Patent Application
20240066523
The present application claims priority to German Patent Application Ser. No. DE 10 2022 121 783.3 filed Aug. 29, 2022, which is incorporated herein by reference.
The invention relates to a material processing device, in particular a crusher, for crushing mineral material, having an internal combustion engine which can be mechanically coupled to a crusher unit via a drive train to drive the latter, the drive train having a motor coupling by means of which the internal combustion engine can be selectively coupled to the drive train for transferring drive power or decoupled therefrom, wherein the drive train comprises a crusher unit coupling by means of which the crusher unit can be selectively coupled to or uncoupled from the drive train, and wherein the drive train comprises a motor generator comprising a motor rotor and a motor stator, which, in a motor mode of operation (motor operation), provides mechanical work for driving the crusher unit and which, in a generator mode of operation (generator operation), is driven by the internal combustion engine to generate electrical power.
Material processing devices in terms of the invention can be crushers, in particular rotary impact crushers, cone crushers or jaw crushers.
From EP 3 804 859 (U.S. 2021079837) a material processing device is known, which can be used for crushing mineral material. This material processing device has an internal combustion engine that drives a transmission via a free-wheel clutch. A further coupling is provided at an output of the transmission. Downstream of this further coupling, a belt drive is used to drive a crusher unit. The transmission has two output shafts. Each of these output shafts drives a motor generator. If the internal combustion engine provides drive power during operation, it is made available to the crusher unit via the drive train, which comprises the free-wheel clutch, the transmission and the coupling. Part of the drive power of the internal combustion engine is transferred to the motor generators as mechanical work via the output shafts of the transmission. The motor generators produce alternating current, which is converted to direct current in converters. The DC current coming from the converters is then combined in a bus line and fed to a further converter. The further converter converts the direct current back to alternating current and feeds it into a main power circuit of the material processing device. Various motors are connected to the main circuit, which can be supplied with electrical energy in that way. In a second operating mode, electrical energy is fed into the main circuit and supplied to the motor generators via the previously described line system. These motor generators generate mechanical power from the supplied current, which can be fed to the transmission via the drive shafts. In this operating state, the internal combustion engine is switched off so that the mechanical work provided by the motor generators can be transferred to the crusher unit via the drive train. The free-wheel clutch prevents the internal combustion engine from being dragged along in this operating state.
The invention addresses the problem of providing a material processing device of the type mentioned above, which makes for an effective power transmission to the crusher unit in a compact design.
This problem is solved in that the motor rotor of the motor generator comprises a motor generator shaft, in that the motor generator shaft is coupled to the output end of the motor coupling in a rotationally fixed manner, and in that the motor generator shaft is coupled to the input end of the crusher unit coupling in a rotationally fixed manner.
According to the invention, the motor generator can now be installed in the construction area between the motor coupling and the crusher unit coupling to save space. In the generator operating mode, the motor generator shaft transfers the mechanical work supplied thereto by the internal combustion engine, preferably directly, to the crusher unit, resulting in a direct power transmission with low power losses. In the motor operating mode, the power supplied electrically is transferred from the motor generator directly via the motor generator shaft to the crusher unit coupling. Here, too, there are significantly lower power losses compared to the standard design.
According to one variant of the invention, the drive train can be made particularly compact if provision is made for the motor generator shaft to be designed as a shaft passing through the motor generator, one end of which is connected to the motor coupling and at the other end of which is connected to the crusher unit coupling.
The motor generator can be integrated into the drive train in a particularly space-saving manner with little construction effort if, according to a possible design variant of the invention, provision is made for the motor rotor to be coupled to the motor generator shaft in a rotationally fixed manner. For this purpose, provision may be made, for instance, for the motor rotor to have a hub, which is connected to the motor generator shaft in a rotationally fixed manner.
In an alternative design of the motor generator, provision may be made for the motor rotor to be rotatably coupled to the motor generator shaft, preferably by means of a transmission. Because the motor rotor is no longer rigidly connected to the motor generator shaft, the speed between the motor rotor and the motor generator shaft can be reduced. This renders designing the motor generator in a suitable way for a given internal combustion engine feasible, for it to fulfill the assigned tasks in the best possible way.
