CN113884167A - Method and system for measuring working capacity of movable crusher - Google Patents

Method and system for measuring working capacity of movable crusher Download PDF

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Publication number
CN113884167A
CN113884167A CN202111079144.7A CN202111079144A CN113884167A CN 113884167 A CN113884167 A CN 113884167A CN 202111079144 A CN202111079144 A CN 202111079144A CN 113884167 A CN113884167 A CN 113884167A
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belt
motor
power
conveying
crusher
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CN113884167B (en
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王帅
李祥科
王元鹏
余孟狄
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Hunan Kute Intelligent Technology Co ltd
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Hunan Kute Intelligent Technology Co ltd
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01G—WEIGHING
    • G01G11/00—Apparatus for weighing a continuous stream of material during flow; Conveyor belt weighers
    • G01G11/04—Apparatus for weighing a continuous stream of material during flow; Conveyor belt weighers having electrical weight-sensitive devices
    • G01G11/043—Apparatus for weighing a continuous stream of material during flow; Conveyor belt weighers having electrical weight-sensitive devices combined with totalising or integrating devices
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R21/00—Arrangements for measuring electric power or power factor

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Abstract

The invention discloses a method and a system for measuring the working capacity of a movable crusher, which are characterized in that the power of a belt conveyor is obtained; measuring the motor idling current, the belt inclination angle, the motor current in the idling state of the finished belt and the working current of the finished belt motor of the crusher; and calculating the required power during the idling of the belt, the consumed power during the loading of the belt, the vertical height of the belt conveying, the horizontal distance of the belt conveying, the resistance coefficient of the motor, the belt conveying capacity, the real-time capacity of the crusher and the total output of the crusher in a fixed time according to the acquired power of the belt conveyor, the measured idle current of the motor, the belt inclination angle, the motor current in the idle state of the finished belt and the working current of the finished belt motor. The invention has simple and reliable measuring means, is not limited by the posture of the crusher, the inclination angle of the belt and the like, and is suitable for various working condition sites; the integration level is high, and the universal element can be used as a universal element only by setting a communication protocol with a control system.

Description

Method and system for measuring working capacity of movable crusher
Technical Field
The invention relates to the field of control of engineering mechanical equipment, and particularly discloses a method and a system for measuring the working capacity of a movable crusher.
Background
Because the current environmental protection policy limits river sand excavation, the mode of crushing into sand by stone is more and more widely adopted, and the market development of the mobile crusher is faster and faster. But the technology of working output calculation (sand tonnage) of the crusher per se is still in a blank state at present.
The general workflow of mobile crushing is: the stone blocks are sent to a feeding belt through the excavator → conveyed to a crushing main machine to be crushed into semi-finished products → an iron remover for removing iron and impurities, a blower for removing impurities → a filter screen for filtering → the finished product sand is discharged through a finished product belt, and unqualified sand returns to the main machine through a return belt to be crushed again.
Because the product is mobile, the problems of trafficability and balance need to be considered, and the mechanism of the conveyor belt of the crusher part is foldable or detachable. Thus, conventional weight measuring methods (e.g., load cell/belt scale) cannot be used on products due to installation problems. And the novel technology (such as radar, image recognition and other auxiliary metering) cannot be normally used even in the working environment with serious dust of the crusher. Therefore, the current work output calculation of the crusher cannot be solved by itself, and only can be metered and fed back after the finished product is transported by a downstream truck. This is both less active and less real-time, and the owner of the equipment cannot actively control the product yield and productivity.
Therefore, the above-mentioned defects existing in the self-weighing of the existing mobile crusher are a technical problem to be solved urgently.
Disclosure of Invention
The invention provides a method and a system for measuring the working capacity of a mobile crusher, and aims to solve the technical problem of the defects existing in the self-weighing process of the existing mobile crusher.
One aspect of the invention relates to a method for measuring the working capacity of a mobile crusher, which comprises the following steps:
obtaining the power of the belt conveyor, wherein the power of the belt conveyor comprises the power P required by the belt when the belt idles1The power P required by the horizontal transmission load of the belt2And belt lifting load heightRequired power P3；
Measuring motor idling current I of finished product motor of crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3；
According to the obtained power of the belt conveyor and the measured idle current I of the motor of the finished product motor of the crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3Calculating the power P required by the belt in idle1Power P consumed when belt is loaded2+P3The belt conveying vertical height H, the belt conveying horizontal distance L and the motor resistance coefficient K;
according to the calculated power P required by the idle belt1Power P consumed when belt is loaded2+P3The belt conveying vertical height H, the belt conveying horizontal distance L and the motor resistance coefficient K are calculated, and the belt conveying amount Qt is calculated1Real-time capacity Qt of crusher2And the total yield m of the crusher in a fixed time.
