WO2009123531A1 - Attenuation of pressure variations in crushers - Google Patents

Attenuation of pressure variations in crushers Download PDF

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Publication number
WO2009123531A1
WO2009123531A1 PCT/SE2009/000160 SE2009000160W WO2009123531A1 WO 2009123531 A1 WO2009123531 A1 WO 2009123531A1 SE 2009000160 W SE2009000160 W SE 2009000160W WO 2009123531 A1 WO2009123531 A1 WO 2009123531A1
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WIPO (PCT)
Prior art keywords
accumulator
pressure
crushing
hydraulic
hydraulic cylinder
Prior art date
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Ceased
Application number
PCT/SE2009/000160
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French (fr)
Inventor
Kristian Burhoff
Mauricio Torres
Johan EDSTRÖM
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Sandvik Intellectual Property AB
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Sandvik Intellectual Property AB
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Filing date
Publication date
Application filed by Sandvik Intellectual Property AB filed Critical Sandvik Intellectual Property AB
Priority to UAA201013080A priority Critical patent/UA100885C2/en
Priority to BRPI0911074A priority patent/BRPI0911074A2/en
Priority to AU2009232465A priority patent/AU2009232465B2/en
Priority to EP09726902.1A priority patent/EP2271427B1/en
Priority to RU2010145132/13A priority patent/RU2487761C2/en
Priority to CN2009801191573A priority patent/CN102046292B/en
Publication of WO2009123531A1 publication Critical patent/WO2009123531A1/en
Anticipated expiration legal-status Critical
Priority to ZA2010/07882A priority patent/ZA201007882B/en
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C2/00—Crushing or disintegrating by gyratory or cone crushers
    • B02C2/02—Crushing or disintegrating by gyratory or cone crushers eccentrically moved
    • B02C2/04—Crushing or disintegrating by gyratory or cone crushers eccentrically moved with vertical axis
    • B02C2/047—Crushing or disintegrating by gyratory or cone crushers eccentrically moved with vertical axis and with head adjusting or controlling mechanisms

