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Sandvik Construction Module 5 ASRi System

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Presentation on theme: "Sandvik Construction Module 5 ASRi System"— Presentation transcript:

1 Sandvik Construction Module 5 ASRi System
A world leader in Construction Module 5 ASRi System Sandvik Construction

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 Sandvik Construction 2

3 Sandvik ASRi System Function
ASRi is a system which automatically regulates the crusher and protects it against overloads during normal operation. Sandvik Construction

4 Sandvik ASRi System Cone crusher automation
One single feature which makes TRUE automation possible. A single cylinder hydraulic adjustment system Sandvik Construction

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) Sandvik Construction

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. Sandvik Construction

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. Sandvik Construction

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 Sandvik Construction

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 Sandvik Construction

10 Sandvik ASRi System Function Sandvik Construction

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. Sandvik Construction

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. Sandvik Construction

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. Sandvik Construction

14 Hydroset Pressure Graph
Sandvik ASRi System Crushing regulation Pressure Current Pressure Average Pressure Average Peak Pressure Hydroset Pressure Graph Welcome to Sandvik Construction

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) Welcome to Sandvik Construction

16 Sandvik ASRi System Display Main screen Status Bar Main Display Area
Menu Bar Sandvik Construction 16

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) Sandvik Construction

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 Sandvik Construction

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. Sandvik Construction

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. Sandvik Construction

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. Sandvik Construction

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. Sandvik Construction

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. Welcome to Sandvik Construction

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 Welcome to Sandvik Construction

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 Welcome to Sandvik Construction

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. Sandvik Construction

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. Sandvik Construction

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 Sandvik Construction

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. Sandvik Construction

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. Sandvik Construction

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 Sandvik Construction 31

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 Sandvik Construction 32

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 Sandvik Construction 33

34 Sandvik Construction A world leader in Construction


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