Further, the power P required when the belt is idle1Comprises the following steps:
P1＝(C×f×L×3.6Gm×V)/367
wherein, P1The power required by the belt idling is C, the damping coefficient of a conveying belt and a bearing is F, the damping coefficient of a carrier roller is L, the effective horizontal conveying distance of the belt conveyor is L, the mass of the conveying belt, the carrier roller and a steering roller is Gm, and the belt speed is V;
power P required by belt horizontal conveying load2Comprises the following steps:
P2＝(C×f×L×Qt1)/367
wherein, P2The power required by the belt to horizontally convey the load is C the damping coefficient of the conveyer belt and the bearing, f the damping coefficient of the carrier roller, L the effective horizontal conveying distance of the belt conveyor and Qt1The belt conveying amount;
power P required by belt to lift load height3Comprises the following steps:
P3＝Qt1×H/367
wherein, P3Power required for lifting the height of the load, Qt1The belt conveying amount is shown as H, and the vertical height of the belt conveying is shown as H.
Further, the power P required when the belt is idle1Calculated by the following formula:
Figure BDA0003262999480000021
wherein, P1U is the power supply voltage, cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2Motor current in an idle state of the finished belt;
power P consumed when belt is loaded2+P3Calculated by the following formula:
Figure BDA0003262999480000031
wherein, P2For horizontal transport of the power, P, required by the belt3The power required for elevating the height of the load for the belt, U is the supply voltage, cos phi is the motor power factor, I2Motor current in the idle state of the finished belt, I3Working current of a finished belt motor is obtained;
the belt transport vertical height H is calculated by the following formula:
H＝L0×sinθ
wherein H is the vertical height of belt conveying, L0Is the length of the belt, theta is the inclination angle of the belt;
the belt conveying horizontal distance L is calculated by the following formula:
L＝L0×cosθ
wherein L is the horizontal distance of belt conveying, L0Is the belt length, theta is the belt inclination angle.
The resistance coefficient K of the motor is calculated by the following formula:
K＝C×f＝P1×367/L×3.6Gm×V
wherein K is the resistance coefficient of the motor, C is the damping coefficient of the conveyer belt and the bearing, f is the damping coefficient of the carrier roller, and P is the damping coefficient of the carrier roller1The belt idling power is needed, L is the horizontal distance of belt conveying, Gm is the mass of the conveying belt, the carrier roller and the steering roller, and V is the belt speed.
Further, the belt conveying amount Qt1Calculated by the following formula:
Qt1＝(P2+P3)×367/(K×L+H)
wherein, Qt1For belt conveying capacity, P2For horizontal transport of the power, P, required by the belt3For the belt to promote the high required power of load, K is the motor resistance coefficient, L is belt transport horizontal distance, H is belt transport vertical height.
Further, the real-time capacity Qt of the crusher2Calculated by the following formula:
Qt2＝635×U×cosφ×(I3-I2)/[635×U×cosφ×(I2-I1)/3.6Gm×V+L0×sinθ]
wherein, Qt2For real-time capacity of the crusher cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2Motor current in the idle state of the finished belt, I3The working current of the belt motor is finished, Gm is the quality of the conveying belt, the carrier roller and the steering roller, V is the belt speed, and L is0Is the length of the belt, theta is the inclination angle of the belt;
the total yield m of the crusher in a fixed time is calculated by the following formula:
Figure BDA0003262999480000041
where m is the total yield of the crusher in a fixed time, Qt2The real-time capacity of the crusher is realized.
Another aspect of the invention relates to a mobile crusher work capacity metering system comprising:
an acquisition module for acquiring the power of the belt conveyor, wherein the power of the belt conveyor comprises the power P required by the belt when the belt idles1The power P required by the horizontal transmission load of the belt2And the power P required by the belt for lifting the load height3；
A measuring module for measuring the motor idle current I of the finished product motor of the crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3；
A first calculation module for calculating the motor idle current I of the finished product motor of the crusher according to the acquired power of the belt conveyor and the measured motor idle current I1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3Calculating the power P required by the belt in idle1Power P consumed when belt is loaded2+P3The belt conveying vertical height H, the belt conveying horizontal distance L and the motor resistance coefficient K;
a second calculation module for calculating the power P required by the belt in idle1Power P consumed when belt is loaded2+P3The belt conveying vertical height H, the belt conveying horizontal distance L and the motor resistance coefficient K are calculated, and the belt conveying amount Qt is calculated1Real-time capacity Qt of crusher2And the total yield m of the crusher in a fixed time.
Further, the power P required when the belt is idle1Comprises the following steps:
P1＝(C×f×L×3.6Gm×V)/367
wherein, P1The power required by the belt idling is C, the damping coefficient of a conveying belt and a bearing is F, the damping coefficient of a carrier roller is L, the effective horizontal conveying distance of the belt conveyor is L, the mass of the conveying belt, the carrier roller and a steering roller is Gm, and the belt speed is V;
power P required by belt horizontal conveying load2Comprises the following steps:
P2＝(C×f×L×Qt1)/367
wherein, P2The power required by the belt to horizontally convey the load is C the damping coefficient of the conveyer belt and the bearing, f the damping coefficient of the carrier roller, L the effective horizontal conveying distance of the belt conveyor and Qt1The belt conveying amount;
power P required by belt to lift load height3Comprises the following steps:
P3＝Qt1×H/367
wherein, P3Power required for lifting the height of the load, Qt1The belt conveying amount is shown as H, and the vertical height of the belt conveying is shown as H.
