Sandvik Construction
A world leader in Construction
Module 5
ASRi System
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
EHS leadership from all employees
Risk based EHS management systems
FIRE ALARM
Certification to OHSAS 18001 & ISO 14001
ASSEMBLY POINTS
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Sustainable and continual improvement
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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Sandvik ASRi System
Cone crusher automation
One single feature which makes
TRUE automation possible.
A single cylinder hydraulic
adjustment system
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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
ASR1 - ASR2 - ASRC - ASR+ - ASRi (1.0) - ASRi (2.0)
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Sandvik ASRi System
Function
Load (a
Resultant
Crushing Force
Load (a)
Measured by power draw induced when driving cone during
crushing.
Load (a)
Load (b)
Measured by the pressure in the Hydroset piston.
Pressure is directly proportional to the crushing force.
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Load (b)
Sandvik ASRi System
Function
Factors Affecting
Material Conditions
Machine Factors
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Moisture Content,
Feed Material Grading,
Bulk Density,
Toughness,
Product Size (Reduction Ratio).
Close Side Setting (Reduction Ratio)
Chamber,
Eccentric Throw,
Speed.
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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Sandvik ASRi System
Function
Factors Affecting
Capacity
(TPH)
Product Size
(CSS)
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Hydroset
Pressure
(Mpa)
Chamber
Volume (Throw)
Power Draw
(kW)
Chamber
Volume (Liners)
Eccentric Speed
(RPM)
Product
Size
/Reduction
Ratio
Sandvik ASRi System
Function
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Sandvik ASRi System
Function
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1.
Automatically adjusts for;
Changes in feed material size.
Changes in material toughness.
Changes in material moisture content.
Manganese wear.
2.
Protects the crusher against overloads during
normal operation.
3.
Allows easy adjustment of product size.
On the fly adjustment
4.
Maintains the maximum crusher performance.
Independent of feed conditions.
5.
Improves production and product quality.
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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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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Sandvik ASRi System
Crushing regulation
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Pressure
Hydroset Pressure Graph
Current Pressure
Average Pressure
Average Peak Pressure
Sandvik ASRi System
Crushing regulation
Pressure
Example A
Pressure Sector
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)
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Average Pressure
(4.5 Mpa)
Sandvik ASRi System
Display
Status Bar
Main screen
Main Display
Area
Menu Bar
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Sandvik ASRi System
Display
Main screen
Running status of the ASRi
and Current program
selection.
Stop: No regulation
program running.
Running: Regulation
program active.
Calibration: System
calibration mode.
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Time and Date settings
(within operation settings)
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Crusher type
(Must match
actual crusher)
and Assigned
Name (within
installation
settings)
Sandvik ASRi System
Display
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Main screen
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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
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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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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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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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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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 crushers operating time.
Total run time (loaded and idle)
Loaded (actual crushing time)
The lower section displays information about the
crushers energy consumption.
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Sandvik ASRi System
Data collection
A-alarm
Alarm List
The most serious type of alarm. An A-alarm will immediately
stop regulation and will also stop the feed to the crusher
the feed interlock output from the ASRi system is used.
Regulation cannot be restarted until the fault has been
if
corrected.
B-alarm
Results in a feed shut-down, if the feed interlock output
the ASRi system is used, but regulation continues while the fault persists.
has been corrected, the feed is restarted and regulation continues as before.
from
When the fault
C-alarm
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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.
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Sandvik ASRi System
Data collection
Alarm List
Alarm Status
Active
A
A Inactive
Time and Date settings
of Alarm Report.
Fault Indicator
Red Critical Condition
Amber Warning Condition
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Alarm description
(brief detail of fault)
Acknowledge
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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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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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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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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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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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.
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Bulgarian
English
Italian
Portuguese
Spanish
Chinese
Finnish
Korean
Swedish
Croatian
French
Norwegian
Portuguese(B
r)
Russian
Czech
German
Polish
Romanian
Danish
Hungarian
Portuguese
Slovenian
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Turkish
Sandvik ASRi System
Password protection
Operator User Name 1001
Operation
Possibility to assign and
activate Operator Password
Service
No Password Protection
Installation
Commissioning / Installation
User Name & Password
Sandvik User Name &
Password
Regulation
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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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A world leader in Construction
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