Patent Grant
11944981
This application claims benefit of German Patent Application No. 10 2020 101 863.0, filed Jan. 27, 2020, and which is hereby incorporated by reference.
The invention relates to a crusher, in particular a rock crusher, having a crusher unit, to which a band conveyor unit having an endlessly circulating band conveyor is directly or indirectly assigned, wherein a magnetic separator having a magnet is held in the area of the band conveyor unit above the band conveyor in the direction opposite from the direction of gravity, and wherein an adjustment unit is provided, which can be used to change the height of the magnet or magnetic separator above the band conveyor.
Crushers for crushing rock material or other mineral raw materials are known in various designs. Such crushers usually have a feed hopper, into which the material to be crushed can be fed. From the feed hopper, the material is routed to a crusher unit. Typical crusher units are known as rotary impact crushers, jaw crushers or cone crushers. In the crusher unit, the material is crushed to the desired particle size. The crushed material leaves the crusher unit and is usually removed via a crusher discharge belt and, where applicable, fed to a band conveyor unit. The band conveyor unit typically has an endless circulating band conveyor. The band conveyor is used to remove the crushed material from the working area of the crusher unit and to pile it onto a rock pile or to route it to a further process step.
The crushers are often used for crushing steel-reinforced concrete or demolition material having metallic impurities. The crushed rock material then also contains such ferromagnetic metal particles. These should not be added to the rock pile. They therefore have to be separated from the mass flow of crushed rock material. Magnetic separators suspended above the band conveyor are used for this purpose.
Such a magnetic separator is known from U.S. Pat. No. 7,905,342 B2, for instance. The magnetic separator has a circulating belt conveyor to which a magnet is assigned. The conveying direction of the circulating belt conveyor is oriented transversely to the conveying direction of the band conveyor, in particular at an angle greater than 30° thereto. When ferromagnetic material is transported on the band conveyor, the magnet of the magnetic separator attracts that material. The belt conveyor then conveys the attracted material out of the working area of the band conveyor for separation.
If larger quantities of ferromagnetic material accumulate in the known crushers, undesirable jams can sometimes occur at the magnetic separator. This will affect the free flow of material on the conveyor and may cause rock material to unintentionally fall off the sides of the conveyor. Sometimes such jams also result in a longer machine downtimes. The operating personnel then has to laboriously remove the jam at the magnetic separator to restore the proper operating condition of the crusher. In addition, removing the jam is an increased safety risk for the operator.
The invention addresses the problem of providing a crusher of the type mentioned above, which provides improved reliability of operation and occupational safety.
The problem of the invention is solved in that the magnetic separator is suspended from at least two limp ties, and in that the limp ties can be adjusted by means of at least one actuator unit to alter the height of the magnet.
Based on this arrangement, the magnetic separator can be optimally aligned to the various applications in relation to the band conveyor. This can be easily done based on the solution according to the invention. For this purpose, only the actuator unit has to be operated in order to vary the height of the magnetic separator. This conversion is simple and can be performed without major machine downtimes. For instance, it may also be provided that the adjustment of the magnetic separator is supported by an external force, in particular using a hydraulic system or an electromotive adjustment of the actuator unit. Then, the operating personnel will not be exposed to much physical strain. The adjustment can be used to optimally assign the magnetic separator to the band conveyor, adapted to the individual application. That in itself significantly reduces the risk of jams forming.
If, however, ferromagnetic material still accumulates on the magnetic separator during operation, the limp ties permit the unit bearing the magnet to oscillate. Surprisingly, it has turned out that this almost completely prevents any jams from forming at the magnetic separator and makes for an uninterrupted operation.
In addition, it has been shown that this pendulum option significantly reduces the force acting on the unit bearing the magnet, resulting in an extended service life.