Further, the power P required when the belt is idle1Calculated by the following formula:
Figure BDA0003262999480000051
wherein, P1U is the power supply voltage, cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2Motor current in an idle state of the finished belt;
power P consumed when belt is loaded2+P3Calculated by the following formula:
Figure BDA0003262999480000052
wherein, P2For horizontal transport of the power, P, required by the belt3The power required for elevating the height of the load for the belt, U is the supply voltage, cos phi is the motor power factor, I2Motor current in the idle state of the finished belt, I3Working current of a finished belt motor is obtained;
the belt transport vertical height H is calculated by the following formula:
H＝L0×sinθ
wherein H is the vertical height of belt conveying, L0Is the length of the belt, theta is the inclination angle of the belt;
the belt conveying horizontal distance L is calculated by the following formula:
L＝L0×cosθ
wherein L is the horizontal distance of belt conveying, L0Is the belt length, theta is the belt inclination angle.
The resistance coefficient K of the motor is calculated by the following formula:
K＝C×f＝P1×367/L×3.6Gm×V
wherein K is the resistance coefficient of the motor, C is the damping coefficient of the conveyer belt and the bearing, f is the damping coefficient of the carrier roller, and P is the damping coefficient of the carrier roller1The belt idling power is needed, L is the horizontal distance of belt conveying, Gm is the mass of the conveying belt, the carrier roller and the steering roller, and V is the belt speed.
Further, the belt conveying amount Qt1Calculated by the following formula:
Qt1＝(P2+P3)×367/(K×L+H)
wherein, Qt1For belt conveying capacity, P2For horizontal transport of the power, P, required by the belt3For the belt to promote the high required power of load, K is the motor resistance coefficient, L is belt transport horizontal distance, H is belt transport vertical height.
Further, the real-time capacity Qt of the crusher2Calculated by the following formula:
Qt2＝635×U×cosφ×(I3-I2)/[635×U×cosφ×(I2-I1)/3.6Gm×V+L0×sinθ]
wherein, Qt2For real-time capacity of the crusher cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2Motor current in the idle state of the finished belt, I3The working current of the belt motor is finished, Gm is the quality of the conveying belt, the carrier roller and the steering roller, V is the belt speed, and L is0Is the length of the belt, theta is the inclination angle of the belt;
the total yield m of the crusher in a fixed time is calculated by the following formula:
Figure BDA0003262999480000061
where m is the total yield of the crusher in a fixed time, Qt2The real-time capacity of the crusher is realized.
The beneficial effects obtained by the invention are as follows:
the invention provides a method and a system for measuring the working capacity of a mobile crusher, which are characterized in that the power of a belt conveyor is obtained, and the power of the belt conveyor comprises the power P required by the idling of a belt1The power P required by the horizontal transmission load of the belt2And the power P required by the belt for lifting the load height3(ii) a Measuring motor idling current I of finished product motor of crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3(ii) a According to the obtained power of the belt conveyor and the measured idle current I of the motor of the finished product motor of the crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3Calculating the power P required by the belt in idle1Power P consumed when belt is loaded2+P3Belt conveying vertical height H, belt conveying horizontal distance L, motor resistance coefficient K and belt conveying amount Qt1Real-time capacity Qt of crusher2And the total yield m of the crusher in a fixed time. According to the method and the system for measuring the working capacity of the mobile crusher, the effective output power of the belt motor of the crusher is calculated by measuring the no-load and load current of the motor, the weight of sand transported by the belt is reversely calculated by assisting the parameters such as the inclination angle of the belt, the length of the belt, the self weight of the belt and the like, and the mass of the sand transported by a finished product belt of the crusher can be indirectly measured without directly weighing the difficult scheme; the measuring means is simple and reliable, is not limited by the posture of the crusher, the inclination angle of the belt and the like, and is suitable for various working condition sites; the integration level is high, and the universal element can be used as a universal element only by setting a communication protocol with a control system.
Drawings
FIG. 1 is a schematic flow chart illustrating a method for measuring working capacity of a mobile crusher according to an embodiment of the present invention;
fig. 2 is a functional block diagram of an embodiment of a working capacity metering system of a mobile crusher according to the present invention.
The reference numbers illustrate:
10. an acquisition module; 20. a measurement module; 30. a first calculation module; 40. and a second calculation module.
Detailed Description
In order to better understand the technical solution, the technical solution will be described in detail with reference to the drawings and the specific embodiments.
As shown in fig. 1 and fig. 2, a first embodiment of the present invention provides a method for measuring working capacity of a mobile crusher, comprising the following steps:
step S100, obtaining the power of the belt conveyor, wherein the power of the belt conveyor comprises the power P required by the idling of a belt1The power P required by the horizontal transmission load of the belt2And the power P required by the belt for lifting the load height3。
The power of the belt conveyor is composed of three parts, namely the power P required by the idle belt1Power P required for horizontal belt conveying load2And the power P required by the belt for lifting the load height3。
The calculation formula of the total power of the belt conveyor is as follows:
P0＝[C×f×L×(3.6Gm×V+Qt)+Qt×H]/367 (1)
in the formula (1), P0The total power of the belt conveyor is C, the damping coefficient of a conveying belt and a bearing (belt inherent constant), f is the damping coefficient of a carrier roller (belt inherent constant), L is the effective horizontal conveying distance of the belt conveyor (belt inherent constant), GM is the mass of the conveying belt, the carrier roller and a steering roller (belt inherent constant), V is the belt speed (because of the constant frequency of a motor, the mass can also be roughly regarded as constant under the condition of no serious overload), Qt is the conveying capacity of the belt (unit ton/hour), and H is the vertical conveying height of the belt.