Definitions

  • the present invention relates to a crusher system comprising a first crushing surface and a second crushing surface, the two crushing surfaces being operative for crushing material between them, the crusher system further comprising a hydraulic system which is operative for adjusting a gap between the first crushing surface and the second crushing surface by adjusting the position of the first crushing surface by means of an hydraulic cylinder connected to said first crushing surface.
  • the present invention further relates to a method of crushing material between a first crushing surface and a second crushing surface.
  • Crushers are utilized in many applications for crushing hard material, such as rocks, ore, etc.
  • One type of crusher is the gyratory crusher, which has a crushing head which is forced to gyrate inside a fixed crushing shell.
  • a crushing chamber, into which pieces of rock are to be fed, is formed between a crushing mantle, which is supported by the crushing head, and the crushing shell.
  • the width of the crushing chamber often referred to as the gap or the setting of the crusher, may be adjusted by means of a hydraulic arrangement.
  • the crusher is subjected to large load variations. Such load variations causes wear, including metal fatigue, in the crusher, and may decrease the life of the crusher.
  • GB 1 517 963 discloses a gyratory crusher having a hydraulic cylinder or an air cylinder for preventing overload situations.
  • a pressure buffer is operative for accommodating sudden heavy load changes in the hydraulic system.
  • the pressure buffer is connected to the hydraulic system and by a point of constriction provided between the cylinder and the pressure buffer.
  • a crusher system comprising a first crushing surface and a second crushing surface, the two crushing surfaces being operative for crushing material between them, the crusher system further comprising a hydraulic system which is operative for adjusting a gap between the first crushing surface and the second crushing surface by adjusting the position of the first crushing surface by means of an hydraulic cylinder connected to said first crushing surface, the crusher system being characterised in that said hydraulic system further comprises an accumulator being connected to said hydraulic cylinder by means of a hydraulic liquid pipe, the accumulator comprising a hydraulic liquid compartment and a gas compartment being separated from the hydraulic liquid compartment, the accumulator being pre-loaded at a pre-loading pressure, being the pressure of the gas compartment when the hydraulic liquid compartment is empty, which is at least 0.3 MPa lower than the mean operating pressure of the hydraulic cylinder, such that the accumulator is active and variations occurring in the hydraulic pressure of the hydraulic cylinder during operation of the crusher system are attenuated.
  • An advantage of this crusher system is that the fatigue stresses on the crusher system can be substantially reduced, because the accumulator, being in hydraulic contact with the hydraulic cylinder during normal operation of the crusher system, is operative for attenuating almost all load changes, such that the load on the crusher system, and in particular the pressure in the hydraulic system, will vary much less compared to the prior art crusher system.
  • the preloading pressure of the accumulator is 0.3 to 1 MPa lower than the mean operating pressure of the hydraulic cylinder. Such a preloading pressure has been found to provide an efficient attenuation of the load on the crusher system, without negatively affecting the crushing of material in the crusher.
  • the natural oscillation frequency, ⁇ a of the accumulator fulfils the condition: ⁇ a > 10 * 2 ⁇ * f r wherein f r is the number of rounds per second of an eccentric operative to make at least one of the first and second crushing surfaces gyrate.
  • the natural frequency, ⁇ n of a system comprising the accumulator and the mass carried by the hydraulic cylinder fulfils the condition: ⁇ n > 4 ⁇ * f r wherein f r is the number of rounds per second of an eccentric operative to make at least one of the first and second crushing surfaces gyrate.
  • the crusher system comprises a control device, which is operative for controlling the preloading pressure of the accumulator in view of the actual mean operating pressure of the hydraulic cylinder.
  • This object is achieved by means of a method of crushing material between a first crushing surface and a second crushing surface, a hydraulic system being operative for adjusting a gap between the first crushing surface and the second crushing surface by adjusting the position of the first crushing surface by means of an hydraulic cylinder connected to said first crushing surface, the method being characterised in that variations occurring in the hydraulic pressure of the hydraulic cylinder are attenuated by means of an accumulator being in contact, via a hydraulic liquid, with said hydraulic cylinder, the accumulator comprising a hydraulic liquid compartment and a gas compartment being separated from the hydraulic liquid compartment, the accumulator being pre-loaded at a pre-loading pressure, being the pressure of the gas compartment when the hydraulic liquid compartment is empty, which is at least 0.3 MPa lower than the mean operating pressure of the hydraulic cylinder.
  • An advantage of this method is that the load variations influencing the crusher are attenuated by means of the accummulator. Thanks to this, the lifetime of a crusher can be increased, and/or the crusher can be operated at a higher mean operating
  • Fig. 1 is a schematic side view and illustrates a crusher system.
  • Fig. 2a-d are diagrams illustrating a hydraulic pressure, and the components thereof, in a prior art crusher.
  • Fig. 3 is a schematic side view and illustrates an accumulator.
  • Fig. 4a is a diagram and illustrates a pressure curve obtained when operating an accumulator with a high preloading pressure.
  • Fig. 4b is a diagram and illustrates a pressure curve obtained when operating an accumulator with a suitable preloading pressure.
  • Fig. 5a is a diagram and illustrates the relation between the volume and pressure of the gas of an accumulator.
  • Fig. 5b is a diagram and illustrates a situation in which the natural oscillation frequency of the accumulator is too low.
  • Fig. 5c is a diagram and illustrates a situation in which the natural oscillation frequency of the accumulator is suitable.
  • Fig. 6 is a schematic side view and illustrates a system formed by the interaction between an accumulator and the weight carried by a hydraulic cylinder.
  • Fig. 7a is a diagram and illustrates a situation in which a natural frequency of a system comprising said weight and the accumulator is too low.
  • Fig. 7b is a diagram and illustrates a situation in which a natural frequency of a system comprising said weight and the accumulator is suitable.
  • Fig. 1 illustrates a crusher system 1.
  • the crusher system 1 comprises a gyratory crusher 2, which is per se known in the prior art, see for example GB 1 517 963.
  • the gyratory crusher 2 comprises a crushing head 4, which supports a first crushing surface formed on a crushing mantle 6 and which is fixed to a vertical shaft 8.
  • the crushing head 4, being fixed to the vertical shaft 8, is movable in the vertical direction by means of a hydraulic cylinder 10 connected to the lower part of the shaft 8.
  • the hydraulic cylinder 10 makes it possible to adjust the width of a gap 12 formed between the crushing mantle 6 and a second crushing surface formed on a stationary crushing shell 14, which surrounds the crushing mantle 6.
  • the crusher system 1 further comprises a hydraulic system 16.
  • the hydraulic system 16 comprises a pump 18, which is operative for pumping hydraulic liquid to or from the hydraulic cylinder 10 via a pipe 20.
  • a dump valve 22 is operative for rapidly dumping hydraulic liquid from the hydraulic cylinder 10, in particular in situations when the gyratory crusher 2 becomes overloaded.
  • the dump valve 22 is operative for dumping the hydraulic liquid into a tank 24, which also serves as a pump sump for the pump 18.
  • the hydraulic system 16 also comprises an accumulator 26, which will be described in more detail hereinafter.
  • the crusher system 1 further comprises a control system 28.
  • the control system 28 comprises a control device 30 which is operative for receiving various signals indicating the operation of the gyratory crusher 2.
  • the control device 30 is operative for receiving a signal from a position sensor 32 which indicates the present vertical position of the vertical shaft 8. From this signal the width of the gap 12 can be calculated.
  • the control device 30 is operative for receiving a signal from a pressure sensor 34, indicating the hydraulic pressure in the hydraulic cylinder 10. Based on the signal from the pressure sensor 34 the control device 30 can calculate the actual mean operating pressure and the peak pressure of the gyratory crusher 2.
  • the control device 30 may also receive a signal from a power sensor 36, which is operative for measuring the power supplied to the gyratory crusher 2 from a motor 38, which is operative for making the vertical shaft 8 gyrate in a per se known manner.
  • the gyratory movement of the vertical shaft 8 is accomplished by the motor 38 driving an eccentric 39, which is arranged around the vertical shaft 8 in a per se known manner, and which is schematically illustrated in Fig. 1.
  • the power sensor 36 may also send a signal to the control device 30 indicating the number of rounds per second (in the unit 1/s or Hz), f r , of the eccentric 39.
  • the control device 30 is operative for controlling the operation of the pump 18, for example in an on/off manner, or in a proportional manner, such that the pump 18 supplies an amount of hydraulic liquid to the hydraulic cylinder 10 that generates a desired vertical position of the vertical shaft 8, and a desired width of the gap 12.
  • the control device 30 is also operative for controlling the opening of the dump valve 22.
  • High pressure peaks such as peaks caused by tramp entering the gap 12, are handled by the control device 30 sending a signal to the dump valve 22 to the extent that immediate opening is required.
  • High, and sudden, pressure peaks, caused by, e.g., tramp are handled by the control device 30 controlling the dump valve 22.