According to a preferred variant of the invention it can be provided that the actuator unit has a synchronization device having synchronization means, wherein the synchronization means couple the ties to each other in a positive and/or non-positive manner for synchronized motion. This measure ensures that the coupling points of the ties of the magnetic separator are raised or lowered synchronously in order to achieve a uniform adjustment of the magnetic separator. Preferably, this can also be used to effect a parallel adjustment motion of the magnet in relation to the band conveyor below.
Particularly preferably the ties are routed via a rotatably mounted deflector for synchronizing their motions. Such deflectors can be formed, for instance, by shafts, gear wheels, sprockets or other rotatably mounted rotating parts. In particular, standardized components can be used, which significantly reduces the cost of parts and assembly.
According to a possible variant of the invention it can be provided that the magnetic separator comprises at least two suspensions, which are spaced apart from each other and to each of which a tension strand of a tie is connected using a coupling element. The points of application of the ties on the magnetic separator are also spaced apart via the spacing of the suspensions. If motion synchronization, as described above, is implemented, these points of application can be adjusted uniformly. Of course, it is also conceivable that no uniform adjustment, but deliberately differing adjustment paths are implemented for the points of application. This can be used to influence the motion behavior of the magnetic separator. This can also be achieved using an appropriately adapted synchronization device.
If synchronization is provided, it can be provided that both tension strands are routed to the synchronization device, that the tension strands are routed via individually assigned deflectors, that the tension strands merge indirectly or directly into holding segments downstream of the deflectors, that at least one of the retaining segments is coupled to an actuator of the actuator unit, and that the deflectors are coupled to each other by a synchronization means. This results in a particularly simple design.
According to a variant of the invention, it may further be provided that the synchronization means preferably comprises at least one shaft. It is also conceivable that the synchronization means is preferably formed, at least in certain areas, by a strand segment of one of the limp ties.
It is conceivable that at least three tension strands of tension mechanisms, preferably four tension strands, are provided, each of which is coupled at a point of application to the magnet unit bearing the magnet.
Two of these tension strands can, for instance, be synchronized using a shaft and the at least one further tension strand can additionally be synchronized with the first two tension strands via a strand segment of one of the limp ties. I.e., no further component is required for the second synchronization and also all tension strands are synchronized with each other.
Particularly preferably, four tension strands are provided, wherein two tension strands are synchronized with each other via one shaft each. The two further tension strands are each coupled and synchronized with a strand segment of a limp tie.
When selecting the suspensions by means of which the tension strands are coupled to the magnetic separator, it is recommended that the magnetic separator comprises at least two suspensions arranged at a distance from each other transversely to the conveying direction of the band conveyor, and/or that the magnetic separator comprises at least two suspensions arranged at a distance from each other in the conveying direction of the band conveyor.
For a 4-point suspension, a reliable suspension is achieved permitting a defined pendulum behavior.
The connection of the actuator unit to the adjustment unit is achieved in a simple manner if it is provided that at least two retaining segments of the two limp ties are connected to a connector of the actuator unit.
Within the scope of the invention, the actuator unit can be designed such that at least one hydraulic unit having a cylinder and a piston adjustably guided therein is provided as the actuator unit, wherein a piston rod is connected to the piston, and that the piston rod or the cylinder is coupled to the adjustment unit by means of a mount. It is also conceivable to use an actuator unit having a hydraulic rotary drive as actuator, which hydraulic rotary drive is coupled to the adjustment unit.
Instead of the hydraulic unit, an electric drive unit, in particular an electric rotary drive or an electric linear drive, can also be used as actuator.
If a motion synchronization system is used, as mentioned above, the use of a hydraulic unit may suffice. The motion synchronization ensures that the tension strands move in a coordinated manner relation to each other.
Advantageously, however, two hydraulic units are provided, wherein the mount of the first hydraulic unit is coupled to a retaining segment of a tie and the mount of the second hydraulic unit is coupled to a retaining segment of a further tie. This not only allows the hydraulic units to be smaller in size, but also renders them much more cost-effective. In addition, redundancy can be implemented in this way. If one hydraulic unit fails, the second hydraulic unit continues to provide the operation and occupational.