The power is split into the three parts, namely:
first, the power P required by the belt in idle1Comprises the following steps:
P1＝(C×f×L×3.6Gm×V)/367 (2)
in the formula (2), P1The power required by the belt in idling is C, the damping coefficient of a conveying belt and a bearing is F, the damping coefficient of a carrier roller is L, the effective horizontal conveying distance of the belt conveyor is L, the mass of the conveying belt, the carrier roller and a steering roller is Gm, and the belt speed is V.
Secondly, the belt horizontally transmits the power P required by the load2Comprises the following steps:
P2＝(C×f×L×Qt1)/367 (3)
in formula (3), P2The power required by the belt to horizontally convey the load is C the damping coefficient of the conveyer belt and the bearing, f the damping coefficient of the carrier roller, L the effective horizontal conveying distance of the belt conveyor and Qt1The belt conveying amount.
Thirdly, the power P required by the belt to lift the load height3Comprises the following steps:
P3＝Qt1×H/367 (4)
in the formula (4), P3Power required for lifting the height of the load, Qt1The belt conveying amount is shown as H, and the vertical height of the belt conveying is shown as H.
Step S200, measuring the motor idling current I of the finished product motor of the crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3。
When the belt motor of the crusher is not connected with the belt, the idle current of the motor is measured to be I through the current transducer1(fixed value, each device only needs to measure once). When the finished product belt of the crusher is unfolded and then runs in a no-load mode, the inclination angle theta of the belt is measured through the inclination angle sensor, the current of the finished product belt which is unfolded in place but does not transmit load gravel is measured through the current transducer, and the current of the motor in the idle state of the finished product belt is I2. When the crusher starts to work, the working current of the loaded finished belt motor is measured to be I in real time through the current transducer3。
Step S300, according to the acquired power of the belt conveyor and the measured idle current I of the motor of the finished product motor of the crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3Calculating the power P required by the belt in idle1Power P consumed when belt is loaded2+P3The device comprises a belt conveying vertical height H, a belt conveying horizontal distance L and a motor resistance coefficient K.
According to a motor power calculation formula, the self no-load power consumption of the motor can be calculated:
Figure BDA0003262999480000081
in the formula (5), U is the power supply voltage, cos phi is the power factor of the motor, and the terms are known; i is1Is the motor idling current of the finished product motor of the crusher.
Power P required when belt is idle1Calculated by the following formula:
Figure BDA0003262999480000091
in the formula (6), P1U is the power supply voltage, cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2The motor current is in the idle state of the finished belt.
Power P consumed when belt is loaded2+P3Calculated by the following formula:
Figure BDA0003262999480000092
in the formula (7), P2For horizontal transport of the power, P, required by the belt3The power required for elevating the height of the load for the belt, U is the supply voltage, cos phi is the motor power factor, I2In an idle state of the beltMechanical current, I3The finished product of the belt motor is the working current.
The belt transport vertical height H is calculated by the following formula:
H＝L0×sinθ (8)
in the formula (8), H is the vertical height of belt conveying, L0Is the belt length, theta is the belt inclination angle.
The belt conveying horizontal distance L is calculated by the following formula:
L＝L0×cosθ (9)
in the formula (9), L is the horizontal distance of belt conveying, L0Is the belt length, theta is the belt inclination angle.
Power P required when belt is idle1Calculated by the following formula:
Figure BDA0003262999480000093
formula (10), P1U is the power supply voltage, cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2The motor current is in the idle state of the finished belt.
Power P consumed when belt is loaded2+P3Calculated by the following formula:
Figure BDA0003262999480000094
in formula (11), P2For horizontal transport of the power, P, required by the belt3The power required for elevating the height of the load for the belt, U is the supply voltage, cos phi is the motor power factor, I2Motor current in the idle state of the finished belt, I3The finished product of the belt motor is the working current.
The belt transport vertical height H is calculated by the following formula:
H＝L0×sinθ (12)
in the formula (12), H is the number of sheetsWith vertical height of transport, L0Is the belt length, theta is the belt inclination angle.
The belt conveying horizontal distance L is calculated by the following formula:
L＝L0×cosθ (13)
in the formula (13), L is the horizontal belt conveying distance, L0Is the belt length, theta is the belt inclination angle.
Step S400, obtaining the required power P during the idle running of the belt according to the calculation1Power P consumed when belt is loaded2+P3The belt conveying vertical height H, the belt conveying horizontal distance L and the motor resistance coefficient K are calculated, and the belt conveying amount Qt is calculated1Real-time capacity Qt of crusher2And the total yield m of the crusher in a fixed time.
