Algorithm for dynamic cone crusher control

Cone crushers are used in the mineral, mining, and aggregate industry for fragmentation of rock materials.Control systems for cone crusher settings are widely used for compensating for wear and protectingthe machines from high pressure. However, these systems focus on the crusher and not the crushed products.By applying measurement devices on the process the crusher can be run optimally from the saleableproducts point of view (unlike most existing systems which only protect the machine) in each time.The measurement devices can be mass flow meters, e.g. conveyor belt scales. To analyze data from theprocess and convert them to a desired CSS value, an algorithm was developed.The developed algorithm is tested and evolved at a real crushing plant for aggregates. The algorithmwas loaded into a computer which could communicate with the crusher control system, read data fromthree mass flow meters, and also interact with the operators. The computer was reachable over the Internetby the researchers at Chalmers and the algorithm was tuned and improved on-line.The result is an algorithm which was capable of providing CSS set-points to the automatic setting regulationsystem. The amount of saleable product from the crushing stage improved 3.5%, when not limitedby the hydraulic pressure, compared to when a fixed closed side setting is used. The use of the algorithmautomatically compensates for changes in the feed material and it also decreases the need for calibrationof the underlying system