The design of the transmission works well in a simple manner if provision is made for the motor generator shaft to have or be assigned a toothing, for at least one gear to mesh with the toothing, and for a toothing of the motor rotor to mesh directly with the gear or gears or with the interposition of at least one further gear.
One possible embodiment of the invention is such that the motor rotor of the motor generator is designed in the form of an internal rotor. This makes for a high power density and thus a high torque can be implemented in a small installation space, which supports the compact design desired in accordance with the invention.
According to the invention, provision may further be made for the motor rotor to comprise a rotor winding and for the motor stator to comprise a stator winding, and for the number of windings of the rotor winding and the stator winding to be identical.
The material processing device according to the invention can be designed in such a way, that in the motor operating mode, in which the motor generator provides mechanical work for driving the crusher unit, the motor coupling is opened in such a way that the combustion motor is disconnected from the drive train and the crusher unit coupling is closed, for a torque transmission from the motor generator shaft to the crusher unit, and that the motor generator is supplied with electrical energy via an external voltage supply or an accumulator.
Further, in the generator operating mode, in which the motor generator is driven by the internal combustion engine to generate electric power, provision may be made for the motor coupling to be closed for torque transfer from the internal combustion engine to the motor rotor and the crusher unit coupling to be in the disengaged state, and for the motor stator to be connected to a primary grid of the material processing device, such that alternating current generated by the motor generator is fed into the primary grid in the second operating mode and is supplied to loads, in particular to one or more electric motors connected to the primary grid and/or to one or more hydraulic pumps.
Further, in the generator mode of operation, in which the motor generator is driven by the internal combustion engine to generate electric power, provision may be made for the motor coupling to be closed for torque transfer from the internal combustion engine to the motor rotor and for the crusher unit coupling to be in the engaged state, and in for the motor stator to be connected to a primary grid of the material processing device, such that alternating current generated by the motor generator is fed into the primary grid in the generator operating mode and supplied to loads, in particular to one or more electric motors connected to the primary grid and/or to one or more hydraulic pumps. Because the crusher coupling is also closed, in this mode the crusher unit is driven by the internal combustion engine and the plant is supplied with electrical power via the motor generator as well.
The material processing device may be a mobile device, wherein undercarriages are provided on both sides of the material processing device extending in the direction of travel, and wherein in the second mode of operation, power generated by the motor generator is supplied to traction motors of the undercarriages to enable the driving mode of the material processing device.
In another embodiment of the invention, driving mode may be implemented when the traction motors are not supplied with electrical energy via the external power supply. Then driving mode can be achieved by the internal combustion engine being activated and it feeding electricity into the primary grid via the motor generator, which is then made available to the traction motors to implement driving mode. In particular, it is possible for the internal combustion engine to drive the crusher unit while in driving mode. However, it is of course also feasible for the crusher unit coupling to be open, such that only driving mode is possible and the crusher unit is uncoupled.
According to the invention, driving mode can also be implemented when the internal combustion engine is not active. In that case, provision may be made, for instance, for the traction motors of the undercarriage to be electrically connected to the primary grid in a further operating mode and for the primary grid to be connected to an external power supply. The traction motors can be directly electrical (the electric motor drives the traction gear) or electrohydraulic (the electric motor drives a hydraulic pump).
The invention is explained in greater detail below based on exemplary embodiments shown in the drawings. In the figures,
The crusher 10 has a chassis 11 that supports the machine components or at least a part of the machine components. At its rear end, the chassis 11 has a cantilever 12. A material feed area is formed in the area of the cantilever 12.
The material feed area includes a feed hopper 20 and a material feed device 16.
The feed hopper 20 may be formed at least in part by hopper walls 21 extending in the longitudinal direction of the crusher 10 and a rear wall 22 extending transversely to the longitudinal direction. The feed hopper 20 leads to the material feed device 16.
As shown in this exemplary embodiment, the material feed device 16 may have a conveyor chute that can be driven by means of a vibratory drive. The feed hopper 20 can be used to feed material to be broken into the crusher 10, for instance using a wheel loader, and to feed it onto the conveyor chute.