Belt conveying amount Qt1Calculated by the following formula:
Qt1＝(P2+P3)×367/(K×L+H) (14)
in formula (14), Qt1For belt conveying capacity, P2For horizontal transport of the power, P, required by the belt3For the belt to promote the high required power of load, K is the motor resistance coefficient, L is belt transport horizontal distance, H is belt transport vertical height.
Further, the real-time capacity Qt of the crusher2Calculated by the following formula:
Qt2＝635×U×cosφ×(I3-I2)/[635×U×cosφ×(I2-I1)/3.6Gm×V+L0×sinθ] (15)
in the formula (15), Qt2The capacity of the crusher is real-time capacity, and the unit is ton/hour; cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2Motor current in the idle state of the finished belt, I3The working current of the belt motor is finished, Gm is the quality of the conveying belt, the carrier roller and the steering roller, V is the belt speed, and L is0Is the belt length, theta is the belt inclination angle.
Crushing machineWithin a fixed time (t)1To t2) The total yield m of (a) is calculated by the following formula:
Figure BDA0003262999480000101
in the formula (16), m is the total yield of the crusher in a fixed time and is expressed in tons; qt2The real-time capacity of the crusher is realized.
Compared with the prior art, the method for measuring the working capacity of the mobile crusher obtains the power of the belt conveyor, wherein the power of the belt conveyor comprises the power P required by the idling belt1The power P required by the horizontal transmission load of the belt2And the power P required by the belt for lifting the load height3(ii) a Measuring motor idling current I of finished product motor of crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3(ii) a According to the obtained power of the belt conveyor and the measured idle current I of the motor of the finished product motor of the crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3Calculating the power P required by the belt in idle1Power P consumed when belt is loaded2+P3Belt conveying vertical height H, belt conveying horizontal distance L, motor resistance coefficient K and belt conveying amount Qt1Real-time capacity Qt of crusher2And the total yield m of the crusher in a fixed time. According to the working capacity metering method of the mobile crusher, the effective output power of a belt motor of the crusher is calculated by measuring the no-load and load current of the motor, the weight of sand conveyed by the belt is inversely calculated by assisting the parameters such as the inclination angle of the belt, the length of the belt, the self weight of the belt and the like, and the mass of the sand conveyed by a finished belt of the crusher can be indirectly measured without directly weighing the difficult-to-realize scheme such as direct weighing; the measuring means is simple and reliable, is not limited by the posture of the crusher, the inclination angle of the belt and the like, and is suitable for various working condition sites; the integration level is high, and only a fixing and control system is neededThe system communication protocol can be used as a universal component.
Preferably, please refer to fig. 2, fig. 2 is a functional block diagram of an embodiment of the mobile crusher working capacity metering system provided by the present invention, in this embodiment, the mobile crusher working capacity metering system includes an obtaining module 10, a measuring module 20, a first calculating module 30 and a second calculating module 40, wherein the obtaining module 10 is configured to obtain a power of a belt conveyor, and the power of the belt conveyor includes a power P required by a belt idling1The power P required by the horizontal transmission load of the belt2And the power P required by the belt for lifting the load height3(ii) a A measuring module 20 for measuring the motor idle current I of the finished product motor of the crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3. A first calculation module 30 for calculating the motor idle current I of the finished crusher motor according to the acquired power of the belt conveyor and the measured motor idle current I1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3Calculating the power P required by the belt in idle1Power P consumed when belt is loaded2+P3The device comprises a belt conveying vertical height H, a belt conveying horizontal distance L and a motor resistance coefficient K. A second calculation module 40 for calculating the power P required for idling of the belt1Power P consumed when belt is loaded2+P3The belt conveying vertical height H, the belt conveying horizontal distance L and the motor resistance coefficient K are calculated, and the belt conveying amount Qt is calculated1Real-time capacity Qt of crusher2And the total yield m of the crusher in a fixed time.
The power of the belt conveyor is composed of three parts, namely the power P required by the idle belt1Power P required for horizontal belt conveying load2And the power P required by the belt for lifting the load height3。
The calculation formula of the total power of the belt conveyor is as follows:
P0＝[C×f×L×(3.6Gm×V+Qt)+Qt×H]/367 (17)
in formula (17), P0The total power of the belt conveyor is C, the damping coefficient of a conveying belt and a bearing (belt inherent constant), f is the damping coefficient of a carrier roller (belt inherent constant), L is the effective horizontal conveying distance of the belt conveyor (belt inherent constant), Gm is the mass of the conveying belt, the carrier roller and a steering roller (belt inherent constant), V is the belt speed (constant can be roughly considered under the condition of no serious overload because of the fixed frequency of a motor), Qt is the conveying capacity of the belt (unit ton/hour), and H is the vertical conveying height of the belt.
The power is split into the three parts, namely:
first, the power P required by the belt in idle1Comprises the following steps:
P1＝(C×f×L×3.6Gm×V)/367 (18)
in the formula (18), P1The power required by the belt in idling is C, the damping coefficient of a conveying belt and a bearing is F, the damping coefficient of a carrier roller is L, the effective horizontal conveying distance of the belt conveyor is L, the mass of the conveying belt, the carrier roller and a steering roller is Gm, and the belt speed is V.
