1. Sandvik Construction Module 5 ASRi System
A world leader in Construction
Module 5
ASRi System
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2. Sandvik ASRi System Environment, Health,Safety Our first priority
Safety first everywhere our equipment is in use and in our own organization
Our aim is to achieve zero work related injuries and illness
EMERGENCY EXITS
FIRE ALARM
ASSEMBLY POINTS
EHS leadership from all employees Risk based EHS management systems Certification to OHSAS & ISO Sustainable and continual improvement
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3. Sandvik ASRi System Function
ASRi is a system which automatically regulates the crusher and protects it against overloads during normal operation.
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4. Sandvik ASRi System Cone crusher automation
One single feature which makes TRUE automation possible.
A single cylinder hydraulic adjustment system
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5. ASR1 - ASR2 - ASRC - ASR+ - ASRi (1.0) - ASRi (2.0)
Sandvik ASRi System
Cone crusher automation Experience
System has been designed specifically to maximise plant production without the crusher operating under a condition which could induce an overload.
Since early in the 1970s six different versions have been developed
ASR ASR ASRC ASR ASRi (1.0) ASRi (2.0)
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6. Resultant Crushing Force
Sandvik ASRi System
Function
Load (a)
Load (b)
Resultant Crushing Force
Load (a)
Measured by power draw induced when driving cone during crushing.
Load (b)
Measured by the pressure in the Hydroset piston.
Pressure is directly proportional to the crushing force.
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7. Sandvik ASRi System Function Factors Affecting Material Conditions
Moisture Content,
Feed Material Grading,
Bulk Density,
Toughness,
Product Size (Reduction Ratio).
Machine Factors
Close Side Setting (Reduction Ratio)
Chamber,
Eccentric Throw,
Speed.
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8. Work Done (Energy) = Toughness x Volume x Reduction Ratio
Sandvik ASRi System
Function Factors Affecting
All crushers have a volumetric and mechanical limit
Toughness of material, feed material grading analysis, volume and reduction ratio all play their part in the ability of crusher to perform the duty over an acceptable lifecycle.
If any combination of these factors overstress the mechanical capability of the crusher it will be necessary to reduce the influence of another.
Example: The demand for greater throughput at the expense of reduction.
Work Done (Energy) = Toughness x Volume x Reduction Ratio
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9. Sandvik ASRi System Function Factors Affecting Capacity (TPH)
Power Draw
(kW)
Hydroset Pressure
(Mpa)
Eccentric Speed (RPM)
Chamber Volume (Liners)
Chamber Volume (Throw)
Product Size (CSS)
Product Size /Reduction
Ratio
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10. Sandvik ASRi System
Function
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11. Sandvik ASRi System Function Automatically adjusts for;
Changes in feed material size.
Changes in material toughness.
Changes in material moisture content.
Manganese wear.
Protects the crusher against overloads during normal operation.
Allows easy adjustment of product size.
On the fly adjustment
Maintains the maximum crusher performance.
Independent of feed conditions.
Improves production and product quality.
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12. Sandvik ASRi System Display Screen ASRi 2 Display Screen
Colour Display
Stainless Steel Construction
LED Touch Screen
IP 65 Rating
Self Heating
M12 Electrical Connectors
USB Port used to update or for use of mouse / Keyboard.
Blue LED indicating system live.
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13. Sandvik ASRi System Crushing programs
A crusher can be operated in 4 modes
Manual: With ASRi disconnected.
With ASRi operational a choice of 3 program modes
Auto CSS: This program will always try and hold a pre-set CSS setting for controlled reduction..
Multi CSS: This program will allow operation between two pre-set CSS over pre-set times and is used when a non-standard product curve is preferred.
Auto Load: This program basically regulates on either power or pressure whichever limit is reached first and so minimises the setting for maximum reduction.
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14. Hydroset Pressure Graph
Sandvik ASRi System
Crushing regulation Pressure
Current Pressure
Average Pressure
Average Peak Pressure
Hydroset Pressure Graph
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15. Sandvik ASRi System Crushing regulation Pressure Example A Example B
Pressure Sector
Example A
Example B
Average Peak Pressure (5.5 Mpa)
Maximum pressure
Average Peak Pressure (5.4 Mpa)
Minimum pressure
Max
Max
Average Pressure (3.6 Mpa)
Average Pressure (4.5 Mpa)
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16. Sandvik ASRi System Display Main screen Status Bar Main Display Area
Menu Bar
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17. Sandvik ASRi System Display Main screen Time and Date settings
(within operation settings)
Running status of the ASRi and Current program selection.
Stop: No regulation program running.
Running: Regulation program active.
Calibration: System calibration mode.
Crusher type (Must match actual crusher) and Assigned Name (within installation settings)
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18. Sandvik ASRi System Display Main screen Menu Bar
Main Normal operation screen to monitor crusher during production.
Op.data Real time data graphing “A” dimension, operating data and program event information.
Alarm Current and Logged alarm information.
History Logged historical data over the previous 12h running time.
Set-up System settings and parameters used by the control system when running.
Sandvik ASRi System
Display Main screen
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19. Sandvik ASRi System Display Main screen CSS Setting
Current close side setting in reference to the main shaft position.
Power Draw
Amount of power being used at any given time during crushing, as the crusher load increase the engine load increase.
Hydroset Pressure
Monitors the pressure while crushing in order to protect the chamber from overload.
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20. Sandvik ASRi System Display Main screen Program Run / Stop button
Auto / Manual Feed Control
To maximise plant throughput.
Shaft Raise / Lower
Used to adjust main shaft position manually.
Program Change
Allows program to be altered.