From the conveyor chute, the material to be broken passes into the area of a screen unit 30. This screen unit 30 may also be referred to as a pre-screening arrangement. At least one screen deck 30.1, 30.2 is disposed in the area of the screen unit 30. In this exemplary embodiment two screen decks 30.1, 30. 2 are used.
A partial fraction of the material to be broken is screened out at the upper screen deck 30.1. This partial fraction already has a sufficient particle size that it no longer needs to be broken in the crusher 10. In this respect, this screened out partial fraction can be routed past a crusher unit 40 through a bypass channel 31.
If a second screen deck 30.2 is used in the screen unit 30, a further fine particle fraction can be screened out from the partial fraction that accumulates below the screen deck 30.1. This fine particle fraction is routed to a lateral discharge conveyor 32 below the screen deck 30.2. The fine particle fraction is diverted from the lateral discharge conveyor 32 and conveyed to a rock pile 70.2 located to the side of the machine.
As
The material to be broken routed from the screen deck 30.1 is routed to the crusher unit 40, as shown in
The crusher unit 40 may be designed to be a rotary impact crusher unit. However, it may also be another crusher unit, for instance a jaw crusher unit of a jaw crusher, a cone crusher unit of a cone crusher, or a roll crusher unit of a roll crusher.
The crusher unit 40 has a crushing rotor 42 driven by an internal combustion engine 41. In
For instance, the outer periphery of the crushing rotor 42 may be equipped with impact bars 43. Opposite from the crushing rotor 42, for instance, wall elements may be disposed, preferably in the form of impact rockers 44.
When the crushing rotor 42 is rotating, the impact bars 43 throw the material to be broken outwards. In so doing, this material hits the impact rockers 44 and is broken due to the high kinetic energy. When the material to be broken is of sufficient particle size to allow the material particles to pass through the gap between the impact rockers 44 and the radially outer ends of the impact bars 43, the broken material exits the crusher unit 40 through the crusher outlet 45.
It is conceivable that in the area of the crusher outlet 45, the broken material routed from the crusher unit 40 is combined with the material routed from the bypass channel 31 and transferred onto a belt conveyor 13. The belt conveyor 13 can be used to convey the material out of the working area of the crusher unit 40.
As shown in the drawings, the belt conveyor 13 may comprise an endless circulating conveyor belt having a slack side 13.3 and a tight side 13.4. The slack side 13.3 is used to catch and transport away the crushed material falling from the crusher outlet 45 of the crusher unit 40. At the belt ends, deflection rollers 13.1, 13.2 can be used to deflect the conveyor belt from the slack side 13.3 to the tight side 13.4 and vice versa. Guides, in particular support rollers, can be provided in the area between the deflection rollers 13.1, 13.2 to change the conveying direction of the conveyor belt, to shape the conveyor belt in a certain way and/or to support the conveyor belt.
The belt conveyor 13 has a belt drive, which can be used to drive the belt conveyor 13. The belt drive can preferably be disposed at the discharge end 13.5 or in the area of the discharge end 13.5 of the belt conveyor 13.
The belt conveyor 13 can be connected, for instance by means of the belt drive, to a control device by means of a control line.
One or more further belt conveyors 60 and/or a return conveyor 80 may be used, which in principle have the same design as the belt conveyor 13. In this respect, reference can be made to the above statements.
A magnet 14 can be disposed above the slack side 13.3 in the area between the feed end and the discharge end 13.5. The magnet 14 can be used to lift iron parts from the broken material and move them out of the conveying area of the belt conveyor 13.
A re-screening device 50 can be disposed downstream of the belt conveyor 13. The crusher unit 50 has a screen housing 51, in which at least one screen deck 52 is mounted. Below the screen deck 52, a housing base 53 is formed, which is used as a collection space for the material screened out at the screen deck 52.
An opening in the lower housing part creates a spatial connection to the further belt conveyor 60. Here, the further belt conveyor 60 forms its feed area 61, wherein the screened material in the feed area 61 is directed onto the slack side of the further belt conveyor 60. The further belt conveyor 60 conveys the screened material towards its discharge end 62. From there, the screened material is transferred to a rock pile 70.1.