Secondly, the belt horizontally transmits the power P required by the load2Comprises the following steps:
P2＝(C×f×L×Qt1)/367 (19)
in the formula (19), P2The power required by the belt to horizontally convey the load is C the damping coefficient of the conveyer belt and the bearing, f the damping coefficient of the carrier roller, L the effective horizontal conveying distance of the belt conveyor and Qt1The belt conveying amount.
Thirdly, the power P required by the belt to lift the load height3Comprises the following steps:
P3＝Qt1×H/367 (20)
in the formula (20), P3Power required for lifting the height of the load, Qt1The belt conveying amount is shown as H, and the vertical height of the belt conveying is shown as H.
When the belt motor of the crusher is not connected with the belt, the idle current of the motor is measured to be I through the current transducer1(fixed value, each device only needs to measure once). When the finished product belt of the crusher runs in no-load operation after being unfolded, the finished product belt of the crusher passes through the inclination angle sensorThe device measures the inclination angle theta of the belt, and measures the current of the finished belt which is unfolded in place but does not transmit load sand through the current transducer, namely the current of the motor in the idle state of the finished belt is I2. When the crusher starts to work, the working current of the loaded finished belt motor is measured to be I in real time through the current transducer3。
According to a motor power calculation formula, the self no-load power consumption of the motor can be calculated:
Figure BDA0003262999480000131
in the formula (21), U is the power supply voltage, cos phi is the motor power factor, and both are known terms; i is1Is the motor idling current of the finished product motor of the crusher.
Power P required when belt is idle1Calculated by the following formula:
Figure BDA0003262999480000132
in the formula (22), P1U is the power supply voltage, cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2The motor current is in the idle state of the finished belt.
Power P consumed when belt is loaded2+P3Calculated by the following formula:
Figure BDA0003262999480000133
in the formula (23), P2For horizontal transport of the power, P, required by the belt3The power required for elevating the height of the load for the belt, U is the supply voltage, cos phi is the motor power factor, I2Motor current in the idle state of the finished belt, I3The finished product of the belt motor is the working current.
The belt transport vertical height H is calculated by the following formula:
H＝L0×sinθ (24)
in the formula (24), H is the vertical height of belt conveying, L0Is the belt length, theta is the belt inclination angle.
The belt conveying horizontal distance L is calculated by the following formula:
L＝L0×cosθ (25)
in the formula (25), L is the horizontal belt conveying distance, L0Is the belt length, theta is the belt inclination angle.
Power P required when belt is idle1Calculated by the following formula:
Figure BDA0003262999480000134
formula (26), P1U is the power supply voltage, cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2The motor current is in the idle state of the finished belt.
Power P consumed when belt is loaded2+P3Calculated by the following formula:
Figure BDA0003262999480000135
in the formula (27), P2For horizontal transport of the power, P, required by the belt3The power required for elevating the height of the load for the belt, U is the supply voltage, cos phi is the motor power factor, I2Motor current in the idle state of the finished belt, I3The finished product of the belt motor is the working current.
The belt transport vertical height H is calculated by the following formula:
H＝L0×sinθ (28)
in the formula (28), H is the vertical height of belt conveying, L0Is the belt length, theta is the belt inclination angle.
The belt conveying horizontal distance L is calculated by the following formula:
L＝L0×cosθ (29)
in the formula (29), L is the horizontal distance of belt conveying, L0Is the belt length, theta is the belt inclination angle.
Belt conveying amount Qt1Calculated by the following formula:
Qt1＝(P2+P3)×367/(K×L+H) (30)
in the formula (30), Qt1For belt conveying capacity, P2For horizontal transport of the power, P, required by the belt3For the belt to promote the high required power of load, K is the motor resistance coefficient, L is belt transport horizontal distance, H is belt transport vertical height.
Further, the real-time capacity Qt of the crusher2Calculated by the following formula:
gt2＝635×U×cosφ×(I3-I2)/[635×U×cosφ×(I2-I1)/3.6Gm×V+L0×sinθ] (31)
in formula (31), Qt2The capacity of the crusher is real-time capacity, and the unit is ton/hour; cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2Motor current in the idle state of the finished belt, I3The working current of the belt motor is finished, Gm is the quality of the conveying belt, the carrier roller and the steering roller, V is the belt speed, and L is0Is the belt length, theta is the belt inclination angle.
The crusher is in a fixed time (t)1To t2) The total yield m of (a) is calculated by the following formula:
Figure BDA0003262999480000141
in the formula (32), m is the total yield of the crusher in a fixed time and is expressed in tons; qt2The real-time capacity of the crusher is realized.