According to a variant of the invention it can also be provided that the hydraulic units are hydraulically synchronized such that the pistons of the two hydraulic units can be adjusted to move synchronously. In this case, there is no need for an additional motion synchronization in the area of the adjustment unit.
For instance, all or some of the limp ties may be formed by ropes. The use of steel cables is conceivable here. It is particularly preferable, however, that at least some of the limp ties are formed by chains, in particular link chains, preferably roller chains or round link chains, and that further preferably the deflector(s) is/are formed by sprockets. Such chains can easily be positively coupled to each other in the area of their chain links. Chains are available inexpensively in bulk and are sufficiently stable for the application according to the invention. If toothed wheels are used as deflectors, the motion of the chains can be easily synchronized.
According to a preferred variant of the invention, it can be provided that the magnetic separator has two supports which are arranged at a distance from each other in the conveying direction of the band conveyor of the band conveyor unit, that deflector elements are mounted on the supports, which deflector elements are used to guide an endlessly circulating belt conveyor of a conveying device such that the transport direction of the belt conveyor extends transversely to the conveying direction of the band conveyor of the band conveyor unit, that the belt conveyor forms two strands between the deflector elements and that the magnet is arranged in the area between the two strands.
Once the position of the magnetic separator has been set, within the scope of the invention the actuator alone suffices to secure this position. Additionally or alternatively, however, it may also be provided that the adjustment position of the magnetic separator is secured by means of an additional locating element. In this way, the actuator unit is unloaded. Preferably, it may be provided that the locating element is formed as a chain, in particular as a link chain, which is attached to the magnetic separator on the one hand and is adjustably attached to a locking element of the machine frame of the crusher on the other hand. Here, the chain again forms a simple component which ensures the reliable transfer of the weight of the magnetic separator in the set position.
Within the scope of the invention, the actuator unit can have a shaft or roller, on which the two limp ties for adjusting the vertical position of the magnet can be wound, or the actuator unit can have two shafts or rollers on each of which one of the limp ties for adjusting the vertical position of the magnet can be wound.
The invention is explained in greater detail below based on an exemplary embodiment shown in the drawings. In the Figures:
In the front area, the crusher 10 has a motor unit 15. The motor unit 15 comprises an internal combustion engine that supplies power to individual units of the crusher 10. Furthermore, the machine frame 12 has an extension arm 16 at the front end, from which a band conveyor unit 60 is suspended. In the rear end area, the crusher 10 has a feed unit 20 comprising a feed hopper. A conveying device 21, preferably a vibratory conveyor, is also arranged in the area of the feed hopper.
An excavator or any other loading device can be used to feed the material to be shredded into the feed hopper of the feed unit 20. The conveying device 21 transports the rock material to a screening device 30. There, the rock material is subjected to a screening process. The screened fine rock material is of a size that does not require further crushing in the downstream crusher unit 40. This screened fine rock material is typically bypassed past the crusher unit 40 and fed directly to the band conveyor unit 60. The coarse rock fraction that has not been screened out is fed to the crusher unit 40.
In this exemplary embodiment, the crusher unit 40 is designed as a jaw crusher. The coarse rock fraction is broken and crushed in the crusher unit 40. The crushed material falls below the crusher unit 40 onto a crusher discharge conveyor 50. The crusher discharge belt, which is preferably formed by a circulating belt conveyor, conveys the crushed rock material towards the band conveyor unit 60.
The band conveyor unit 60 comprises a band conveyor. This band conveyor is formed by an endless circulating means of conveyance. The band conveyor has a feed end 61 in the area of the crusher discharge belt. The crusher discharge conveyor 50 transfers the rock material to the band conveyor of the band conveyor unit 60 in the area of the feed end. The conveyor then transports the rock material towards a discharge end 62. Here the rock material leaves the band conveyor unit to be heaped onto a pile.
In this exemplary embodiment, an option is shown, in which a cover 63 is used to cover the top of the band conveyor of the band conveyor unit 60 to prevent rock material from accidentally falling off the band conveyor. The cover 63 forms a discharge opening 64 in the area of the discharge end 62.
