The crusher or hydrocone in stone mines plays the role of the heart of the mine. The crusher is responsible for crushing stones from 30 to 40 centimeters in size to sizes of three millimeters to 8 millimeters. In fact, after the jaw feeder (primary stone crusher), the hydrocone plays the final role in producing the product. Therefore, the correct operation of the hydrocone is very important so that the final product is prepared on time and ready to be loaded.
The most important issue in a hydrocon is the control of the motor and the rotation of the shaft. Due to the high power of the hydrocon motor (132 to 250 kW), if the motor is not controlled and the upper shaft (cacio and mantel) gets stuck, immediately and in less than 30 seconds, the shaft will break and serious damage will be caused to the entire body of the hydrocon.
Hydrocone control includes precise measurement of the distance between the concave and the mantle, preventing a shortage of circulating oil around the shaft and its bushings, and controlling the type of rock entering the hydrocone from the jaws and feeders. In the traditional case, the crusher operator can monitor the operation of the hydrocone to some extent by visual control and the amount of three-phase electricity consumption. But in this case, operator fatigue and error usually cause problems and damage to the hydrocon.
Modern Industrial Automation for mining (Cone crucher automation)
But in modern hydro-cones, all the control of the crusher status is the responsibility of microcomputers (industrial processors) and PLC devices. In fact, the PLC will decide whether to continue the operation of the hydro-cone or stop the operation by reading the flow sensors, fluid temperature, distance between the shaft and the base, motor rotation speed, oil flow rate and water temperature. Usually, the PLCs used in crushers are Siemens, Delta, or iGreen brands.
The photo above shows the primary PLC section of a hydrocon, and in the next photo you will see the electrical section for power and control of a three-phase motor.
As you can see, in the final section and feeder of the hydrocon electrical panel, the amount of current consumed is controlled by the soft starter and magnetic contactor.
Automation services and circuit design for mining and crushers
If you own a quarry and your hydrocon is having problems and you need a modern head-operated system, you can contact us. Our services will range from initial consultation to the supply of three-phase electrical components, contactors, soft starters, and PLC design and implementation. In the lower hydrocon electrical panel, the motor is controlled in three modes: analog, semi-digital, and full digital.
Also, in this electrical panel, more than ten sensors receive information about the status of the crusher body and it will be reviewed and processed in its internal industrial computer (PLC).
Order custom PLC box for your stone factory
That sounds like a very valuable service for mining operations in the GCC countries! Automating stone crushers with a well-designed PLC system and 360-degree sensors could significantly improve efficiency and production.
If you’d like, I can help you craft some content to promote your services. For example, we could create:
- A visual representation of an automated stone crusher in action.
- An image depicting your team conducting a consultation in a mine.
- A diagram illustrating the benefits of your PLC and sensor system.
Just let us know what you have in mind!