  • Fig. 2a illustrates, schematically, the hydraulic liquid pressure measured by a pressure sensor, similar to the sensor 34, when operating a gyratory crusher, which is similar to the gyratory crusher 2, in accordance with the teachings of the prior art.
  • the Y-axis of the diagram of Fig. 2a represents the pressure, P, in Pascal
  • the X-axis of the diagram represents the time, in seconds.
  • the total time span, which is illustrated in the diagram of Fig. 2a, is about 1 second.
  • Fig. 2b illustrates a first component of the pressure, namely the mean operating pressure.
  • a high mean operating pressure indicates an efficient operation of the gyratory crusher, meaning higher reduction ratios of rock size, and for that reason it is desired to keep the mean operating pressure as high as possible. Over the mean operating pressure other, unwanted, components are superimposed, as will be illustrated with reference to Fig. 2c and 2d.
  • Fig. 2c illustrates a second component of the pressure, namely what can be called the synchronous or sinusoidal component.
  • the sinusoidal component is caused by the gyratory movement of the vertical shaft, causing a sinusoidal component having the same frequency as the frequency of gyration of the vertical shaft.
  • the period of the sinusoidal component corresponds to one turn of the eccentric making the vertical shaft gyrate.
  • the sinusoidal component is mainly caused by an uneven distribution of the material fed to the crusher, geometric eccentricity of the crushing mantle and/or the crushing shell, etc.
  • the pressure will have a peak corresponding, in time, to occasions when the gap has, due to the gyratory movement of the vertical shaft, its most narrow width at said one side.
  • the peaks of the sinusoidal component indicated by a T in Fig. 2c, correspond to the highest pressure levels in the gyratory crusher, and result in the highest load on the gyratory crusher.
  • a control device controlling the operation of a prior art gyratory crusher is operative for controlling a hydraulic pump, which is similar to the pump 18, to supply a hydraulic operating pressure which is as high as possible, without causing damage to the gyratory crusher.
  • the peaks, T, of the sinusoidal component is normally what sets the upper limit for such a hydraulic operating pressure.
  • Fig. 2d illustrates a third component of the pressure, namely the high frequency component. This component is caused by the nature of the crushing process itself. As can be seen from Fig. 2d the amplitude of the third component is rather small compared to the second component illustrated with reference to Fig. 2c. However, since the three components are in reality added to each other, the third component adds also to the peaks of the sinusoidal component, thereby further increasing the pressure variation.
  • the present invention concerns a crusher system 1 in which the pressure variations caused by the second component, i.e., the synchronous or sinusoidal component, and the third component, i.e., the high frequency component, are minimized, and in which the first component, i.e., the mean operating pressure, can be maximized, such that the gyratory crusher 2 operates in an efficient manner, without being exposed to large fatigue stresses.
  • the second component i.e., the synchronous or sinusoidal component
  • the third component i.e., the high frequency component
  • the accumulator 26 has a special design to be operative for filtering out small and rapid pressure changes, pressure changes that cannot be handled by either the pump 18 or the dump valve 22. This function of the accumulator 26 has been made possible by a design of the accumulator 26, which will be described hereinafter and which provides for improved crushing efficiency and an increased life of the gyratory crusher 2, due to the reduced pressure variations.
  • Fig. 3 illustrates the accumulator 26 in more detail.
  • the accumulator 26 comprises an accumulator body 40 which is connected to the pipe 20, which has been described hereinbefore with reference to Fig. 1 , by means of a connecting pipe 42.
  • the accumulator body 40 has a flexible inner membrane 44 which separates a hydraulic liquid compartment 46 from a pressurized gas compartment 48.
  • the pipe 20 is connected to the hydraulic cylinder 10 illustrated hereinbefore with reference to Fig. 1.
  • a first parameter in the design of the accumulator 26 is the preloading pressure.
  • the pressurized gas compartment 48 is filled by a gas, which is often nitrogen gas, but which could also be air, or another gas.
  • the preloading pressure of the accumulator 26 is the pressure of the gas in the pressurized gas compartment 48 when the hydraulic liquid compartment 46 is completely empty.
  • the flexible inner membrane 44 will be forced, by the action of the pressurized gas, to the bottom of the accumulator body 40, i.e., towards the point were the connecting pipe 42 is connected to the accumulator body 40, and there will be basically no hydraulic liquid inside the accumulator body 40.
  • the pressure in the hydraulic system 16 is lower than the pre-loading pressure the accumulator 26 is not operating.
  • the preloading pressure is set to such a value that the accumulator 26 is active during operation of the gyratory crusher 2.
  • the preloading pressure is preferably at least 0.3 MPa lower than the lowest mean operating pressure of the gyratory crusher 2. In some cases, operation at the lowest mean operating pressure occurs only rarely. In such cases the preloading pressure could be set to be at least 0.3 MPa lower than the normal mean operating pressure of the gyratory crusher 2.
  • the preloading pressure should be 0.3-1.0 MPa lower than the lowest mean operating pressure, or 0.3-1.0 MPa lower than the normal mean operating pressure, as the case may be, of the gyratory crusher 2.
  • the gyratory crusher 2 would be operating at a mean operating pressure in the range of 3-5 MPa (absolute pressure), i.e., with a lowest mean operating pressure of 3 MPa (a), then the preloading pressure of the accumulator 26 should, for example, be maximum 2.7 MPa (a). If, on the other hand, operating at the lowest mean operating pressure of 3 MPa (a) is quite rare, and the crusher normally operates at a mean operating pressure of 4 MPa (a), then the preloading pressure of the accumulator 26 could be set to be maximum 3.7 MPa (a).
  • the accumulator 26 will, due to the set preloading pressure, be active to attenuate the pressure variations that more or less continuously occur in the hydraulic cylinder 10 due to the normal crushing process. Since the preloading pressure of the accumulator 26 is at least 0.3 MPa lower than the mean operating pressure, there will, during normal operation of the gyratory crusher 2, always be some hydraulic fluid in the hydraulic liquid compartment 46 of the accumulator 26, such that both increases and decreases in the hydraulic pressure of the hydraulic cylinder 10 can be attenuated. As illustrated in for example Fig.
  • valve or similar device arranged in the pipe 20 between the hydraulic cylinder 10 and the accumulator 26, which means that the accumulator 26 will be in continuous hydraulic fluid contact with the hydraulic cylinder 10 during normal crushing operation of the crusher system 1 and will be active to attenuate the normal pressure variations occurring in the hydraulic cylinder 10.
  • the preloading pressure of the accumulator 26 could be variable.
  • a supply 27 of pressurized nitrogen gas is schematically illustrated with dotted lines.
  • the control device 30 could be operative to control the supply 27 of pressurized nitrogen gas to supply a suitable nitrogen pressure to the pressurized gas compartment 48 of the accumulator 26.
  • the control device 30 could be operative for controlling the preloading pressure of the accumulator 26, such that the preloading pressure is always below the actual mean operating pressure at that specific occasion.
  • control device 30 calculates, based on information from the pressure sensor 34, that the mean operating pressure is 4 MPa (a), then it could order the supply 27 of pressurized nitrogen gas to supply a preloading pressure of 3.5 MPa (a) to the accumulator 26.
  • the control device 30 calculates the mean operating pressure to be 3.7 MPa (a), and then orders the supply 27 of pressurized nitrogen gas to supply a preloading pressure of 3.2 MPa (a) to the accumulator 26.
  • the control device 30 would, in accordance with this option, ensure that the preloading pressure of the accumulator 26 is always lower than the mean operating pressure, and is suitable for the mean operating pressure in question.
  • a further option includes a shut-off in the connecting pipe 42, such that the accumulator 26 could be taken off line temporarily when the pressure in the hydraulic system 16 is too low, "too low” meaning that the pressure in the hydraulic system 16 is almost equal to, or lower than, the preloading pressure of the accumulator 26, to avoid that the flexible inner membrane 44 of the accumulator 26 keeps hitting the bottom of the accumulator body 40 causing a risk of damage to the membrane 44.
  • Fig. 4a illustrates the hydraulic liquid pressure curve P resulting from operation with an accumulator having a preloading pressure PP which is higher than the actual mean operating pressure M of the crusher. As compared to the pressure curve illustrated in Fig. 2a, the highest peaks are cut by means of this accumulator, but the pressure still varies considerably.
  • Fig. 4b illustrates the hydraulic liquid pressure curve P resulting from operation with the accumulator 26, illustrated in Fig. 1 , having a preloading pressure PP that is about 0.5 MPa lower than the lowest mean operating pressure LM, in accordance with the principles of preferred preloading pressures, as described hereinbefore. At the occasion illustrated in Fig. 4b the actual mean operating pressure M is higher than the lowest mean operating pressure LM.
  • the accumulator 26 has a very quick response to pressure variations. By this is meant that variations in the volume of hydraulic liquid in the accumulator 26 must occur as soon as possible after a pressure variation has occurred in the hydraulic cylinder 10, which has been described hereinbefore with reference to Fig. 1.
  • the natural oscillation frequency of the accumulator 26 depends on the mass of hydraulic liquid inside the accumulator body 40 and in the connecting pipe 42, both of which have been illustrated hereinbefore with reference to Fig. 3, and the spring constant of the accumulator 26 at the working point.
