Real-time algorithm for cone crusher control with two variables

Cone crushers are used in the mineral, mining, and aggregate industry for fragmentation of rock materials, minerals and ores. Systems used for controlling the Closed Side Setting (CSS) on cone crushers, and thereby the size reduction, are widely used to compensate for wear of the manganese crushing liners and to protect the machines from overloads. With a frequency converter also the eccentric speed in a cone crusher can be adjusted in real-time in addition to the CSS. The eccentric speed affects the dynamic interaction between the rock material and the crusher liners. Especially the number of compressions the material is exposed to is affected and also the local compression of the rock material is affected, thus the particle-size distribution of the product. Eccentric speed also affects crusher capacity. Real-time feedback data on the sellable product streams can be obtained by applying mass-flow sensors to the process. The adjustment of these two online parameters in real-time can result in an increased potential for production yield; however, a nontrivial optimization problem with a large solution space also arises. As the feed material also varies, the optimal setting for the parameters varies in time.Herein, we report the development of a monitoring and control system including a two variable online algorithm for the selection of the setpoint for eccentric speed with respect to the current CSS. The different product yields from the crushing plant were monitored by mass-flow meters and continuously evaluated by a fitness function. A model for the outcome of the crushing stage, with the two parameters eccentric speed and CSS, was fitted mathematically to the measurement data. However, since the process varies continuously, due to the wear of crushers and screens and feed material variations, the performance landscape is also continuously varying. Therefore, an Evolutionary Operation (EVOP) approach was adopted, wherein the variations are instead used to continuously find an operating point closest to the optimal.The developed algorithm was tested and evolved at a crushing plant for aggregates that produces around 400,000 tonnes aggregates per year. The algorithm was implemented in a computer that communicated with the frequency converter and retrieved data from ten mass-flow meters in the process. The operator was able to interact and supervise the system through a Human Machine Interface (HMI). The result is an algorithm that can determine the position and direction of a dynamic speed control to continuously improve the process-operation point. The magnitude of the improvement potential compared to a fixed speed operation is from 5% to 20%.     

颚式破碎机自适应控制系统的设计与实现

以美卓C140颚式破碎机为控制对象,利用激光物位检测技术,设计配套传感器系统,通过在破碎机上方合适位置安装2台激光物位计,解决了破碎腔中的料位和下部矿仓料位检测的难题。以破碎机电流和 破碎腔料位为控制变量,利用自适应控制算法,调节重板给矿机的给矿速度和启停,实现了美卓C140颚式破碎机自动给矿运行。3条颚式破碎系统实现自动化后操作人员数量由原来的14人减少至5人,操作内容也由原 来机械重复式操作改为简单的定时巡检,达到了人员优化和减轻作业人员劳动强度的目的。该系统填补了地下矿山颚式破碎机自动控制的空白,具有很好的推广价值。     

破碎方式对邦铺钼铜矿石可磨性及钼浮选的影响

分别采用高压辊磨工艺和传统破碎工艺将西藏墨竹工卡县邦铺钼铜矿石破碎到-3.2 mm,分析了两种破碎产品的粒度特性,测定了两种破碎方式下矿石的 Bond球磨功指数,考察了两种破碎方式对后续球磨-钼浮选的影响。结果表明：高压辊磨产品比传统破碎产品细粒级含量多且粒度分布更均匀;高压辊磨产品在不同目标粒度下的Bond 球磨功指数比传统破碎产品至少降低9.05%;高压辊磨产品和传统破碎产品浮选钼的最佳磨矿细度分别为-0.074 mm占65%和75%,相应地,前者的Bond球磨功指数比后者降低10.87%,但浮钼回收率减少2.32个百分点。     

A comparative study between cone crushers and theoretically optimal crushing sequences

The supply of minerals, ores and aggregates are crucial for the continuous development of today’s society. With a rising world population, growing urbanization, and increasing standards of living, the performance and efficiency of existing crushers must be improved in order to meet the escalating demand on these products. The current paper thus presents a comparative study between existing cone crushers and theoretically optimal crushing sequences.Full scale experiments are conducted in order to examine the effects of Closed Side Setting (CSS), stroke, and eccentric speed on crusher output. The performance of the examined cone crusher is then compared against what is considered as theoretically optimal. The subsequent analysis shows that significant gains can be made in terms of both product yield and overall capacity by adjusting crusher operation depending on the conditions at hand, e.g. increasing the CSS while maintaining the same stroke or decreasing the eccentric speed. It is also shown that a mixture of breakages modes is more optimal than the sole application of one optimized breakage mode.     

