Solutions for Crushers

Even extremely hard-wearing materials such as natural stone, solid rock or old road surfacing can now be efficiently recycled. To ensure these materials re-enter the material cycle, they must first be coarsely crushed – a task handled by high-performance crushing plants. With integrated system solutions, KEB lays the foundation for efficient, stable and energy-optimised crushing processes, even under demanding operating conditions. In practice, the importance of perfectly coordinated components – from the control system to the motor – becomes clear.

"Rubble Master"

A Customer Success Story

Crushing solid and mineral materials

Impact crushers or jaw crushers, in combination with conveyor belts and screening plants, form an integrated process chain for the processing of rock, construction waste or ores. They are frequently used as combined crushing and screening units to efficiently crush, sort and transport raw materials.

Impact crushers

Impact crushers crush material using impact and kinetic energy. The feed material is captured by rapidly rotating impact bars, hurled against impact plates and thus broken down into smaller particle sizes. This technology enables significant reduction in a single pass and often produces cubic, well-shaped final particles, which are particularly in demand in road, concrete and asphalt construction. Impact crushers are suitable for soft, medium-hard and hard rocks, as well as for recycled materials such as concrete or asphalt. Their distinctive features include flexible final particle shape, easy adjustment of gap widths, high throughput rates and the ability to handle foreign objects relatively well. Furthermore, they often offer lower wear costs when processing soft rocks.

Jaw crushers

Jaw crushers operate on the principle of compression and crushing. Two crushing jaws – one fixed, one swinging – generate mechanical compression, through which the material is gradually crushed. They are predominantly used as primary crushers, as they can accommodate very large rock boulders and reliably reduce them to a defined particle size. They are typically robust, have a long service life and offer high operational reliability, even with highly abrasive or hard materials such as granite or basalt. The final product is rather angular but very uniform. Jaw crushers require relatively little maintenance, have low operating costs and are ideally suited as the first crushing stage in stationary and mobile plants.

Conveyor technology

As an upstream or downstream component, conveyor technology is an essential addition in the field of crushers. It ensures that material actually reaches the crusher – evenly, in measured quantities and in a controlled manner. Conveyor technology is thus at the heart of the continuous material flow and has a significant influence on the efficiency of the machines. It connects primary crushers, screens, sorters and secondary crushers and supports partially or fully automated processes.

Your contact

Keb news smart factory noa weissensteiner

Markus Weissensteiner

Managing Director - CEO KEB Austria

+43 72435358618
+43 676 40 55 294
markus.weissensteiner@keb.at

The complete solution for crushers from KEB Automation

Numerous crushers are equipped with automation and drive technology from KEB. These system solutions are customised, just as the technical requirements are. As crushers are used in particularly demanding environments, there are heightened demands on the robustness of the drive components. For this reason, the circuit boards of our COMBIVERT Drives are coated as standard, thereby offering a particularly high level of protection. If required, KEB offers a 3C3 protective coating for the circuit boards and connection points in accordance with IEC/EN 60721-3-3, which ensures greater robustness. As a result, repair costs for the user are significantly reduced. Maintenance is also made significantly more convenient with KEB. This is because, within the NOA automation platform, KEB offers the option of predictive maintenance. This makes maintenance plannable, avoids downtime and saves costs. Control technology and HMIs tailored to the drives for operating the machine and visualising existing machine data complete the system solution.

The drives feature a sensorless algorithm designed to handle unpredictable high load peaks and react with high dynamics. This ensures constant crusher performance, even with irregular machine feed rates. The option of encoder-free control also enables cost savings, as it eliminates the need for cables and the encoder. KEB uses water-cooled motors and drives, which are characterised by their compact design, particularly in compact crushers. High efficiency reduces the crushers’ fuel consumption and makes the machines future-proof and eligible for subsidies. Of particular interest for mobile crushers: the drive can be powered directly from the mains or via a diesel generator, meaning the machine can be operated even without a mains connection and without any modifications.

KEB also ensures reliable motion in conveyor technology for crushers. For example, conveyor belts are driven by the COMBIVERT S6 Servo Drives. Helical gearboxes with an efficiency of 94 to 96 per cent handle the transmission of high torques.

Technology

Cooling concepts

KEB’s drive controllers take over challenging drive tasks so that machines and systems can operate with utmost efficiency. Cutting-edge, technical solutions ensure that they “keep a cool head” at all times. With its air, liquid and oil cooling systems, KEB offers three different cooling technologies which make the drives highly scalable and allow them to be used easily in various applications. Not just the cooling options, but also the way they are fitted provide machine and system operators with a high level of flexibility. In addition to control cabinet installation, the cooling systems can also be implemented as a push-through version.

Functional safety

Electrical machines and systems are subject to increasingly stringent safety requirements. Simplify your safety concept with the KEB drive controller’s integrated safety functions. Speeds, positions and various other functions are monitored directly in the drive electronics. The KEB safety control integrates the requirements of safety technology into the functional control environment. Safe communication with the control level serves as a widely used and established FSoE (Safety over EtherCat) solution – alternatively, communication via ProfiSafe is also available. In addition to, or instead of, a safe field bus system, individual safety functions can also easily be switched on and off via digital inputs. With the certification of sensorless safety functions, in some cases speed-related functions can also be implemented without a sensor system.

More about functional safety

Protective coating

Harsh ambient conditions can attack the electronic components inside machines and systems, causing permanent damage. This is where the optional 3C3 protective coating (IEC/EN 60721-3-3 Class 3C2) comes into play on the printed circuit boards of our drive controllers. Adapted to the environmental demands, the coating provides protection and prevents defects and unwanted downtimes. Overall, the service life of inverters is extended – with positive impacts on the operating costs.

Sensorless control (SCL/ASCL)

ASCL (Asynchronous Sensorless Closed Loop) and SCL (Sensorless Closed Loop) are proven sensorless control methods developed by KEB Automation. They are advantageous in situations where high output speeds usually make it very difficult or even impossible to attach a sensor. Suitable for asynchronous, synchronous, reluctance, linear, spindle or torque motors, these methods ensure optimal and precise control and sensorless positioning – and are also inexpensive and easy to install. The underlying software contains coordinated virtual motor models.