  • the natural oscillation frequency of the accumulator 26 should be substantially higher than the frequency of rotation of the eccentric 39, illustrated hereinbefore with reference to Fig. 1.
  • the natural oscillation frequency of the accumulator 26 can be calculated based on the following equation:
  • cog natural oscillation frequency of accumulator 26 including connecting pipe 42, unit: [rad /s]
  • ⁇ P/ ⁇ V the rate of variation of pressure with respect to the variation of gas volume in the accumulator at a certain mean pressure, unit: [Pa/m 3 ]
  • Fig. 5a illustrates the relation between the volume of gas in the gas compartment 48 of the accumulator 26, and the pressure of the gas in the gas compartment 48.
  • the x-axis is the volume of gas in m 3
  • the y-axis is the pressure in Pa.
  • the solid curve illustrates the relation between the pressure and the volume of the gas in the gas compartment 48.
  • the preloading pressure has been marked at the right of the curve. At the preloading pressure the volume of gas in the gas compartment 48 is maximal.
  • the expression ⁇ P/ ⁇ V of eq. 1.1 above is calculated as the derivative of the volume/pressure curve of Fig. 5a at the mean pressure. This derivative is illustrated as a straight dotted line in Fig. 5a.
  • ⁇ P/ ⁇ V is to some extent dependent on the mean operating pressure.
  • ⁇ P/ ⁇ V is preferably calculated at a mean operating pressure of 4 MPa.
  • the natural oscillation frequency of the accumulator 26 is designed to fulfil the following condition:
  • oo a natural oscillation frequency of accumulator 26 including connecting pipe 42, unit: [rad/s]
  • f r number of rounds per second of eccentric 39, see Fig. 1 , unit: [Hz].
  • the natural oscillation frequency ⁇ a in rad/s of the accumulator 26 is designed to be at least 10 times higher than the frequency of rotation (calculated as the number of rounds per second multiplied by 2 ⁇ ), in rad/s, of the eccentric 39, i.e., to be at least 10 times higher than the frequency of gyration of the vertical shaft 8 in rad/s.
  • the number of rounds per second of the eccentric 39 would typically be 3-7 rounds per second.
  • Fig. 5b illustrates a situation in which the natural oscillation frequency ⁇ a of the accumulator 26 is too low, i.e., considerably lower than 10 times the frequency of rotation of the eccentric 39, in rad/s.
  • the actual operating pressure P swings considerably around the mean operating pressure M.
  • Fig. 5c illustrates a situation in which the natural oscillation frequency ⁇ a of the accumulator 26 fulfils the requirement of eq. 1.2.
  • the operating pressure P is, in Fig. 5c, all the time rather close to the mean operating pressure M.
  • a further condition for obtaining a short response time of the accumulator 26 is that the accumulator 26 should be arranged close to the hydraulic cylinder 10. The following condition should be fulfilled:
  • v velocity of sound in hydraulic liquid, unit: [m/s].
  • f r number of rounds per second of the eccentric, see Fig. 1 , unit: [Hz].
  • the distance L is also illustrated schematically in Fig. 1.
  • a pressure wave generated in the hydraulic cylinder 10 has a finite velocity it will take some time for the accumulator 26 to respond to a pressure variation occurring in the hydraulic cylinder 10, thereby causing a response delay.
  • the equation 2.1 specifies a design which provides for a small response delay, and, thus, a quick reaction of the accumulator 26 to pressure variations occurring in the hydraulic.
  • Fig. 6 illustrates, schematically, a system formed by the accumulator
  • the accumulator 26 is in continuous hydraulic fluid contact with the hydraulic cylinder 10 during normal crushing operation in the crusher system and will be active to attenuate the normal pressure variations occurring in the hydraulic cylinder 10.
  • the crusher system 1 of Fig. 1 should be designed to avoid oscillation of the system formed by the interaction between the accumulator 26 and the vertical shaft 8.
  • a force F is generated by the crushing of material in the gyratory crusher. This force acts on the vertical shaft 8, which in turn co-operates with the hydraulic cylinder 10.
  • the force F has a sinusoidal component at the frequency of rotation of the eccentric 39, as illustrated hereinbefore in Fig. 2c. If the natural frequency of the system formed by the vertical shaft 8, the crushing head 4, the crushing mantle 6, the hydraulic cylinder 10, the accumulator 26, and the pipes 20, 42, is too low, and close to the frequency of rotation of the eccentric 39, i.e., too close to the frequency of gyration of the vertical shaft 8, then there is a risk of resonance of the system, resulting in big oscillations.
  • the natural frequency of the system can be calculated in the following way:
  • CG n natural frequency of the system including the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26, unit: [rad/s].
  • a h section area of the piston of the hydraulic cylinder 10, see Fig. 6, unit: [m 2 ].
  • M total mass of vertical shaft 8, crushing head 4, and crushing mantle 6, unit [kg].
  • ⁇ P/ ⁇ V pressure-volume variation due to accumulator 26, as explained hereinbefore with reference to Fig. 5a, unit: [Pa/m 3 ].
  • the natural oscillation frequency of the system including the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26 is designed to fulfil the following condition:
  • CO n natural frequency of the system including the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26, unit [rad/s].
  • f r number of rounds per second of the eccentric 39, see Fig. 1 , unit: [Hz].
  • the natural frequency ⁇ n of the system comprising the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26 is designed to be about 2 times higher than the frequency of rotation (calculated as the number of rounds per second multiplied by 2 ⁇ ) of the eccentric 39, in rad/s, i.e., to be about 2 times higher than the frequency of gyration of the vertical shaft 8, in rad/s.
  • Fig. 7a illustrates a situation in which the natural frequency ⁇ n of the system comprising the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26 is too low, i.e., considerably lower than 2 times the frequency of rotation of the eccentric 39, in rad/s.
  • the actual operating pressure P swings considerably around the mean operating pressure M.
  • the operating pressure swings more with such a wrongly designed accumulator illustrated with reference to Fig. 7a, due a resonance phenomenon, than the case in which no accumulator at all is used, as illustrated in Fig. 2a.
  • Fig. 7b illustrates a situation in which the natural oscillation frequency ⁇ n of the system comprising the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26 fulfils the requirement of eq. 3.2.
  • Fig. 7a there is in Fig. 7b no resonance at all, and the sinusoidal component illustrated hereinbefore with reference to Fig. 2c, has been almost completely dampened.
  • the operating pressure P is all the time rather close to the mean operating pressure M.
  • the accumulator 26 With a proper design of the accumulator 26, in accordance with the conditions described hereinbefore, it will work as a spring that attenuates pressure variations.
  • the pressure in the hydraulic cylinder 10 tends to fluctuate, as described hereinbefore with reference to Fig. 2a to 2d.
  • Pressure peaks in the hydraulic cylinder 10 are attenuated by hydraulic liquid flowing from the hydraulic cylinder 10 to the accumulator 26.
  • Pressure drops in the hydraulic cylinder 10 are attenuated by hydraulic liquid flowing from the accumulator 26 to the hydraulic cylinder 10.
  • the pressure in the hydraulic cylinder 10 is kept more even, compared to the prior art.
  • the volume of the accumulator 26 has not been described in detail.
  • the volume of the accumulator 26 depends on the volume of hydraulic liquid that will enter, or leave, the accumulator 26 when the accumulator 26 attenuates pressure variations.
  • the volume of the accumulator 26 will depend on the size of the crusher, and the expected magnitude of the pressure variations that are to be attenuated.
  • a person skilled in the art could find, by routine experimentation, a suitable volume of the accumulator for a certain type of crusher.
  • the accumulator 26 results, as described hereinbefore, in a more even pressure in the hydraulic cylinder 10, which results in an increased crusher life, due to decreased fatigue stresses on the gyratory crusher 2. It is also possible, as alternative to increased life, or in combination therewith, to operate the gyratory crusher 2 at a higher mean operating pressure, resulting in an increased crushing efficiency of the gyratory crusher 2.
  • the heavy and sudden pressure changes are handled by the dump valve 22, as mentioned hereinbefore.
  • the dump valve 22 could be an automatic valve that opens automatically at a certain pressure.
  • the control device 30 would then, preferably, be designed to, in addition to the above mentioned function of opening the dump valve 22 in situations when the pressure in the hydraulic liquid is over a preset pressure, opening the dump valve 22 when the width of the gap 12 is under a preset limit, such that the hydraulic liquid from the accumulator 26 is dumped to the tank 24, instead of being forwarded to the hydraulic cylinder 10, in such situations when the vertical shaft 8 tends to move upwards.
  • the accumulator 26 is in continuous hydraulic fluid contact with the hydraulic cylinder 10 to be active for attenuating pressure variations occurring during normal crushing operation.
  • the accumulator 26 is directly coupled to the hydraulic cylinder 10, and there is no valve arranged in the pipe 20 between the hydraulic cylinder 10 and the accumulator 26.
  • a shut-off valve could be arranged in this pipe 20, or more preferably in the connecting pipe 42, for the purpose of isolating the accumulator 26 from the hydraulic system 16 when service or repair needs to be done to the accumulator 26.
  • a shut-off valve could be arranged in this pipe 20, or more preferably in the connecting pipe 42, for the purpose of isolating the accumulator 26 from the hydraulic system 16 when service or repair needs to be done to the accumulator 26.
  • there is no attenuating function of the accumulator 26 meaning that periods of having such a shut-off valve shut should be kept as short as possible.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Food Science & Technology (AREA)
  • Crushing And Grinding (AREA)
  • Disintegrating Or Milling (AREA)
  • Percussive Tools And Related Accessories (AREA)
  • Supply Devices, Intensifiers, Converters, And Telemotors (AREA)

