regard to the V-seat arrangement 25 and the stop
pins 403.
The tramp iron relief system 15 hereinbefore described is designed
to process such non-crushable objects through the crusher 1 and
return the crusher 1 to normal operation. In order for the crusher
1 to be essentially fully automated, a control system 421 thereof
must be able to detect bowl float and respond accordingly. The control
system 421 includes a plurality of separation sensors 423 that are
adapted to detect separation of the upper frame portion 23 from
the lower frame portion 21. For applications employing two of the
separation sensors 423 the sensors 423 are generally mounted 180.degree.
apart on the lower frame portion 21 whereby the separation sensors
423 can sense a metallic target of the upper frame portion 23 such
as a bottom surface of the upper radial member 377.
The separation sensors 423 are adapted to sense a range of separations
of the upper frame portion 23 from the lower frame portion 21 such
as from 4 to 11 mm., s and to communicate an analog voltage to a
control unit 425 wherein that voltage is proportional to the amount
of separation. The control unit 425 is configured to operatively
detect a pre-defined bowl float condition, such as greater than
one hundred twenty pulses within one minute wherein the magnitude
of those pulses correspond to a separation between the upper frame
portion 23 and the lower frame portion 21 of greater than 1.5 mm.
It is to be understood that signals from any one of the separation
sensors 423 is sufficient to define bowl float as one of the separation
sensors 423 may be situated wherein there is little or no separation
between the upper frame portion 23 and the lower frame portion 21
and, in fact, produce signals that would indicate "negative"
separation.
Alternatively, variations in the pressure of the hydraulic fluid
of the tramp iron relief system 15 may be used as an indicator of
bowl float.
If the control unit 425 determines that the defined bowl float
condition does exist, the control unit 425 may take various courses
of action, including signaling shut down of the crusher 1 as hereinbefore
described in regard to the shut down controls 247 or causing the
clamp cylinders 189 to release some of their clamping pressure and
causing the drive motors 193 to rotate the bonnet 31 whereby the
separation between the bowl liner 35 and the mantel 63 are increased.
Due to the manner is which the bonnet 31 is elevatable relative
to the upper frame portion 23 the bowl float condition can be automatically
removed as the crusher 1 continues the crushing operation. The clamping
pressure is reduced only enough, such as by fifty percent, to allow
the drive motors 193 to rotate the bonnet 31 and is not entirely
removed to prevent encouragement of bowl float of greater and possibly
more destructive magnitude. The association between the clamp cylinders
189 and the drive motors 193 is indicated by the dashed line designated
by the numeral 427 in FIG. 17.
The amount of rotation of the bonnet 31 needed to eliminate the
bowl float condition can be determined and controlled by the control
unit 425. For example, the control unit 425 can monitor signals
from the separation sensors 423 to determine in real time when the
definition of bowl float is no longer present and accordingly discontinue
operation of the drive motors 193. Or, the control unit 425 can
cause the drive motors 193 to rotate the bonnet 31 for a short,
selected period of time and re-examine whether the definition of
bowl float is still satisfied. If so, similar rotations can be repeated
until bowl float ceases. Further, the control unit 425 can cause
the drive motors 193 to rotate the bonnet 31 through a selected
angular rotation in order to produce a corresponding increase in
the spacing between the bowl liner 35 and mantel 63 which was known
to eliminate similar bowl float conditions.
The control system 421 includes monitoring means configured to
operatively monitor changes in spacing between the bowl liner 35
and the mantel 63 such as a pair of proximity switches 431 for
monitoring rotation of the bonnet 31 through a selected angular
rotation whereby the spacing between the bowl liner 35 and the mantel
63 is increased or decreased by a known amount. The proximity switches
431 are mounted on one of the drive motors 193 whereby each of the
proximity switches 431 detects and counts the number of teeth of
a toothed arrangement, such as a gear 433 of the drive motor 193
passing thereby, as shown in FIG. 18. For an application wherein
the ring gear 191 has one hundred sixty teeth and the threads 33
have a pitch of two inches, eight teeth which represents one twentieth
of one revolution of the ring gear 191 would represent an change
in elevation of the bonnet 31 of 1/20 times two inches, or 0.1 inch.
The proximity switches 431 are spaced whereby quadrature signals
therefrom are out of phase with each other, similar to that of a
two channel optical encoder, thereby permitting devices monitoring
those signals to determine whether the gear 433 is turning clockwise
or counterclockwise.
The control system 421 also provides means for setting the closed
side setting of the crusher 1. The closed side setting occurs at
the lower end of the crushing chamber 211 whereat the surface of
the bowl liner 35 is parallel to the corresponding surface of the
mantel 63 sometimes referred to as the parallel zone. The control
system 421 includes calibrating or zeroing means for determining
a closed side setting of essentially zero, such as by operating
the crusher 1 empty without any material being crushed therein,
by operating the drive motors 193 to rotate the ring gear 191 such
that the bowl liner 35 is displaced downwardly toward the mantel
63 and by observing the point at which the crusher 1 assumes bowl
float condition as the closed side setting nears a separation of
zero, sometimes referred to as "crusher zero".