The present embodiment provides aCompared with the prior art, the working capacity metering system of the mobile crusher adopts the acquisition module, the measurement module, the first calculation module and the second calculation module, and obtains the power of the belt conveyor, wherein the power of the belt conveyor comprises the power P required by the idling belt1The power P required by the horizontal transmission load of the belt2And the power P required by the belt for lifting the load height3(ii) a Measuring motor idling current I of finished product motor of crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3(ii) a According to the obtained power of the belt conveyor and the measured idle current I of the motor of the finished product motor of the crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3Calculating the power P required by the belt in idle1Power P consumed when belt is loaded2+P3Belt conveying vertical height H, belt conveying horizontal distance L, motor resistance coefficient K and belt conveying amount Qt1Real-time capacity Qt of crusher2And the total yield m of the crusher in a fixed time. According to the working capacity metering system of the mobile crusher, the effective output power of the belt motor of the crusher is calculated by measuring the no-load and load current of the motor, the weight of sand conveyed by the belt is inversely calculated by assisting the parameters such as the inclination angle of the belt, the length of the belt, the self weight of the belt and the like, and the mass of the sand conveyed by a finished product belt of the crusher can be indirectly measured without directly weighing the difficult-to-realize scheme; the measuring means is simple and reliable, is not limited by the posture of the crusher, the inclination angle of the belt and the like, and is suitable for various working condition sites; the integration level is high, and the universal element can be used as a universal element only by setting a communication protocol with a control system.
While preferred embodiments of the present invention have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all such alterations and modifications as fall within the scope of the invention. It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.

Claims (10)

1. A working capacity metering method of a mobile crusher is characterized by comprising the following steps:
obtaining the power of a belt conveyor, wherein the power of the belt conveyor comprises the power P required by the belt when the belt idles1The power P required by the horizontal transmission load of the belt2And the power P required by the belt for lifting the load height3；
Measuring motor idling current I of finished product motor of crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3；
According to the obtained power of the belt conveyor and the measured idle current I of the motor of the finished product motor of the crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3Calculating the power P required by the belt in idle1Power P consumed when belt is loaded2+P3The belt conveying vertical height H, the belt conveying horizontal distance L and the motor resistance coefficient K;
according to the calculated power P required by the idle belt1Power P consumed when belt is loaded2+P3The belt conveying vertical height H, the belt conveying horizontal distance L and the motor resistance coefficient K are calculated, and the belt conveying amount Qt is calculated1Real-time capacity Qt of crusher2And the total yield m of the crusher in a fixed time.
2. The method according to claim 1, wherein the power P required for idling belt is P1Comprises the following steps:
P1＝(C×f×L×3.6Gm×V)/367
wherein, P1The power required by the belt idling is C, the damping coefficient of a conveying belt and a bearing is F, the damping coefficient of a carrier roller is L, the effective horizontal conveying distance of the belt conveyor is L, the mass of the conveying belt, the carrier roller and a steering roller is Gm, and the belt speed is V;
the belt horizontally transmits the power P required by the load2Comprises the following steps:
P2＝(C×f×L×Qt1)/367
wherein, P2The power required by the belt to horizontally convey the load is C the damping coefficient of the conveyer belt and the bearing, f the damping coefficient of the carrier roller, L the effective horizontal conveying distance of the belt conveyor and Qt1The belt conveying amount;
the power P required by the belt for lifting the load height3Comprises the following steps:
P3＝Qt1×H/367
wherein, P3Power required for lifting the height of the load, Qt1The belt conveying amount is shown as H, and the vertical height of the belt conveying is shown as H.
3. The method according to claim 2, wherein the power P required for idling belt is P1Calculated by the following formula:
Figure FDA0003262999470000021
wherein, P1U is the power supply voltage, cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2Motor current in an idle state of the finished belt;
power P consumed when the belt is loaded2+P3Calculated by the following formula:
Figure FDA0003262999470000022
wherein, P2For horizontal transport of the power, P, required by the belt3The power required for elevating the height of the load for the belt, U is the supply voltage, cos phi is the motor power factor, I2Motor current in the idle state of the finished belt, I3Working current of a finished belt motor is obtained;
the belt conveying vertical height H is calculated by the following formula:
H＝L0×sinθ
wherein H is the vertical height of belt conveying, L0Is the length of the belt, theta is the inclination angle of the belt;
the belt conveying horizontal distance L is calculated by the following formula:
L＝L0×cosθ
wherein L is the horizontal distance of belt conveying, L0Is the belt length, theta is the belt inclination angle.
The motor resistance coefficient K is calculated by the following formula:
K＝C×f＝P1×367/L×3.6Gm×V
wherein K is the resistance coefficient of the motor, C is the damping coefficient of the conveyer belt and the bearing, f is the damping coefficient of the carrier roller, and P is the damping coefficient of the carrier roller1The belt idling power is needed, L is the horizontal distance of belt conveying, Gm is the mass of the conveying belt, the carrier roller and the steering roller, and V is the belt speed.
4. The mobile crusher working capacity metering method of claim 3, characterized in that the belt conveying amount Qt1Calculated by the following formula:
Qt1＝(P2+P3)×367/(K×L+H)
wherein, Qt1For belt conveying capacity, P2For horizontal transport of the power, P, required by the belt3For the belt to promote the high required power of load, K is the motor resistance coefficient, L is belt transport horizontal distance, H is belt transport vertical height.
5. The mobile crusher working capacity meter of claim 4Method, characterized in that the crusher is capable of producing Qt real time2Calculated by the following formula:
Qt2＝635×U×cosφ×(I3-I2)/[635×U×cosφ×(I2-I1)/3.6Gm×V+L0×sinθ]
wherein, Qt2For real-time capacity of the crusher cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2Motor current in the idle state of the finished belt, I3The working current of the belt motor is finished, Gm is the quality of the conveying belt, the carrier roller and the steering roller, V is the belt speed, and L is0Is the length of the belt, theta is the inclination angle of the belt;
the total yield m of the crusher in a fixed time is calculated by the following formula:
Figure FDA0003262999470000031
where m is the total yield of the crusher in a fixed time, Qt2The real-time capacity of the crusher is realized.