多级串联破碎数学模型的多目标物理规划研究

双层多级盘式辊压破碎机采用多级串联的方式破碎物料,是一种新型破碎设备。根据物理规划理论,建立了破碎比的多目标数学模型,运用遗传算法进行了优化研究,得到的结果满足设计要求。同时对双层多级盘式辊压破碎机与高压辊磨机进行了对比分析,其中高压辊磨机的轴线压力值是双层多级盘式辊压破碎机的9倍,单位面积压力值是双层多级盘式辊压破碎机的2.6倍。所以多级串联辊压破碎可以解决高压辊磨机磨损严重的问题并且可以实现大破碎比的目的。     

破碎方式对某磁铁矿石磨矿速度和Bond球磨功指数的影响

为验证破碎方式对磨矿速度和Bond球磨功指数的影响,使用某磁铁矿选矿厂的鄂式破碎产品、圆锥破碎产品和高压辊磨产品,分别进行磨矿动力学试验和Bond球磨功指数试验。结果表明：①高压辊磨产品的可磨性最好,圆锥破碎产品次之,鄂式破碎产品最差。同一破碎产品的磨矿速度随着磨矿时间的增加而降低。不同破碎产品,随着磨矿时间增加,颗粒性质逐步均匀并接近,磨矿速度逐步接近,破碎方式对磨矿速度的影响逐步降低。②Bond球磨功指数试验表明,在磨矿产品粒度大于0.10 mm时,破碎方式对磨矿的能耗影响显著,高压辊磨产品最节能;当磨矿产品粒度小于0.10 mm时,破碎方式对磨矿的能耗影响降低。破碎工艺中增加高压辊磨机,对于增大磨机处理量、降低磨矿能耗十分有益。     

Mathematical modeling on multi-stage series crushing ratio distribution based on fuzzy physical programming

Double-layer, multi-roller plate crusher is a new device, that uses a multi-stage series crushing style to break particles, with the crushing ratio distribution directly influencing the machine’s performance. Three crushing ratios of 2.25, 2.15 and 2.01, used for fuzzy physical programming, were determined. The comparison of the optimized result between the double-layer multi-roller plate crusher and a high pressure roll grinder showed that the double-layer multi-roller plate crusher had a better performance, reducing crushing force and wear.     

破碎硐室粉尘浓度空间分布规律的数值模拟

为了掌握破碎硐室内粉尘浓度的空间分布规律,获取通风除尘设计的合理参数,以西石门铁矿提升车间系统27号破碎硐室为研究背景,依据气固两相流理论,运用计算流体力学的离散相模型（DPM）对破碎硐室粉尘浓度进行数值模拟,并与现场实测的粉尘浓度分布情况进行对比分析,模拟结果与实测数据基本吻合。研究结果表明：硐室空间内破碎机及给矿机附近区域粉尘浓度较大,并以破碎机及给矿机为中心径向逐步降低;捕捉壁面条件下粉尘浓度较之反弹壁面要低;当27/40斜坡道进风,且风速为1 m/s时,硐室空间内粉尘沉降效果较好;安装抽风除尘系统除尘率能达到90%以上,硐室大部分空间粉尘浓度保持在2 mg/m 3以内。     

不同破碎方式下产品磨矿特性的对比研究

对西藏墨竹工卡邦铺钼铜矿进行了高压辊磨和传统破碎,然后对两种产品进行了分批磨矿试验,应用磨矿动力学原理,并借助MATLAB 7.1软件分析了高压辊磨产品和传统破碎产品磨矿过程中各个粒级的磨矿速度。结果表明:在磨矿初期,高压辊磨产品的磨矿速度大于传统破碎产品的磨矿速度;在粗级别(-3.2+0.105 mm)中,高压辊磨产品磨矿速度的最大值高于传统破碎产品,而且粒度越粗,磨矿速度的最大值相差越大;随着磨矿时间的继续增加,磨机中粗粒级的含量越来越少,磨矿概率迅速降低,从而导致高压辊磨产品的磨矿速度小于传统破碎产品的磨矿速度,对于粗粒级(-3.2+0.105 mm)这种现象尤为明显;针对上述现象提出"高压辊磨—粗粒选择性快速磨矿"这一概念。     