Abstract

A crusher system (1) comprises a first crushing surface (6) and a second crushing surface (14), the two crushing surfaces (6, 14) being operative for crushing material between them. The crusher system (1) further comprises a hydraulic system (16) which is operative for adjusting a gap (12) between the first crushing surface (6) and the second crushing surface (14) by adjusting the position of the first crushing surface (6) by means of an hydraulic cylinder (10) connected to said first crushing surface (6). The hydraulic system (16) further comprises an accumulator (26) being connected to said hydraulic cylinder (10) by means of a hydraulic liquid pipe (20, 42). The accumulator (26) has a preloading pressure, which is at least 0.3 MPa lower than the mean operating pressure of the hydraulic cylinder (10).

Description

ATTENUATION OF PRESSURE VARIATIONS IN CRUSHERS
Technical Field of the Invention
The present invention relates to a crusher system comprising a first crushing surface and a second crushing surface, the two crushing surfaces being operative for crushing material between them, the crusher system further comprising a hydraulic system which is operative for adjusting a gap between the first crushing surface and the second crushing surface by adjusting the position of the first crushing surface by means of an hydraulic cylinder connected to said first crushing surface. The present invention further relates to a method of crushing material between a first crushing surface and a second crushing surface.
Background Art
Crushers are utilized in many applications for crushing hard material, such as rocks, ore, etc. One type of crusher is the gyratory crusher, which has a crushing head which is forced to gyrate inside a fixed crushing shell. A crushing chamber, into which pieces of rock are to be fed, is formed between a crushing mantle, which is supported by the crushing head, and the crushing shell. The width of the crushing chamber, often referred to as the gap or the setting of the crusher, may be adjusted by means of a hydraulic arrangement. During the crushing of rock, ore etc. the crusher is subjected to large load variations. Such load variations causes wear, including metal fatigue, in the crusher, and may decrease the life of the crusher. GB 1 517 963 discloses a gyratory crusher having a hydraulic cylinder or an air cylinder for preventing overload situations. A pressure buffer is operative for accommodating sudden heavy load changes in the hydraulic system. The pressure buffer is connected to the hydraulic system and by a point of constriction provided between the cylinder and the pressure buffer.
While the pressure buffer of GB 1 517 963 may be operative for reducing the negative effects of sudden heavy load changes, it is not effective for reducing the normal load variations that cause fatigue failure in the crusher.
Summary of the Invention
It is an object of the present invention to provide a crusher system in which the risks of fatigue failure is reduced.
It is a further object of the present invention to provide a crusher system in which the load can be increased, without decreasing the lifetime of the crusher.
These objects are achieved with a crusher system comprising a first crushing surface and a second crushing surface, the two crushing surfaces being operative for crushing material between them, the crusher system further comprising a hydraulic system which is operative for adjusting a gap between the first crushing surface and the second crushing surface by adjusting the position of the first crushing surface by means of an hydraulic cylinder connected to said first crushing surface, the crusher system being characterised in that said hydraulic system further comprises an accumulator being connected to said hydraulic cylinder by means of a hydraulic liquid pipe, the accumulator comprising a hydraulic liquid compartment and a gas compartment being separated from the hydraulic liquid compartment, the accumulator being pre-loaded at a pre-loading pressure, being the pressure of the gas compartment when the hydraulic liquid compartment is empty, which is at least 0.3 MPa lower than the mean operating pressure of the hydraulic cylinder, such that the accumulator is active and variations occurring in the hydraulic pressure of the hydraulic cylinder during operation of the crusher system are attenuated.
An advantage of this crusher system is that the fatigue stresses on the crusher system can be substantially reduced, because the accumulator, being in hydraulic contact with the hydraulic cylinder during normal operation of the crusher system, is operative for attenuating almost all load changes, such that the load on the crusher system, and in particular the pressure in the hydraulic system, will vary much less compared to the prior art crusher system. According to one embodiment of the present invention the preloading pressure of the accumulator is 0.3 to 1 MPa lower than the mean operating pressure of the hydraulic cylinder. Such a preloading pressure has been found to provide an efficient attenuation of the load on the crusher system, without negatively affecting the crushing of material in the crusher. According to one embodiment of the present invention the natural oscillation frequency, ωa, of the accumulator fulfils the condition: ωa > 10*2π*fr wherein fr is the number of rounds per second of an eccentric operative to make at least one of the first and second crushing surfaces gyrate. An advantage of this embodiment is that the response of the accumulator is very quick, such that it can respond to very quick load changes.
According to one embodiment of the present invention the distance L, as seen along the hydraulic liquid path, between the hydraulic cylinder and the accumulator, fulfils the condition: L <= v /(20* fr) wherein v is the velocity of sound in the hydraulic liquid, and fr is the number of rounds per second of an eccentric operative to make at least one of the first and second crushing surfaces gyrate. An advantage of this embodiment is that the response of the accumulator to load changes is not delayed by a long time for these load changes to influence the accumulator.
According to one embodiment of the present invention the natural frequency, ωn, of a system comprising the accumulator and the mass carried by the hydraulic cylinder fulfils the condition: ωn > 4π*fr wherein fr is the number of rounds per second of an eccentric operative to make at least one of the first and second crushing surfaces gyrate. An advantage of this embodiment is that resonance related problems in the attenuation of pressure variations is avoided.
According to one embodiment the crusher system comprises a control device, which is operative for controlling the preloading pressure of the accumulator in view of the actual mean operating pressure of the hydraulic cylinder. An advantage of this embodiment is that the preloading pressure can be varied to be suitable for the actual operating conditions of the crusher. It is a still further object of the present invention to provide a method of crushing material, by means of which method the fatigue stresses on the crusher can be reduced.
This object is achieved by means of a method of crushing material between a first crushing surface and a second crushing surface, a hydraulic system being operative for adjusting a gap between the first crushing surface and the second crushing surface by adjusting the position of the first crushing surface by means of an hydraulic cylinder connected to said first crushing surface, the method being characterised in that variations occurring in the hydraulic pressure of the hydraulic cylinder are attenuated by means of an accumulator being in contact, via a hydraulic liquid, with said hydraulic cylinder, the accumulator comprising a hydraulic liquid compartment and a gas compartment being separated from the hydraulic liquid compartment, the accumulator being pre-loaded at a pre-loading pressure, being the pressure of the gas compartment when the hydraulic liquid compartment is empty, which is at least 0.3 MPa lower than the mean operating pressure of the hydraulic cylinder. An advantage of this method is that the load variations influencing the crusher are attenuated by means of the accummulator. Thanks to this, the lifetime of a crusher can be increased, and/or the crusher can be operated at a higher mean operating pressure.
These and other aspects of the invention will be apparent from and elucidated with reference to the claims and the embodiments described hereinafter.
Brief Description of the Drawings
The invention will hereafter be described in more detail and with reference to the appended drawings.
Fig. 1 is a schematic side view and illustrates a crusher system. Fig. 2a-d are diagrams illustrating a hydraulic pressure, and the components thereof, in a prior art crusher.
Fig. 3 is a schematic side view and illustrates an accumulator. Fig. 4a is a diagram and illustrates a pressure curve obtained when operating an accumulator with a high preloading pressure.
Fig. 4b is a diagram and illustrates a pressure curve obtained when operating an accumulator with a suitable preloading pressure.
Fig. 5a is a diagram and illustrates the relation between the volume and pressure of the gas of an accumulator.
Fig. 5b is a diagram and illustrates a situation in which the natural oscillation frequency of the accumulator is too low.
Fig. 5c is a diagram and illustrates a situation in which the natural oscillation frequency of the accumulator is suitable. Fig. 6 is a schematic side view and illustrates a system formed by the interaction between an accumulator and the weight carried by a hydraulic cylinder.
Fig. 7a is a diagram and illustrates a situation in which a natural frequency of a system comprising said weight and the accumulator is too low. Fig. 7b is a diagram and illustrates a situation in which a natural frequency of a system comprising said weight and the accumulator is suitable.
Detailed Description of Preferred Embodiments of the Invention Fig. 1 illustrates a crusher system 1. The crusher system 1 comprises a gyratory crusher 2, which is per se known in the prior art, see for example GB 1 517 963. The gyratory crusher 2 comprises a crushing head 4, which supports a first crushing surface formed on a crushing mantle 6 and which is fixed to a vertical shaft 8. The crushing head 4, being fixed to the vertical shaft 8, is movable in the vertical direction by means of a hydraulic cylinder 10 connected to the lower part of the shaft 8. The hydraulic cylinder 10 makes it possible to adjust the width of a gap 12 formed between the crushing mantle 6 and a second crushing surface formed on a stationary crushing shell 14, which surrounds the crushing mantle 6. The crusher system 1 further comprises a hydraulic system 16. The hydraulic system 16 comprises a pump 18, which is operative for pumping hydraulic liquid to or from the hydraulic cylinder 10 via a pipe 20. A dump valve 22 is operative for rapidly dumping hydraulic liquid from the hydraulic cylinder 10, in particular in situations when the gyratory crusher 2 becomes overloaded. The dump valve 22 is operative for dumping the hydraulic liquid into a tank 24, which also serves as a pump sump for the pump 18. The hydraulic system 16 also comprises an accumulator 26, which will be described in more detail hereinafter.
The crusher system 1 further comprises a control system 28. The control system 28 comprises a control device 30 which is operative for receiving various signals indicating the operation of the gyratory crusher 2. Thus, the control device 30 is operative for receiving a signal from a position sensor 32 which indicates the present vertical position of the vertical shaft 8. From this signal the width of the gap 12 can be calculated. Furthermore, the control device 30 is operative for receiving a signal from a pressure sensor 34, indicating the hydraulic pressure in the hydraulic cylinder 10. Based on the signal from the pressure sensor 34 the control device 30 can calculate the actual mean operating pressure and the peak pressure of the gyratory crusher 2. The control device 30 may also receive a signal from a power sensor 36, which is operative for measuring the power supplied to the gyratory crusher 2 from a motor 38, which is operative for making the vertical shaft 8 gyrate in a per se known manner. The gyratory movement of the vertical shaft 8 is accomplished by the motor 38 driving an eccentric 39, which is arranged around the vertical shaft 8 in a per se known manner, and which is schematically illustrated in Fig. 1. The power sensor 36 may also send a signal to the control device 30 indicating the number of rounds per second (in the unit 1/s or Hz), fr, of the eccentric 39. The control device 30 is operative for controlling the operation of the pump 18, for example in an on/off manner, or in a proportional manner, such that the pump 18 supplies an amount of hydraulic liquid to the hydraulic cylinder 10 that generates a desired vertical position of the vertical shaft 8, and a desired width of the gap 12. The control device 30 is also operative for controlling the opening of the dump valve 22. High pressure peaks, such as peaks caused by tramp entering the gap 12, are handled by the control device 30 sending a signal to the dump valve 22 to the extent that immediate opening is required. Thus, in the crusher system 1 long term variations in the hydraulic pressure, e.g., variations that occur over time spans of 1 second and more, are handled by the control device 30 controlling the pump 18. High, and sudden, pressure peaks, caused by, e.g., tramp, are handled by the control device 30 controlling the dump valve 22.
