Sandvik Construction A world leader in Construction Module 5 ASRi System

Sandvik ConstructionA world leader in Construction

Module 5ASRi System

Safety first everywhere our equipment is in use and in our own organization

Our aim is to achieve zero work related injuries and illness

EHS leadership from all employees

Risk based EHS management systems

Certification to OHSAS 18001 & ISO 14001

Sustainable and continual improvement

EMERGENCY EXITS

FIRE ALARM

ASSEMBLY POINTS

2 Sandvik Construction

Our first priority

Sandvik ASRi System Environment, Health,Safety

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Sandvik ASRi System Function

ASRi is a system which automatically regulates the crusher and protects it against overloads during normal operation.


Sandvik ASRi System Cone crusher automation

One single feature which makes TRUE automation possible. A single cylinder hydraulic adjustment system


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)



Load (a)

Load (b)

Load (a)

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 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.



Work Done (Energy) = Toughness x Volume x Reduction Ratio

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.



Capacity(TPH)

Power Draw(kW)

Hydroset Pressure

(Mpa)

Eccentric Speed (RPM)

Chamber Volume (Liners)

Chamber Volume (Throw)

Product Size (CSS)

Product Size

/ReductionRatio




Sandvik ASRi System Function 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 DisplayStainless Steel ConstructionLED Touch ScreenIP 65 RatingSelf Heating M12 Electrical Connectors

USB Port used to update or for use of mouse / Keyboard.

Blue LED indicating system live.


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.

Welcome to Sandvik Construction14Hydroset Pressure Graph

Current PressureAverage PressureAverage Peak Pressure

Sandvik ASRi System Crushing regulation Pressure

Welcome to Sandvik Construction15

Sandvik ASRi System Crushing regulation Pressure

Max Max

Example A Example B

Average Peak Pressure (5.5 Mpa)

Average Peak Pressure (5.4 Mpa)

Average Pressure (3.6 Mpa)

Average Pressure (4.5 Mpa)

Pressure Sector

Maximum pressure

Minimum pressure


Sandvik ASRi System Display Main screen

16

Status Bar

Menu Bar

Main Display Area



Crusher type (Must match

actual crusher) and Assigned Name (within installation settings)

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.



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.



CSS SettingCurrent close side setting in reference to the main shaft position.Power DrawAmount of power being used at any given time during crushing, as the crusher load increase the engine load increase.

Hydroset PressureMonitors the pressure while crushing in order to protect the chamber from overload.



Program Run / Stop button

Shaft Raise / LowerUsed to adjust main shaft position manually.

Program ChangeAllows program to be altered.

Auto / Manual Feed ControlTo maximise plant throughput.

CalibrationUsed to calibrate manganese wear in relation to shaft position.


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 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 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.


Sandvik ASRi System Data collection Alarm List

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


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 ConditionAmber – Warning Condition

AA


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 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.


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 – 0.58mmCS – 0.34mm

Sandvik ASRi SystemCSS 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


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 leadMetal to Metal calibrationUsing 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 calibrationWith 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 CalibrationIf selected the system carries out an occassional calibration automatically considering as a prompt reduction in power draw.


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 ASRi System Language Availability

31

Turkish

Slovenian

Romanian

Portuguese

Polish

Norwegian

Korean

Hungarian

German

French

Finnish

Danish

Czech

Croatian

Chinese

Bulgarian

Russian

ItalianEnglish

SwedishPortuguese(Br)

SpanishPortuguese

The ASRi 2.0 display screen has 22 different language options which can be changed to suit local area / operator dialect.


Sandvik ASRi System Password protection

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Operation

Service

Installation

Regulation

Operator User Name 1001

Possibility to assign and activate Operator Password

No Password Protection

Commissioning / Installation User Name & Password

Sandvik User Name & Password

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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


Sandvik ConstructionA world leader in Construction

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Sandvik Construction A world leader in Construction Module 5 ASRi System