As
The basic structure of the magnetic separator 70 can be seen in
To assist in the conveying action of the belt conveyor 76, ribs 76.3 projecting radially outwardly from the belt conveyor 76 are provided.
Protection plates 71.1 are provided below the supports 71, 72 to provide lateral protection for the belt conveyor 76. To improve the protective effect of the belt conveyor 76 or the deflector elements 74, 75, the protection plates 71.1 may also have folded edges 71.2.
An adjustment unit 80, which is shown in detail in
The two further ties 82 and 85 are attached to the front support 71, in the conveying direction of the band conveyor, at the front suspensions 77.1. Again, corresponding coupling elements 82.3, 85.3 are used.
The two ties 82 and 85, which are spaced apart transversely to the conveying direction of the band conveyor, are each routed to a deflector 93, starting from the front suspensions 77.1, forming one tension strand each 82.1, 85.1.
The deflectors 93 are formed by gears, which may be sprockets for link-chains as in this case. The design of the sprockets for link-chains is illustrated by way of example in
A synchronization means 94 of an actuator unit 90 is arranged above the support 71. The synchronizing means 94 comprises a shaft 94.1. This shaft 94.1 is rotatably mounted at its two longitudinal ends by means of one bearing part 94.2 each. The bearing components 94.2 may be attached to the boom 16 of the crusher 10.
Two of the deflectors 93 are installed at each of the two longitudinal ends of the shaft 94.1. To this end, the shaft 94.1 is inserted through the bores 93.2. The deflectors 93 are secured for co-rotation by means of a feather key which is effective between the notch 93.3 of the deflectors 93 and the shaft 94.1. A suitable stop connection, for instance a stop shoulder, is used to secure the deflectors 93 to the shaft 94. It is also conceivable to weld or clamp the deflectors 93 to the shaft 94. Then a feather key and stop shoulder are not required.
Then the two ties 82 and 85 are routed to the two tension strands 82.1 and 85.1 each via a deflector 93. Beyond the deflectors 93, the ties 82, 85 have retaining segments 82.2, 85.2. The end of this retaining segment 82.2, 85.2 is connected to a connector 83, 86. The connector 83, 86 may again be formed by a shackle. The connectors 83, 86 provides a connection to a mounts 91.4, 92.4 of actuators 91, 92 of the actuator unit 90.
In the context of the invention, the actuators 91, 92 may be formed by hydraulic cylinders. For instance, the actuators 91, 92 may also be of identical design, reducing the number of parts required.
For instance, the actuators 91, 92 may comprise cylinders 91.2, 92.2. Pistons are adjustably guided in the cylinders 91.2, 92.2. Piston rods 91.3, 92.3 are connected to the pistons. The mounts 91.4, 92.4 are arranged at the free ends of the piston rods 91.3, 92.3. The cylinder 91.2, 92.2 has a holder 91.1, 92.1 facing away from the piston rods 91.3, 92.3. This holder 91.1, 92.1 can be used to secure the cylinder 91.2, 92.2 to the machine frame 12.
The deflectors 93 are again part of a synchronization means 95. According to the above embodiments, the deflectors 93 are coupled to a shaft 95.1 of the synchronization means 95 for co-rotation. The design of the synchronizing means 95 is largely similar to the design of the synchronizing means 94 described above, i.e., reference can be made to the above explanations to avoid repetition. Again, bearing parts 95.2 are provided for the shaft 95.1, which bearing parts can be bolted to the boom 16.
The tension strands 81.1 and 84.1 are routed around the deflectors 93 and, beyond the deflectors 93, the ties 81 and 84 form synchronization means 81.3 and 84.3. I.e., these synchronization means 81.3, 84.3 are formed by segments of the ties 81 and 84 used as chains.