The material not screened out at the screen deck 52 of the re-screening device 50 is conveyed from the screen deck 52 onto a branch belt 54. The branch belt 54 can also be designed as a belt conveyor, i.e., reference can be made to the explanations given above with respect to the belt conveyor 13. In
At its discharge end, the branch belt 54 transfers the un-screened material, also referred to as oversize material, to the feed area 81 of the return conveyor 80. The return conveyor 80, which may be a belt conveyor, conveys the oversize material towards the feed hopper 20. At its discharge end 82, the return conveyor 80 transfers the oversize material into the material flow, specifically preferably into the material feed area. The oversize material can therefore be returned to the crusher unit 40 and crushed to the desired particle size.
The drive train 90 comprises a motor coupling 91, a motor generator 92, and a crusher unit coupling 93.
On its input end the motor coupling 91 is coupled to the drive shaft 41.1 of the internal combustion engine 41 in a rotationally fixed manner. The output end of the motor coupling 91 is connected to the motor generator 92 and coupled thereto on the input end.
On the output end of the motor generator 92, the crusher unit coupling may be coupled at the input end in a rotationally fixed manner. The output end of the crusher unit coupling 93 is connected directly or indirectly (indirectly, as in this example by means of the belt drive) to the crusher unit 40.
The motor generator 92 is connected to an electric connection 94. This electrical connection 94 can be used to dissipate the current generated by the motor generator 92 or current can be supplied to the motor generator 92 if it is to be operated as an electric motor.
The electrical connection 94 may be coupled to a converter 95. The converter 95, in turn, is connected to a primary grid 96 of the crushing plant 10.
The converter 95 is designed to convert the current supplied thereto by the motor generator 92 into a form suitable for the primary grid 96. Conceivably, the converter 95 is also adapted to convert the power provided by the primary grid 96 into a suitable form to provide power to the motor generator 92.
Electrical loads of the material processing device are connected to the primary grid 96. For instance, one or more electric motors, for instance for the hydraulic system 97/98 also as direct electric motors 99, can be connected to drive the material feed device 16 (for instance the vibration drive), the screen unit (for instance the screen drive), the belt drives of the belt conveyors, the rescreening device 50 and/or another working machine (not shown) as electrical loads. It is also conceivable that the electric traction motors of the undercarriage 15 are connected to the primary grid 96. In addition or alternatively, provision may also be made for the magnet 15 or other electric loads to be connected.
At the same time, the internal combustion engine 41 may also drive the motor generator 92. In that way, the motor generator 92 generates a current, which is routed to the converter 95 via the electrical connection 94. The converter 95 converts the current supplied thereto into a suitable form and routes it into the primary grid 96. In the primary grid 96, the electricity is then made available to one or more of the electrical loads mentioned above.
In particular, in the motor operating mode, the motor coupling 91 may be open. This prevents the internal combustion engine 41, which is deactivated in the motor operating state, from being dragged along.
Thus, the toothing 92.2, the one or more gears 92.3, and optionally the other gears form a gear reduction that can be used to step down the speed between the motor generator shaft 92.1 and the motor rotor 92.6.
As
Instead of the setup shown in
When the motor generator 92 is operated as an electric motor, current is supplied to the motor stator 92.8 via the connection 94. This induces a magnetic field which causes the motor rotor 92.6 to rotate. This rotational motion is either transferred indirectly into the motor generator shaft 92.1 via the gear(s) 92.3 and the toothing 92.2, or the rotation is transferred directly into the motor generator shaft 92.1. When the motor coupling 91 is open, the motor generator 92, operating as an electric motor, can then drive the belt drive and thus the crusher unit 40 via the closed crusher unit coupling 93 and the drive shaft 46.
If the motor generator 92 is to be operated in generator mode, the internal combustion engine 41 is activated and the motor coupling 91 is closed. This causes the motor generator shaft 92.1 to be driven by means of the internal combustion engine 41 and the motor rotor 92.6 to be set in rotary motion. Due to the effective electromagnetic field between the motor rotor 92.6 and the motor generator 92.8, the current generated in the motor stator 92.8 is transferred via the connection 94. In this operating state, either the crusher unit coupling 93 can be open or it is also conceivable that the crusher unit 40 is operated when the crusher unit coupling is closed.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2022 121 783.3 | Aug 2022 | DE | national |