Fig. 2a illustrates, schematically, the hydraulic liquid pressure measured by a pressure sensor, similar to the sensor 34, when operating a gyratory crusher, which is similar to the gyratory crusher 2, in accordance with the teachings of the prior art. The Y-axis of the diagram of Fig. 2a represents the pressure, P, in Pascal, and the X-axis of the diagram represents the time, in seconds. The total time span, which is illustrated in the diagram of Fig. 2a, is about 1 second. When analysing the pressure curve of Fig. 2a it has been found that it comprises three components.
Fig. 2b illustrates a first component of the pressure, namely the mean operating pressure. A high mean operating pressure indicates an efficient operation of the gyratory crusher, meaning higher reduction ratios of rock size, and for that reason it is desired to keep the mean operating pressure as high as possible. Over the mean operating pressure other, unwanted, components are superimposed, as will be illustrated with reference to Fig. 2c and 2d.
Fig. 2c illustrates a second component of the pressure, namely what can be called the synchronous or sinusoidal component. The sinusoidal component is caused by the gyratory movement of the vertical shaft, causing a sinusoidal component having the same frequency as the frequency of gyration of the vertical shaft. Hence, the period of the sinusoidal component corresponds to one turn of the eccentric making the vertical shaft gyrate. The sinusoidal component is mainly caused by an uneven distribution of the material fed to the crusher, geometric eccentricity of the crushing mantle and/or the crushing shell, etc. If, for example, most of the material to be crushed is fed to one side of the gap, then the pressure will have a peak corresponding, in time, to occasions when the gap has, due to the gyratory movement of the vertical shaft, its most narrow width at said one side. The peaks of the sinusoidal component, indicated by a T in Fig. 2c, correspond to the highest pressure levels in the gyratory crusher, and result in the highest load on the gyratory crusher. A control device controlling the operation of a prior art gyratory crusher is operative for controlling a hydraulic pump, which is similar to the pump 18, to supply a hydraulic operating pressure which is as high as possible, without causing damage to the gyratory crusher. The peaks, T, of the sinusoidal component is normally what sets the upper limit for such a hydraulic operating pressure.
Fig. 2d illustrates a third component of the pressure, namely the high frequency component. This component is caused by the nature of the crushing process itself. As can be seen from Fig. 2d the amplitude of the third component is rather small compared to the second component illustrated with reference to Fig. 2c. However, since the three components are in reality added to each other, the third component adds also to the peaks of the sinusoidal component, thereby further increasing the pressure variation. The present invention concerns a crusher system 1 in which the pressure variations caused by the second component, i.e., the synchronous or sinusoidal component, and the third component, i.e., the high frequency component, are minimized, and in which the first component, i.e., the mean operating pressure, can be maximized, such that the gyratory crusher 2 operates in an efficient manner, without being exposed to large fatigue stresses.
In the crusher system 1 the accumulator 26 has a special design to be operative for filtering out small and rapid pressure changes, pressure changes that cannot be handled by either the pump 18 or the dump valve 22. This function of the accumulator 26 has been made possible by a design of the accumulator 26, which will be described hereinafter and which provides for improved crushing efficiency and an increased life of the gyratory crusher 2, due to the reduced pressure variations.
Fig. 3 illustrates the accumulator 26 in more detail. The accumulator 26 comprises an accumulator body 40 which is connected to the pipe 20, which has been described hereinbefore with reference to Fig. 1 , by means of a connecting pipe 42. The accumulator body 40 has a flexible inner membrane 44 which separates a hydraulic liquid compartment 46 from a pressurized gas compartment 48. The pipe 20 is connected to the hydraulic cylinder 10 illustrated hereinbefore with reference to Fig. 1. Thus, the pressure changes occurring in the hydraulic cylinder 10 as a result of the crushing of material in the gyratory crusher 2 will propagate through the pipe 20 and further through the connecting pipe 42 and will influence the hydraulic liquid compartment 46 of the accumulator body 40.
A first parameter in the design of the accumulator 26 is the preloading pressure. The pressurized gas compartment 48 is filled by a gas, which is often nitrogen gas, but which could also be air, or another gas. The preloading pressure of the accumulator 26 is the pressure of the gas in the pressurized gas compartment 48 when the hydraulic liquid compartment 46 is completely empty. When the preloading pressure has been applied to the pressurized gas compartment 48 and the hydraulic liquid compartment 46 is at a lower pressure than the preloading pressure, the flexible inner membrane 44 will be forced, by the action of the pressurized gas, to the bottom of the accumulator body 40, i.e., towards the point were the connecting pipe 42 is connected to the accumulator body 40, and there will be basically no hydraulic liquid inside the accumulator body 40. Hence, when the pressure in the hydraulic system 16 is lower than the pre-loading pressure the accumulator 26 is not operating.
The preloading pressure is set to such a value that the accumulator 26 is active during operation of the gyratory crusher 2. Thus, the preloading pressure is preferably at least 0.3 MPa lower than the lowest mean operating pressure of the gyratory crusher 2. In some cases, operation at the lowest mean operating pressure occurs only rarely. In such cases the preloading pressure could be set to be at least 0.3 MPa lower than the normal mean operating pressure of the gyratory crusher 2. Preferably, the preloading pressure should be 0.3-1.0 MPa lower than the lowest mean operating pressure, or 0.3-1.0 MPa lower than the normal mean operating pressure, as the case may be, of the gyratory crusher 2. Thus, if the gyratory crusher 2 would be operating at a mean operating pressure in the range of 3-5 MPa (absolute pressure), i.e., with a lowest mean operating pressure of 3 MPa (a), then the preloading pressure of the accumulator 26 should, for example, be maximum 2.7 MPa (a). If, on the other hand, operating at the lowest mean operating pressure of 3 MPa (a) is quite rare, and the crusher normally operates at a mean operating pressure of 4 MPa (a), then the preloading pressure of the accumulator 26 could be set to be maximum 3.7 MPa (a). As is clear from the above, the accumulator 26 will, due to the set preloading pressure, be active to attenuate the pressure variations that more or less continuously occur in the hydraulic cylinder 10 due to the normal crushing process. Since the preloading pressure of the accumulator 26 is at least 0.3 MPa lower than the mean operating pressure, there will, during normal operation of the gyratory crusher 2, always be some hydraulic fluid in the hydraulic liquid compartment 46 of the accumulator 26, such that both increases and decreases in the hydraulic pressure of the hydraulic cylinder 10 can be attenuated. As illustrated in for example Fig. 1 there is no valve or similar device arranged in the pipe 20 between the hydraulic cylinder 10 and the accumulator 26, which means that the accumulator 26 will be in continuous hydraulic fluid contact with the hydraulic cylinder 10 during normal crushing operation of the crusher system 1 and will be active to attenuate the normal pressure variations occurring in the hydraulic cylinder 10.
In accordance with an alternative embodiment, also illustrated with reference to Fig. 1 , the preloading pressure of the accumulator 26 could be variable. In Fig. 1 a supply 27 of pressurized nitrogen gas is schematically illustrated with dotted lines. The control device 30 could be operative to control the supply 27 of pressurized nitrogen gas to supply a suitable nitrogen pressure to the pressurized gas compartment 48 of the accumulator 26. Hence, the control device 30 could be operative for controlling the preloading pressure of the accumulator 26, such that the preloading pressure is always below the actual mean operating pressure at that specific occasion. For example, if the control device 30 calculates, based on information from the pressure sensor 34, that the mean operating pressure is 4 MPa (a), then it could order the supply 27 of pressurized nitrogen gas to supply a preloading pressure of 3.5 MPa (a) to the accumulator 26. At another occasion the control device 30 calculates the mean operating pressure to be 3.7 MPa (a), and then orders the supply 27 of pressurized nitrogen gas to supply a preloading pressure of 3.2 MPa (a) to the accumulator 26. Hence, irrespective of the actual mean operating pressure, the control device 30 would, in accordance with this option, ensure that the preloading pressure of the accumulator 26 is always lower than the mean operating pressure, and is suitable for the mean operating pressure in question. It will be appreciated that changes in the preloading pressure would normally be made before starting operation of the crusher 2. However, changes in the preloading pressure could also be performed during operation of the gyratory crusher 2, in which case the control device 30 would have to account for the fact that the hydraulic liquid is at a higher than atmospheric pressure when determining the gas pressure to be supplied to the pressurized gas compartment 48 of the accumulator 26. A further option includes a shut-off in the connecting pipe 42, such that the accumulator 26 could be taken off line temporarily when the pressure in the hydraulic system 16 is too low, "too low" meaning that the pressure in the hydraulic system 16 is almost equal to, or lower than, the preloading pressure of the accumulator 26, to avoid that the flexible inner membrane 44 of the accumulator 26 keeps hitting the bottom of the accumulator body 40 causing a risk of damage to the membrane 44.
Fig. 4a illustrates the hydraulic liquid pressure curve P resulting from operation with an accumulator having a preloading pressure PP which is higher than the actual mean operating pressure M of the crusher. As compared to the pressure curve illustrated in Fig. 2a, the highest peaks are cut by means of this accumulator, but the pressure still varies considerably. Fig. 4b illustrates the hydraulic liquid pressure curve P resulting from operation with the accumulator 26, illustrated in Fig. 1 , having a preloading pressure PP that is about 0.5 MPa lower than the lowest mean operating pressure LM, in accordance with the principles of preferred preloading pressures, as described hereinbefore. At the occasion illustrated in Fig. 4b the actual mean operating pressure M is higher than the lowest mean operating pressure LM. As can be seen from a reference to Fig. 4b the accumulator 26 results in very smooth appearance of the hydraulic liquid pressure curve P. Such smooth pressure behaviour decreases the fatigue stresses on the gyratory crusher 2, and also makes it possible to operate at a higher mean operating pressure, without exceeding the maximum pressure limits.
To obtain a suitable operation of the accumulator 26 it is also preferable that the accumulator 26 has a very quick response to pressure variations. By this is meant that variations in the volume of hydraulic liquid in the accumulator 26 must occur as soon as possible after a pressure variation has occurred in the hydraulic cylinder 10, which has been described hereinbefore with reference to Fig. 1. The natural oscillation frequency of the accumulator 26 depends on the mass of hydraulic liquid inside the accumulator body 40 and in the connecting pipe 42, both of which have been illustrated hereinbefore with reference to Fig. 3, and the spring constant of the accumulator 26 at the working point. The natural oscillation frequency of the accumulator 26 should be substantially higher than the frequency of rotation of the eccentric 39, illustrated hereinbefore with reference to Fig. 1. The natural oscillation frequency of the accumulator 26 can be calculated based on the following equation:
Figure imgf000014_0001
The following parameters are included in this equation: cog = natural oscillation frequency of accumulator 26 including connecting pipe 42, unit: [rad /s]
Ap = section area of the connecting pipe 42, see Fig. 3, unit: [m2] m = mass of hydraulic liquid in connecting pipe 42 including the hydraulic liquid in the liquid compartment 46, unit: [kg]
ΔP/ΔV= the rate of variation of pressure with respect to the variation of gas volume in the accumulator at a certain mean pressure, unit: [Pa/m3]
Fig. 5a illustrates the relation between the volume of gas in the gas compartment 48 of the accumulator 26, and the pressure of the gas in the gas compartment 48. Hence, the x-axis is the volume of gas in m3, and the y-axis is the pressure in Pa. The solid curve illustrates the relation between the pressure and the volume of the gas in the gas compartment 48. The preloading pressure has been marked at the right of the curve. At the preloading pressure the volume of gas in the gas compartment 48 is maximal. The expression ΔP/ΔV of eq. 1.1 above is calculated as the derivative of the volume/pressure curve of Fig. 5a at the mean pressure. This derivative is illustrated as a straight dotted line in Fig. 5a. Hence, the expression ΔP/ΔV is to some extent dependent on the mean operating pressure. When calculating coa in accordance with eq. 1.1 it is normally best to calculate ΔP/ΔV at a mean operating pressure which lays between the maximum and minimum mean operating pressures at which the crusher will normally operate. Hence, if the crusher may operate at mean operating pressures of 3-5 MPa, the ΔP/ΔV is preferably calculated at a mean operating pressure of 4 MPa.
The natural oscillation frequency of the accumulator 26 is designed to fulfil the following condition:
ωa > 10*2π*fr [eq. 1.2]
The following parameters are included in this equation: ooa = natural oscillation frequency of accumulator 26 including connecting pipe 42, unit: [rad/s] fr = number of rounds per second of eccentric 39, see Fig. 1 , unit: [Hz].
Hence, the natural oscillation frequency ωa in rad/s of the accumulator 26 is designed to be at least 10 times higher than the frequency of rotation (calculated as the number of rounds per second multiplied by 2π), in rad/s, of the eccentric 39, i.e., to be at least 10 times higher than the frequency of gyration of the vertical shaft 8 in rad/s. In the gyratory crusher 2, the number of rounds per second of the eccentric 39 would typically be 3-7 rounds per second.
Fig. 5b illustrates a situation in which the natural oscillation frequency ωa of the accumulator 26 is too low, i.e., considerably lower than 10 times the frequency of rotation of the eccentric 39, in rad/s. As can be seen from Fig. 5b the actual operating pressure P swings considerably around the mean operating pressure M.
Fig. 5c illustrates a situation in which the natural oscillation frequency ωa of the accumulator 26 fulfils the requirement of eq. 1.2. As can be seen from a comparison with Fig. 5b, there is in Fig. 5c almost no trace of the sinusoidal shape that is rather marked in Fig. 5b. Thus, the operating pressure P is, in Fig. 5c, all the time rather close to the mean operating pressure M.
A further condition for obtaining a short response time of the accumulator 26 is that the accumulator 26 should be arranged close to the hydraulic cylinder 10. The following condition should be fulfilled:
L <= v /(2OMr) [eq. 2.1]
The following parameters are included in this equation:
v = velocity of sound in hydraulic liquid, unit: [m/s]. fr = number of rounds per second of the eccentric, see Fig. 1 , unit: [Hz].
L = distance, as seen along the hydraulic liquid path, between the hydraulic cylinder 10, and the accumulator 26, both of which have been described with reference to Fig. 1 , unit: [m].
The distance L is also illustrated schematically in Fig. 1. As a pressure wave generated in the hydraulic cylinder 10 has a finite velocity it will take some time for the accumulator 26 to respond to a pressure variation occurring in the hydraulic cylinder 10, thereby causing a response delay. The equation 2.1 specifies a design which provides for a small response delay, and, thus, a quick reaction of the accumulator 26 to pressure variations occurring in the hydraulic. cylinder 10. Fig. 6 illustrates, schematically, a system formed by the accumulator
26 and the vertical shaft 8 of the gyratory crusher 2, the vertical shaft 8 including, in this regard, the weight of the crushing head 4 and the crushing mantle 6. As illustrated, the accumulator 26 is in continuous hydraulic fluid contact with the hydraulic cylinder 10 during normal crushing operation in the crusher system and will be active to attenuate the normal pressure variations occurring in the hydraulic cylinder 10. The crusher system 1 of Fig. 1 should be designed to avoid oscillation of the system formed by the interaction between the accumulator 26 and the vertical shaft 8. As illustrated in Fig, 6, a force F is generated by the crushing of material in the gyratory crusher. This force acts on the vertical shaft 8, which in turn co-operates with the hydraulic cylinder 10. The force F has a sinusoidal component at the frequency of rotation of the eccentric 39, as illustrated hereinbefore in Fig. 2c. If the natural frequency of the system formed by the vertical shaft 8, the crushing head 4, the crushing mantle 6, the hydraulic cylinder 10, the accumulator 26, and the pipes 20, 42, is too low, and close to the frequency of rotation of the eccentric 39, i.e., too close to the frequency of gyration of the vertical shaft 8, then there is a risk of resonance of the system, resulting in big oscillations. The natural frequency of the system can be calculated in the following way:
Figure imgf000017_0001
The following parameters are included in this equation:
CGn = natural frequency of the system including the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26, unit: [rad/s].
Ah = section area of the piston of the hydraulic cylinder 10, see Fig. 6, unit: [m2]. M = total mass of vertical shaft 8, crushing head 4, and crushing mantle 6, unit [kg].
ΔP/ΔV= pressure-volume variation due to accumulator 26, as explained hereinbefore with reference to Fig. 5a, unit: [Pa/m3].
The natural oscillation frequency of the system including the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26 is designed to fulfil the following condition:
ωn > 4π*fr [eq. 3.2]
The following parameters are included in this equation:
COn = natural frequency of the system including the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26, unit [rad/s]. fr = number of rounds per second of the eccentric 39, see Fig. 1 , unit: [Hz].
Hence, the natural frequency ωn of the system comprising the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26 is designed to be about 2 times higher than the frequency of rotation (calculated as the number of rounds per second multiplied by 2π) of the eccentric 39, in rad/s, i.e., to be about 2 times higher than the frequency of gyration of the vertical shaft 8, in rad/s.
Fig. 7a illustrates a situation in which the natural frequency ωn of the system comprising the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26 is too low, i.e., considerably lower than 2 times the frequency of rotation of the eccentric 39, in rad/s. As can be seen from Fig. 7a the actual operating pressure P swings considerably around the mean operating pressure M. When comparing Fig. 7a and Fig. 2a it can be seen that, in fact, the operating pressure swings more with such a wrongly designed accumulator illustrated with reference to Fig. 7a, due a resonance phenomenon, than the case in which no accumulator at all is used, as illustrated in Fig. 2a.
Fig. 7b illustrates a situation in which the natural oscillation frequency ωn of the system comprising the vertical shaft 8, the crushing head 4, the crushing mantle 6, and the accumulator 26 fulfils the requirement of eq. 3.2. As can be seen from a comparison with Fig. 7a, there is in Fig. 7b no resonance at all, and the sinusoidal component illustrated hereinbefore with reference to Fig. 2c, has been almost completely dampened. Thus, the operating pressure P is all the time rather close to the mean operating pressure M.
With a proper design of the accumulator 26, in accordance with the conditions described hereinbefore, it will work as a spring that attenuates pressure variations. When uneven feeding of material, segregation of material into small and large fractions on the feed conveyor belt, and geometric eccentricity of the crushing mantle 6 and/or the crushing shell 14 occurs, the pressure in the hydraulic cylinder 10 tends to fluctuate, as described hereinbefore with reference to Fig. 2a to 2d. Pressure peaks in the hydraulic cylinder 10 are attenuated by hydraulic liquid flowing from the hydraulic cylinder 10 to the accumulator 26. Pressure drops in the hydraulic cylinder 10 are attenuated by hydraulic liquid flowing from the accumulator 26 to the hydraulic cylinder 10. Hence, the pressure in the hydraulic cylinder 10 is kept more even, compared to the prior art.
The volume of the accumulator 26 has not been described in detail. The volume of the accumulator 26 depends on the volume of hydraulic liquid that will enter, or leave, the accumulator 26 when the accumulator 26 attenuates pressure variations. Thus, the volume of the accumulator 26 will depend on the size of the crusher, and the expected magnitude of the pressure variations that are to be attenuated. A person skilled in the art could find, by routine experimentation, a suitable volume of the accumulator for a certain type of crusher.
The accumulator 26 results, as described hereinbefore, in a more even pressure in the hydraulic cylinder 10, which results in an increased crusher life, due to decreased fatigue stresses on the gyratory crusher 2. It is also possible, as alternative to increased life, or in combination therewith, to operate the gyratory crusher 2 at a higher mean operating pressure, resulting in an increased crushing efficiency of the gyratory crusher 2. The heavy and sudden pressure changes are handled by the dump valve 22, as mentioned hereinbefore. As alternative to the control device 30 controlling the dump valve 22, the dump valve 22 could be an automatic valve that opens automatically at a certain pressure.
In situations where the feed of material to the gyratory crusher 2 is suddenly stopped the pressure in the hydraulic cylinder 10 drops rapidly. In such a situation the accumulator 26 will forward hydraulic liquid to the hydraulic cylinder 10, which may make the vertical shaft 8 move vertically upwards. Such a vertical movement is not desired, since it may cause contact between the crushing mantle 6 and the crushing shell 14. The control device 30 would then, preferably, be designed to, in addition to the above mentioned function of opening the dump valve 22 in situations when the pressure in the hydraulic liquid is over a preset pressure, opening the dump valve 22 when the width of the gap 12 is under a preset limit, such that the hydraulic liquid from the accumulator 26 is dumped to the tank 24, instead of being forwarded to the hydraulic cylinder 10, in such situations when the vertical shaft 8 tends to move upwards.
It will be appreciated that numerous modifications of the embodiments described above are possible within the scope of the appended claims.
Above the attenuation of pressure variations in a gyratory crusher has been described. It will be appreciated that the present invention can be utilized also for other types of crushers in which at least one crushing surface is connected to a hydraulic cylinder, the pressure variations of which needs to be attenuated. The present invention can also be applied to crushers in which two, or more, crushing surfaces are connected to separate hydraulic cylinders.
Hereinbefore it has been described that the accumulator 26 is in continuous hydraulic fluid contact with the hydraulic cylinder 10 to be active for attenuating pressure variations occurring during normal crushing operation. As has been disclosed, see for example Fig. 1 and Fig. 6, the accumulator 26 is directly coupled to the hydraulic cylinder 10, and there is no valve arranged in the pipe 20 between the hydraulic cylinder 10 and the accumulator 26. It will be appreciated that a shut-off valve could be arranged in this pipe 20, or more preferably in the connecting pipe 42, for the purpose of isolating the accumulator 26 from the hydraulic system 16 when service or repair needs to be done to the accumulator 26. It will be appreciated, furthermore, that when such a shut-off valve is shut, there is no attenuating function of the accumulator 26, meaning that periods of having such a shut-off valve shut should be kept as short as possible.
The disclosures in the Swedish patent application No. 0800760-1 , from which this application claims priority, are incorporated herein by reference.