The synchronization means 81.3 and 84.3 transition into the retaining segments 81.4 and 84.4, respectively. At their longitudinal ends, the retaining segments 84.4 and 81.4 are each connected to mounts 92.4, 91.4 of actuators 92, 91. Preferably, the same connector 83, 86, which is used for coupling the ties 82 and 85, is also used for securing. Then, the traction means 82 and 81 are secured to the connector 83 and the ties 84 and 85 are secured to the connector 86.
To reduce the number of parts required, it may be provided in particular in the context of the invention that all the ties 81, 82, 84, 85 are formed by chains of identical design.
The associated deflector elements 93 of the front synchronization means 94 and the synchronization means 81.3 of the tie 81 are used to motion-synchronize the motion of the first tension strand 81.1 of the tie 81 with the motion of the first tension strand 82.1 of the tie 82. In this case, the two deflector elements 93 may in particular be formed by two sprockets for link-chains, which are interconnected for co-rotation and which are preferably arranged directly adjacent to each other.
The associated deflector elements 93 of the front synchronization means 94 and the synchronization means 84.3 of the tie 84 are used to motion-synchronize the motion of the first tension strand 84.1 of the tie 81 with the motion of the first tension strand 85.1 of the tie 85. In this case, the two deflector elements 93 may in particular be formed by two sprockets for link-chains, which are interconnected for co-rotation and which are preferably arranged directly adjacent to each other.
According to the present embodiment of the invention, moreover, the two ties 81 and 84 are synchronized in motion via the rear synchronization means 95 by means of the deflectors 93 and the shaft 95.1.
Obviously, this synchronization using the synchronization means is not essential, because the motion of the two traction means 81, 84 has been synchronized with the motion of the traction means 82 and 85 via the front synchronization means 94. However, in the variant shown in
In summary, the ties 81, 82, 84, 85 are motion-synchronized with each other. Accordingly, the suspensions 77.1, 77.2 can be interadjusted in a synchronized manner, in particular they can be raised or lowered.
During operation, the crushed rock material passes onto the band conveyor of the band conveyor unit 60. The band conveyor, driven by the conveyor motor 66 via a drive shaft 66.1, then continuously conveys the rock material towards the discharge end 62. The rock material is transported past the magnetic separator 70 on its way from the feed end 61 to the discharge end 62.
If then ferromagnetic material is present in the extracted rock material, for instance steel reinforcement, it will be attracted to the magnet 79 of the magnetic separator 70. This ferrous material then adheres to the belt conveyor 76 in the area of the bottom strand 76.2. The belt conveyor 76, due to its circulating motion, conveys this ferrous material to the deflector element 74, 75 against which the bottom strand runs. As soon as this ferrous material then enters the area of the deflector element 74 or 75, the distance between the ferrous material and the magnet 76 increases. This terminates the magnetic connection and the removed ferrous material passes onto a guide element 65 (see
If a jam now occurs at the magnetic separator 70, for instance if a lot of ferrous material has to be separated at the same time, then the magnetic separator 70 can compensate for the force effects occurring due to the jam in an oscillating manner because of the limp ties 81, 82, 84, 85 in the area of the tension strands 81.1, 84.1,2 and 80.1, 85.1. Reliable operation is maintained in this way.
As can be seen in
The above explanations illustrate that according to the invention, the crusher 10 is equipped with a crusher unit 40, wherein a band conveyor unit 60 having an endlessly circulating band conveyor is assigned to the crusher unit. The magnetic separator 70 and its magnet 79 are held in the area of the band conveyor unit 60 above the band conveyor in the direction opposite from the direction of gravity. The adjustment unit 80 permits a change of height of the magnet 79 above the band conveyor.
The magnetic separator 70 is suspended from at least two limp ties 81, 82, 84, 85 and these limp ties 81, 82, 84, 85 can be adjusted by means of at least one actuator unit 90 to change the height of the magnet 79.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2020 101 863.0 | Jan 2020 | DE | national |
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| Number | Date | Country | |
|---|---|---|---|
| 20210229110 A1 | Jul 2021 | US |
