Stone Crushing Machine using IOT

Project Title

Stone Crushing Machine using IOT

Project Area of Specialization Internet of ThingsProject Summary

We need to save or conserve energy because most of the energy sources we depend on, like coal and natural gas can’t be replaced. Once we use them up, they are gone forever. Saving power is very important, instead of using the power in unnecessary times it should be switched off. In any construction industry “CRUSHING MACHINE” is one of the major power consuming factors. Rocks, ores, and their sub products have always been of great importance for civilization. For example, as mentioned in De Re Metallica—one of the oldest known books about mineral processing—back in the Medieval Age, male slaves and peasants, the ’breakage section’, swung heavy mallets and hammers to break rocks to produce gravel or extract metals. Gravel and aggregates were used to build castles, churches, and watchtowers, and metal was melted and transformed into silverware, ornaments, and weapons. We have come a long way regarding technology and labor rights; however, the fundamental need to break rocks to provide the raw material for other industries remains, and is expected to remain in the foreseeable future. In this internship, all the interns were linked with Sindh assembly parliamentarians. We have to provide them research assistance and arrange different on-ground sessions at their constituency and at different hotels and virtual sessions on countering violent extremism and domestic violence against females by promoting peace in which different people from various backgrounds were engage 

Project Objectives

In both the mineral processing and the quarrying industries, Stone crushers perform secondary and tertiary crushing tasks, in which the ore diameter is reduced from as large as 250 mm to less than 10 mm.  The main differences are that in the quarrying industry, (i) the product of a crushing circuit is the final product (crushed material may be processed further in the mineral processing industry), (ii) the final product has a relatively lower value than the product from the mineral processing industry, and (iii) the final product must meet stringent requirements, concerning both particle shape and particle size distribution (such as the CE marking of aggregates). Thus, the quarrying industry has sought advanced crushing technology and process control strategies to maximize profit (Svenson and Steer, 1990). On the other hand, in the mineral processing industry, the product of a tertiary crushing circuit typically goes through several more comminution and concentration steps until the valuable mineral is liberated from the raw ore. For this reason, state of the art Stone crusher  control  technology in the mineral processing industry seems to be lagging; the crushing stage is overlooked because it is only a part of a mining plant, and variations in crusher performance are rarely a cause for concern, unless the implications are catastrophic (Bearman and Briggs, 1998). Additionally, the mineral processing industry is mostly concerned with the particle size distribution of the product (Evertsson, 2000); i.e., the product shape is rarely important

Project Implementation Method

Arguably, the most well-known cone crusher model was developed by Whiten (1972). The model was derived from the population balance equation formulated by Epstein (1947). Whiten (1972) modeled the cone crusher by assuming that it behaves as a single mixer with a classifier at steady-state, as follows: xp  =  (I? C)(I ? BC) ? 1 xf (1) where B and C are the  breakage  and  classification  matrices, respectively. I is an identity matrix, fp and xf are the feed and product particle size distribution, respectively. Static models are sufficient in some applications, such as modelling a cone crusher in a plant wide context in which it’s dynamic and residence times (approximately a few seconds) are negligible compared to the other process units. On the other hand, dynamic models allow the effects of disturbances with faster dynamics to be studied, especially in circuits where all units have low residence times (e.g., a circuit comprising exclusively of crushers, conveyors, and screens).

Different models have been developed, which can be classified as either population balance, empirical, or data-driven models. It should be noted that despite being reported in the cone crusher literature, discrete element method (DEM) modeling is not considered in this section. DEM is a numerical technique that tracks the progress of each particle in the simulated system over time by integrating the equations of motion of each entity. DEM models have been used to gain a better understanding of the flow and breakage processes inside the cone crusher, and for  power draw and  liner wear predictions (e.g., Cleary et al., 2017; Delaney et al., 2015; Quist and Evertsson, 2010; Quist, 2012). These models are computationally expensive and, to the best of our knowledge, have not been applied to the process control of cone crushers. The interested reader is referred to Weerasekara et al. (2013) for an extensive review of the state-of-the-art of DEM models in the mineral processing industry.

Benefits of the Project

In this way, the features of the functioning of the crushing and screening plant scheme elements have been determined due to the need to automate the crushing and sorting production.

Based on the design parameters of the crushers it is shown that the size of the crushing product, which is a certain weight average diameter of the crushed product grain is its main stochastic characteristic.

It is established that the task of the crushing process automatic regulation is to maintain the final product`s specified size and to maximize the energy supplied to the crushing aggregates by optimally loading the crushers.

The software for the automated process control system of crushing stone materials has been proposed, which makes it possible to integrate a set of interconnected technological units in the one hardware and technical complex management, the efficiency of their joint operation is largely determined by the conformance degree and the speed of the two-way information exchange.

Technical Details of Final Deliverable

In this way, the features of the functioning of the crushing and screening plant scheme elements have been determined due to the need to automate the crushing and sorting production. Based on the design parameters of the crushers it is shown that the size of the crushing product, which is a certain weight average diameter of the crushed product grain is its main stochastic characteristic. It is established that the task of the crushing process automatic regulation is to maintain the final product`s specified size and to maximize the energy supplied to the crushing aggregates by optimally loading the crushers. The software for the automated process control system of crushing stone materials has been proposed, which makes it possible to integrate a set of interconnected technological units in the one hardware and technical complex management, the efficiency of their joint operation is largely determined by the conformance degree and the speed of the two-way information exchange. The developed system provided a significant operator`s comfort increase by providing him with a single user interface to manage various technological units from one operator station and an additional volume of information and services.

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries Manufacturing Core Technology Internet of Things (IoT)Other Technologies Artificial Intelligence(AI)Sustainable Development Goals Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	70000
stone crushing machine	Equipment	1	70000	70000