回收金属破碎机数字化样机及破碎机理计算机仿真研究

上世纪70年代以来,CAD技术在制造业中得到了最为广泛和深入的应用;80年代初,以信息集成为核心的计算机集成制造系统（CIMS）开始得到实施;80年代末,以过程集成为核心的并行工程（cE）进一步提高了制造业的水平;跨入90年代,先进制造技术进一步向更高水平发展,出现了绿色制造（GM）、敏捷制造（AM）等一系列全新概念;进入本世纪初,随着几乎无界的数字化技术的迅猛发展,虚拟制造（VM）已成为制造业研究和应用的热点,并已被公认为未来产品设计、开发的必然趋势,同时也是制造技术后进国家尽快消化吸收先进技术,实现由“追随模式”到“自主开发”跨越式发展的有效手段。     

大山选矿厂二系列3万t／d破碎系统改造

由于停车频繁,作业率低,大山选矿厂碎矿系统生产能力低,故障主要出在圆锥破碎机、皮带运输机、振动筛和粗矿堆振动放矿机等关键设备上。采取相应的技术改造措施,用两台SVEDALA的H－8000圆锥破碎机替代两台SYMONS圆锥破碎机,改造了皮带运输机、振动筛和粗矿堆振动放矿机等,取得了预期的效果。     

惯性圆锥破碎机结构原理与应用研究

惯性圆锥破碎机是一种具有独特原理和结构的新型节能超细破碎设备．能实现物料的选择性破碎,满足“多碎少磨”新工艺的要求、该机不仅破碎比大产品粒度细而均匀。而且单位电耗低,能破碎任何硬度的脆性物料,可用于金属及非金属矿、冶金、材料、化工、磨料、建材等行业的物料破碎。本文简述了惯性圆锥破碎机的工作原理及结构特点,井通过实例证明了该机在粉碎工程领域中的良好应用前景。     

惯性圆锥破碎机在金属矿山的研究应用

惯性圆锥破碎机是一种具有独特原理和结构的新型节能超细破碎设备,能实现物料的选择性破碎,满足“多碎少磨”新工艺的要求。该机不仅破碎比大,产品粒度细而均匀,而且单位电耗低,能破碎任何硬度的脆性物料,十分适合于金属矿山的破碎磨矿流程。本文简述了惯性圆锥破碎机的结构特点和工作原理,介绍了该机在金属矿山的应用情况。     

双齿辊破碎机破碎过程研究

为了研究双齿辊破碎机破碎物料的过程,首先对物料破碎理论进行分析,得出了双齿辊破碎机是准静压、剪切弯曲组合破碎的结论。其次,运用Solid Works和LS-DYNA建立了辊齿破碎煤块的三维仿真有限元模型,分析了物料颗粒在破碎过程中的受力情况,得出了物料在破碎瞬时处于稳定的平衡状态的结论,并对破碎过程进行了动态仿真分析。最后,经过分析可知,辊齿在破碎物料时,煤块的局部首先受到冲击和挤压作用而出现裂纹,随着齿辊的转动及辊齿切入煤块的深度增加,裂纹扩展直至出现煤体崩落;得到了煤块在整个破碎过程中的应力变化情况及分布规律。研究结果为辊齿的结构参数优化、物料破碎过程分析提供了一定依据。     

Particle damage and exposure analysis in HPGR crushing of selected copper ores for column leaching