Claims

1. A crusher system comprising a first crushing surface (6) and a second crushing surface (14), the two crushing surfaces (6, 14) being operative for crushing material between them, the crusher system further comprising a hydraulic system (16) which is operative for adjusting a gap (12) between the first crushing surface (6) and the second crushing surface (14) by adjusting the position of the first crushing surface (6) by means of an hydraulic cylinder (10) connected to said first crushing surface (6), c h a r a c t e r i s e d in that said hydraulic system (16) further comprises an accumulator (26) being connected to said hydraulic cylinder (10) by means of a hydraulic liquid pipe (20, 42), the accumulator (26) comprising a hydraulic liquid compartment (46) and a gas compartment (48) being separated from the hydraulic liquid compartment (46), the accumulator (26) having a preloading pressure, being the pressure of the gas compartment (48) when the hydraulic liquid compartment (46) is empty, which is at least 0.3 MPa lower than the mean operating pressure of the hydraulic cylinder (10), such that the accumulator (26) is active and variations occurring in the hydraulic pressure of the hydraulic cylinder (10) during operation of the crusher system (1) are attenuated.
2. A crusher system according to claim 1 , wherein the preloading pressure of the accumulator (26) is 0.3 to 1 MPa lower than the mean operating pressure of the hydraulic cylinder (10).
3. A crusher system according to any one of claims 1-2, wherein the natural oscillation frequency, ωa, of the accumulator (26) fulfils the condition:
ωa > 10*2π*fr
wherein fr is the number of rounds per second of an eccentric (39) operative to make at least one of the first and second crushing surfaces (6, 14) gyrate.
4. A crusher system according to any one of claims 1-3, wherein the distance L, as seen along the hydraulic liquid path (20, 42), between the hydraulic cylinder (10) and the accumulator (26), fulfils the condition:
L <= v /(2OMr) wherein v is the velocity of sound in the hydraulic liquid, and fr is the number of rounds per second of an eccentric (39) operative to make at least one of the first and second crushing surfaces (6, 14) gyrate.
5. A crusher system according to any one of claims 1-4, wherein the natural frequency, ωn, of a system including the accumulator (26) and the mass (4, 6, 8) carried by the hydraulic cylinder (10) fulfils the condition:
ωn > 4π*fr
wherein fr is the number of rounds per second of an eccentric (39) operative to make at least one of the first and second crushing surfaces (6, 14) gyrate.
6. A crusher system according to any one of claims 1-5, wherein the crusher system (1) comprises a control device (30), which is operative for controlling the preloading pressure of the accumulator (26) in view of the actual mean operating pressure of the hydraulic cylinder (10).
7. A crusher system according to any one of claims 1-6, wherein the crusher system (1) comprises a gyratory crusher (2), the hydraulic cylinder
(10) being operative for adjusting the vertical position of a crushing head (4) operative for supporting the first crushing surface (6).
8. A method of crushing material between a first crushing surface (6) and a second crushing surface (14), a hydraulic system (16) being operative for adjusting a gap (12) between the first crushing surface (6) and the second crushing surface (14) by adjusting the position of the first crushing surface (6) by means of an hydraulic cylinder (10) connected to said first crushing surface (6), c h a r a c t e r i s e d in that variations occurring in the hydraulic pressure of the hydraulic cylinder (10) are attenuated by means of an accumulator (26) being in contact, via a hydraulic liquid, with said hydraulic cylinder (10), the accumulator (26) comprising a hydraulic liquid compartment (46) and a gas compartment (48) being separated from the hydraulic liquid compartment (46), the accumulator (26) having a preloading pressure, being the pressure of the gas compartment (48) when the hydraulic liquid compartment (46) is empty, which is at least 0.3 MPa lower than the mean operating pressure of the hydraulic cylinder (10).
9. A method of crushing material according to claim 8, wherein the preloading pressure of the accumulator (26) is 0.3 to 1 MPa lower than the mean operating pressure of the hydraulic cylinder (10).
10. A method of crushing material according to any one of claims 8-9, wherein the actual preloading pressure of the accumulator (26) is controlled in view of the actual mean operating pressure of the hydraulic cylinder (10).
PCT/SE2009/000160 2008-04-04 2009-03-26 Attenuation of pressure variations in crushers Ceased WO2009123531A1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
UAA201013080A UA100885C2 (en) 2008-04-04 2009-03-26 Attenuation of pressure oscillations in crushers
BRPI0911074A BRPI0911074A2 (en) 2008-04-04 2009-03-26 attenuation of pressure variations in crushers
AU2009232465A AU2009232465B2 (en) 2008-04-04 2009-03-26 Attenuation of pressure variations in crushers
EP09726902.1A EP2271427B1 (en) 2008-04-04 2009-03-26 Attenuation of pressure variations in crushers
RU2010145132/13A RU2487761C2 (en) 2008-04-04 2009-03-26 Reducing pressure vibrations in crushers
CN2009801191573A CN102046292B (en) 2008-04-04 2009-03-26 Attenuation of pressure variations in crushers
ZA2010/07882A ZA201007882B (en) 2008-04-04 2010-11-03 Attenuation of pressure variations in crushers

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE0800760A SE532320C2 (en) 2008-04-04 2008-04-04 Attenuation of pressure variations in crushers
SE0800760-1 2008-04-04

Publications (1)

Publication Number Publication Date
WO2009123531A1 true WO2009123531A1 (en) 2009-10-08

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US (1) US7883042B2 (en)
EP (1) EP2271427B1 (en)
CN (1) CN102046292B (en)
AU (1) AU2009232465B2 (en)
BR (1) BRPI0911074A2 (en)
CL (1) CL2009000818A1 (en)
RU (1) RU2487761C2 (en)
SE (1) SE532320C2 (en)
UA (1) UA100885C2 (en)
WO (1) WO2009123531A1 (en)
ZA (1) ZA201007882B (en)

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FI123801B (en) * 2012-04-12 2013-10-31 Metso Minerals Inc Crusher monitoring and control system and method, crusher and crusher control method
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FI126939B (en) * 2013-05-28 2017-08-15 Metso Minerals Inc Procedure for using a crusher, crushing system and crushing plant
CN104525352B (en) * 2014-11-18 2016-04-13 中国矿业大学 A kind of method of mine crushing machine anti-resonance vibration
EP3669990B1 (en) * 2018-12-21 2023-08-16 Metso Sweden AB Monitoring system
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CN113510001B (en) * 2021-05-21 2022-06-10 徐州徐工矿业机械有限公司 Method for accurately adjusting discharge port of crusher
WO2024155210A1 (en) * 2023-01-18 2024-07-25 Общество с ограниченной ответственностью "КС-ТЕХНОЛОГИИ" Cone crusher with improved hydraulic system
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Publication number Publication date
AU2009232465B2 (en) 2014-01-09
CL2009000818A1 (en) 2010-02-05
UA100885C2 (en) 2013-02-11
RU2487761C2 (en) 2013-07-20
EP2271427A4 (en) 2017-05-17
US20090256015A1 (en) 2009-10-15
CN102046292A (en) 2011-05-04
EP2271427B1 (en) 2019-07-24
SE532320C2 (en) 2009-12-15
RU2010145132A (en) 2012-05-20
CN102046292B (en) 2013-04-24
AU2009232465A1 (en) 2009-10-08
US7883042B2 (en) 2011-02-08
BRPI0911074A2 (en) 2016-08-02
EP2271427A1 (en) 2011-01-12
SE0800760L (en) 2009-10-05
ZA201007882B (en) 2013-04-24

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