Then, the drive motors 193 are reversed and rotated by the desired
"number of teeth" needed to provide the corresponding
separation between the bowl liner 35 and the mantel 63 across the
parallel zone. As the parallel zone is not horizontal but, instead,
is oriented at an acute angle, it should be understood that such
angular relationship must be taken into consideration when determining
the magnitude of vertical displacement of the bowl liner 35 that
is needed in order to obtain the desired closed side setting. The
desired closed side setting can be keyed into the control unit 425
by a user, with the control unit 425 in conjunction with the proximity
switches 431 and the drive motors 193 automatically establishing
the closed side setting. It is to be understood that a user can
input a new closed side setting, as indicated by the numeral 435
in FIG. 17 such as for producing crushed material for a different
project that requires different size specifications and the control
unit 425 adjusting the closed side setting accordingly.
The gradation of crushed material exiting from the crusher 1 is
dependent on the accuracy of the settings, and particularly the
closed side setting. Thus, if the rate of wear of the bowl liner
35 and the mantel 63 for each hour that the crusher 1 is known,
the control unit 425 can periodically and automatically operate
the drive motors 193 to accordingly re-establish and maintain the
desired closed side setting. A rate of wear can be input into the
control unit 425 by the user. Periodically, such as each morning
at startup, "crusher zero" can be re-determined. The displacement
required to return to crusher zero, actual closed side setting,
can be automatically compared with the "calculated" closed
side setting operationally established during the previous crushing
period and, after adjusting for the number of hours that the crusher
1 was operated during that previous crushing period, automatically
determine, or "learn", a new rate of wear that is automatically
stored by the control unit 425. A more recent "learned"
rate of wear can be automatically determined as frequently as desired.
It is known in the art that as the closed side setting decreases
for a crusher powered by an electrically driven prime mover 397
a load sensor 441 such as a signal indicating the amperage drawn
by the prime mover 397 increases; conversely, as the closed side
setting increases, such as by wearing of crushing surfaces during
the crushing operation, the amperage drawn by the prime mover 397
as indicated by the load sensor 441 decreases. Thus, in addition
to adjusting the closed side setting based on rate of wear per operating
hour of the crusher, the control system 421 may also monitor the
amperage drawn by the prime mover 397. The amperage is determined
by the load sensor 441 and communicated to the control unit 425
where it is filtered and smoothed. If the amperage has increased
or decreased by a designated amount from the amperage known to correspond
to the desired closed side setting, the control unit 425 automatically
activates the drive motors 193 to narrow the closed side setting
to increase the amperage drawn by the prime mover 397 or to widen
the closed side setting to decrease that amperage, as appropriate.
As the closed side setting decreases, the power utilized by the
crusher 1 will increase and the temperature of the lubricating oil
in the oil pan 233 will increase accordingly; conversely, as the
closed side setting increases, such as by wearing during the crushing
operation, the temperature of the lubricating oil in the oil pan
233 will decrease. Thus, for a crusher 1 utilizing a non-electrically
driven primer mover 397 such as a diesel engine or the like, signals
from the load sensor 441 such as a governor in the case of a non-electrically
driven prime mover 397 or an oil pan temperature sensor 445 for
example, may be used in conjunction with a non-electrically driven
prime mover 397 similarly to the load sensor 441 as used with an
electrically driven prime mover 397. It should be understood that
it may be desirable to also use the oil pan temperature sensor 445
in conjunction with the load sensor 441 when utilizing an electrically
driven prime mover 397.
The control unit 425 may also be used to sufficiently elevate the
bonnet 31 whereby the threads 33 are no longer enmeshed and the
bonnet 31 and bowl liner 35 and be hoisted from the upper frame
portion 23. A user input 435 such as a "clearing" or
other appropriate command, may be entered instructing the control
unit 425 to partially or totally release the clamp cylinders 189
and to activate the drive motors 193 until the threads 33 of the
bonnet 31 disengage from the threads 33 of the upper frame portion
23.
Indicator means, such as a removal proximity switch 451 signals
the control unit 425 when the threads 33 are either disengaged or
will be disengaged after a predetermined additional angular rotation
of the bonnet 31 such as an additional one-half revolution for
example. An orifice or notch 461 in the wall 197 as shown in FIG.
19 activates the removal proximity switch 451 as the threads 33
are clear or almost clear as aforesaid. The control unit 425 then
deactivates the drive motors 193 or deactivates them after the pre-determined
additional angular rotation of the bonnet 31.
The control system 421 may also include tracking means for tracking
the quantity of bowl float conditions that occur within a selected
time interval. In the event that the quantity of bowl float conditions
occurring within the selected time interval exceeds a pre-determined
quantity, which may indicate that the user is operating the crusher
1 in a manner that may considerably shorten the useful life of the
crusher 1 the control unit 425 may also include shutdown means
for shutting down the crusher 1 whereafter the crusher 1 can only
be reactivated by the owner of the crusher 1. In addition, the control
system 421 may track the total lifetime quantity of bowl float conditions
occurring to the crusher 1 to thereby provide some indication of
the remaining useful life of the crusher 1.
Although the foregoing discussions have described the control system
421 as being an integral part of the crusher 1 it is to be understood
that adaptation of the control system 421 to numerous other crusher
designs, both present existing and future designs, lies within the
nature and spirit of the present invention.
It is to be understood that the control unit 425 may include the
shutdown controls 247 as hereinbefore described, with signals from
the flow monitor 253 and the pressure transducer 243 being communicated
to the control unit 425.
It is to be understood that while certain forms of the present
invention have been illustrated and described herein, it is not
to be limited to the specific forms or arrangement of parts described
and shown. |