In mining operations, jaw and gyratory crushers are generally used for primary crushing, and cone crushers are used for secondary crushing. During the past decade, however, high-pressure grinding rolls (HPGR) are being considered due to potential processing benefits such as energy savings, improved exposure/liberation and particle weakening. At this time there is no detailed quantification of particle damage and downstream benefits from HPGR crushing are uncertain. In the present research, copper ores (copper oxide ore and copper sulfide ore) were crushed by a jaw crusher and by HPGR and the products were evaluated for particle damage and copper grain exposure by X-ray computed tomography. Column leaching was done to determine the rate and extent of copper recovery.X-ray computed tomography analysis and laboratory column leaching experiments for copper oxide ore revealed that products from HPGR crushing have more particle damage and higher copper recoveries when compared with products of the same size class from jaw crusher crushing. Generally the copper recovery from column leaching of the oxide ore was found to be dependent on the extent of grain exposure, which increases with a decrease in particle size.In the case of the copper sulfide ore, copper recovery was found to be independent of the crushing technique despite the fact that more particle damage was observed in products from HPGR crushing. This unexpected behavior for the copper sulfide ore might be due to the high head grade and strong leach solution. Column leaching results also show that about 80–90% of the copper was recovered from the copper sulfide ore in a relatively short leaching time irrespective of crushing technique. As expected, copper recoveries improved with a decrease in the particle size of the copper sulfide ore as exposure of copper mineral grains increased.     

惯性圆锥破碎机破碎机理与工作特性分析

介绍了惯性圆锥破碎机的工作原理与结构。通过分析惯性圆锥破碎机破碎力的特点,讨论了破碎力对产品的影响;分析了排料间隙大小对设备工作能耗以及产品粒度的影响。在此基础上,讨论了利用惯性圆锥破碎机改进破碎流程的方法。利用惯性圆锥破碎机产品粒度的特点来降低磨机入料的途径可以有效地降低破碎流程的能耗及钢耗,实现节能降耗。根据工业生产现状,概括了惯性圆锥破碎机的研究方向。     

GYP-300惯性圆锥破碎机的性能与应用

惯性圆锥破碎机是一种具有独特原理和结构的新型节能超细破碎设备,能实现物料的选择性破碎,满足"多碎少磨"新工艺的要求。该机不仅破碎比大,产品粒度细而均匀,而且单位电耗低,能破碎任何硬度的脆性物料。本文简述了GYP-300惯性圆锥破碎机的结构特点和性能指标,并通过实例证明了该机在粉碎工程领域中的良好应用前景。     

大破碎比宽系列外动颚式破碎机研究

外动颚式破碎机是北京矿冶研究总院拥有自主知识产权的新型破碎设备,其大破碎比特性满足了"多碎少磨—早抛多抛"新破碎工艺的要求。随着低品位矿石的开发利用和选矿厂处理能力的提高,按国标颚式破碎系列型谱研究开发的大破碎比颚式破碎机的处理能力就不相匹配,为此我们研究开发了宽腔型外动颚式破碎机,目前已经在十多个矿山企业得到成功应用。     

盘式辊压破碎机单磨辊能耗分析

建立了能耗模型,对影响因素进行分析,可以为设计和运行参数的选择提供依据。通过挤压区和滑移区压应力分析,得到粉碎腔压应力分布曲线,从而建立盘式辊压破碎机单个磨辊单位能耗模型。在物料能有效粉碎的前提下,应采用较小的磨辊直径、较低的磨辊力和较大的盘辊间隙。在第3级磨辊粉碎试验中,最大压应力在15～35 MPa时,各尺寸细粒级产品随着最大压应力的提高而增加,之后再提高最大压应力,细粒级产品含量增加不再明显。盘辊间隙取5~25 mm比较适宜,单位能耗试验结果与能耗模型基本相符。     

Prediction of worn geometry in cone crushers

A cone crusher is used for crushing rock material in mines and quarries. The performance of the crusher changes during its lifetime due to wear of the crusher liners. Previous research has made it possible to model, simulate and optimize the performance of a given crusher. A problem is that due to wear the optimized geometry will change and the performance will suffer. To design crusher geometry for optimized performance throughout the lifetime of the liners, it is desirable to predict the worn geometry. This paper presents a method for this purpose. In a previous study, a wear model was investigated for a laboratory scale crusher. This model has been implemented in a cone crusher. The controller in a modern cone crusher can, for example, keep the close side setting or the power draw constant. Such a controller was implemented in the model. Measurements of the worn geometry were conducted in order to validate the wear model. The worn geometry is well predicted although the wear rate, estimated from experiments presented in a previous study, was overestimated. The effect of constant power control and wear on various output parameters was studied in simulations.