6. A mobile crusher work capacity metering system, comprising:
an acquisition module (10) for acquiring the power of a belt conveyor, including the power P required when the belt is idle1The power P required by the horizontal transmission load of the belt2And the power P required by the belt for lifting the load height3；
A measuring module (20) for measuring the motor idle current I of the finished product motor of the crusher1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3；
A first calculation module (30) for calculating the motor idle current I of the finished crusher motor according to the acquired power of the belt conveyor and the measured motor idle current I1Belt inclination angle theta, finished belt idling state motor current I2Working current I of finished belt motor3Calculating the power P required by the belt in idle1Power P consumed when belt is loaded2+P3The belt conveying vertical height H, the belt conveying horizontal distance L and the motor resistance coefficient K;
a second calculation module (40) for calculating the power P required when the belt is idle1Power P consumed when belt is loaded2+P3The belt conveying vertical height H, the belt conveying horizontal distance L and the motor resistance coefficient K are calculated, and the belt conveying amount Qt is calculated1Real-time capacity Qt of crusher2And the total yield m of the crusher in a fixed time.
7. The mobile crusher working capacity metering system of claim 6, wherein the power P required for the belt to idle is P1Comprises the following steps:
P1＝(C×f×L×3.6Gm×V)/367
wherein, P1The power required by the belt idling is C, the damping coefficient of a conveying belt and a bearing is F, the damping coefficient of a carrier roller is L, the effective horizontal conveying distance of the belt conveyor is L, the mass of the conveying belt, the carrier roller and a steering roller is Gm, and the belt speed is V;
the belt horizontally transmits the power P required by the load2Comprises the following steps:
P2＝(C×f×L×Qt1)/367
wherein, P2The power required by the belt to horizontally convey the load is C the damping coefficient of the conveyer belt and the bearing, f the damping coefficient of the carrier roller, L the effective horizontal conveying distance of the belt conveyor and Qt1The belt conveying amount;
the power P required by the belt for lifting the load height3Comprises the following steps:
P3＝Qt1×H/367
wherein, P3Power required for lifting the height of the load, Qt1The belt conveying amount is shown as H, and the vertical height of the belt conveying is shown as H.
8. As claimed in claim 7The system for measuring the working capacity of the mobile crusher is characterized in that the power P required by the idle belt is P1Calculated by the following formula:
Figure FDA0003262999470000041
wherein, P1U is the power supply voltage, cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2Motor current in an idle state of the finished belt;
power P consumed when the belt is loaded2+P3Calculated by the following formula:
Figure FDA0003262999470000042
wherein, P2For horizontal transport of the power, P, required by the belt3The power required for elevating the height of the load for the belt, U is the supply voltage, cos phi is the motor power factor, I2Motor current in the idle state of the finished belt, I3Working current of a finished belt motor is obtained;
the belt conveying vertical height H is calculated by the following formula:
H＝L0×sinθ
wherein H is the vertical height of belt conveying, L0Is the length of the belt, theta is the inclination angle of the belt;
the belt conveying horizontal distance L is calculated by the following formula:
L＝L0×cosθ
wherein L is the horizontal distance of belt conveying, L0Is the belt length, theta is the belt inclination angle.
The motor resistance coefficient K is calculated by the following formula:
K＝C×f＝P1×367/L×3.6Gm×V
wherein K is the resistance coefficient of the motor, and C is the outputDamping coefficient of belt and bearing, f is damping coefficient of carrier roller, P1The belt idling power is needed, L is the horizontal distance of belt conveying, Gm is the mass of the conveying belt, the carrier roller and the steering roller, and V is the belt speed.
9. The mobile crusher work capacity metering system of claim 8, wherein the belt delivery capacity Qt1Calculated by the following formula:
Qt1＝(P2+P3)×367/(K×L+H)
wherein, Qt1For belt conveying capacity, P2For horizontal transport of the power, P, required by the belt3For the belt to promote the high required power of load, K is the motor resistance coefficient, L is belt transport horizontal distance, H is belt transport vertical height.
10. The mobile crusher working capacity metering system of claim 9, wherein the crusher real-time capacity Qt2Calculated by the following formula:
Qt2＝635×U×cosφ×(I3-I2)/[635×U×cosφ×(I2-I1)/3.6Gm×V+L0×sinθ]
wherein, Qt2For real-time capacity of the crusher cos phi is the motor power factor, I1Motor idle current for the finished motor of the crusher, I2Motor current in the idle state of the finished belt, I3The working current of the belt motor is finished, Gm is the quality of the conveying belt, the carrier roller and the steering roller, V is the belt speed, and L is0Is the length of the belt, theta is the inclination angle of the belt;
the total yield m of the crusher in a fixed time is calculated by the following formula:
Figure FDA0003262999470000051
where m is the total yield of the crusher in a fixed time, Qt2To breakThe real-time capacity of the crusher.
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