Calibration
Used to calibrate manganese wear in relation to shaft position.
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21. Sandvik ASRi System Data collection Op.Data
The ASRi can present detailed information on the different measured and calculated signals, events etc. Some statistics are also presented that are continuously updated on the screen. The Operating data screen is available from the [Op. data] menu in all operating modes.
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22. Sandvik ASRi System Data collection Op.Data Event List
The Event list screen displays information about changes which have occurred in regulation mode.
The list is presented in chronological order but can also be temporarily sorted in Group order, Time order, or Event text order by pressing the corresponding title bar at the top of the columns.
The event list can contain up to 200 events depending on type.
When the list is full, the oldest event is deleted to make room for a new one.
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23. Sandvik ASRi System Data display Analogue real time information
The Overview screen displays information about the crusher's operating time.
The indicators in the upper section of the screen shows;
Current motor power, Current Hydroset pressure, Current CSS Setting, Lubrication oil temperature, “A” dimension.
The middle section displays information about the crusher’s operating time.
Total run time (loaded and idle)
Loaded (actual crushing time)
The lower section displays information about the crusher’s energy consumption.
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24. Sandvik ASRi System Data collection Alarm List A B C A-alarm
The most serious type of alarm. An A-alarm will immediately stop regulation and will also stop the feed to the crusher if the feed interlock output from the ASRi system is used Regulation cannot be restarted until the fault has been corrected.
B-alarm
Results in a feed shut-down, if the feed interlock output from the ASRi system is used, but regulation continues while the fault persists When the fault has been corrected, the feed is restarted and regulation continues as before.
C-alarm
A warning that indicates that an undesirable condition has been reached. These conditions are not harmful to the machine and neither regulation nor feed are interrupted. A B C
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25. Sandvik ASRi System Data collection Alarm List
Time and Date settings of Alarm Report.
Alarm Status Active Inactive
Alarm description
(brief detail of fault)
Acknowledge
Fault Indicator
Red – Critical Condition
Amber – Warning Condition A
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26. Sandvik ASRi System Data collection History
The ASRi system continuously monitors the various signals and values. These are logged in historical data log files. The different History screens can be accessed from the [History] menu.
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27. Sandvik ASRi System Data display History Overview Overview
Allows user to see historical information of CSS, Average power and Average peak pressure all on a single display screen.
This can be used to analyse the data traces against each other to analyse the historic performance of the crusher.
Pumping activity and feeder operation are also noted.
History can be displayed in time periods of 10 seconds,1,minute,10,minutes, 1 hour and 12,hours. The shorter the historic period the more detail is available but the shorter is the recovery period.
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28. Sandvik ASRi System CSS measurement ”A” dimension
CSS is not measured but calculated by the program. The position of the piston and therefore the shaft is measured by a capacitance probe at the bottom of the crusher. By relating to the “A” dimension the CSS can be calculated
A maximum shaft travel distance is pre-determined by the program settings to ensure that the mantle will not be able to collide with the spider frame.
This figure is used during calibration to determine the bottom position (185mm (CH440)) and also a metal to metal position.
Once calibrated the “A” dimension can be checked by measuring between the mantle nut to the spider frame.
For each 1mm of shaft (“A” dimension) movement CSS is adjusted by;
CH – 0.58mm
CS – 0.34mm
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29. Sandvik ASRi System Calibration for liner wear
When in regulating mode the system cannot determine the wear or rate of wear. So it is necessary to occasionally calibrate the setting. The system will notify if the period between calibrations is too long.This can be initiated by the operator in one of two ways--either metal to metal or with lead
Metal to Metal calibration
Using the touch screen through the calibration window the MM method is selected. Thereafter the ASRi will take control raising the shaft until the mantle touches the concave. Any increase in the “A” dimension will be recognised as wear. The system will then calculate a new higher position for the shaft and return the setting to the programed limit. This is the most common method used with CH crushers The procedure takes a no more than a minute.
Lead calibration
With CS crushers it is nearly always impossible to obtain a metal to metal contact. So measurement of the CSS is done by the operator using a lead and the information keyed into the ASRi which can then calculate and reset.
Auto Calibration
If selected the system carries out an occassional calibration automatically considering as a prompt reduction in power draw.
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30. Sandvik ASRi System Data collection Liner wear Overview
The Liner wear screen displays historical data on main shaft contact position in relation to time and energy consumption. It gives an indication of the liner wear over time. Data can be stored for up to 10 liner sets.
This can then be used to compare the wear life of each liner set and the energy consumption to determine each life cycle.
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31. Sandvik ASRi System Language Availability
The ASRi 2.0 display screen has 22 different language options which can be changed to suit local area / operator dialect.
Bulgarian
English
Italian
Portuguese
Spanish
Chinese
Finnish
Korean
Portuguese(Br)
Swedish
Croatian
French
Norwegian
Russian
Turkish
Czech
German
Polish
Romanian
Danish
Hungarian
Portuguese
Slovenian
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32. Sandvik ASRi System Password protection Operation Service Installation
Operator User Name 1001
Possibility to assign and activate Operator Password
Operation
Service
No Password Protection
Commissioning / Installation User Name & Password
Installation
Regulation
Sandvik User Name & Password
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33. Sandvik ASRi System Summary of Benefits
Today Sandviks customers have to maximise return on their investment . This means not only achieving the maximum throughput from their crushers but having control in a way that maximises the quality and volume of their most saleable products, while reducing maintenance costs especially unplanned and expensive traumatic failure. To achieve this the customer has to have control especially of the setting at which the crusher operates. This can only be accomplished with a setting control system such as ASRi
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34. Sandvik Construction A world leader in Construction