The cone crusher is an indispensable equipment in complex ore mineral processing and a variant of the cone crusher is the inertia cone crusher. A real-time dynamic model based on the multibody dynamic and discrete element method is established to analyze the performance of the inertia cone crusher. This model considers an accurate description of the mechanical motions, the nonlinear contact, and the ore material loading response. Especially the calibration of ore material simulated parameters is based on the Taguchi method for the Design of Experiments. For model verification, the industrial-scale experiment was conducted on a GYP1200 inertia cone crusher. Two different drive speeds were included in the experiments, and the testing devices were used to acquire crusher performances, for instance, displacement amplitude, power draw, product size distribution, and throughput capacity in order to accurately compare simulation results. The preliminary model can be qualitatively evaluated the flow pattern of particles and quantitatively evaluated the crushing force distribution in the concave. Furthermore, the simulation predicts the variety of crusher performances using the drive speed and the fixed cone mass as input variables. The simulation model provides novel insight regarding the improvement of linings wear period, lowering manufacturing cost, and obtaining optimal operation parameters.

Inertia cone crushers are widely used in complex ore mineral processing. The two mass variables (fixed cone mass and moving cone mass) affect the dynamic performance of the inertia cone crusher. Particularly the operative crushing force of the moving cone and the amplitude of the fixed cone are affected, and thus the energy consumption of the crusher. In this paper, the process of crushing steel slag is taken as a specific research object, to analyze the influence of two mass variables on the inertia cone crusher performance. A real-time dynamic model based on the multi-body dynamic (MBD) and the discrete element method (DEM) is established. Furthermore, the influence of the fixed cone mass and moving cone mass on the operative crushing force, amplitude and average power draw are explored by the design of simulation experiments. The predictive regression models of inertia cone crusher performance are obtained using response surface methodology (RSM). After increasing the fixed cone mass, the optimized amplitude, average power and moving cone mass are decreased by 37.1%, 33.1% and 10%, respectively, compared to without the adjustment. Finally, a more effective dynamic balancing mechanism of inertia cone crusher is achieved, which can utilize the kinetic energy of a balancer, and minimize the mass of the fixed and moving cone. The fixed cone mass and moving cone mass of a balancing crusher are decreased by 78.9% and 22.8%, respectively, compared to without the balancing mechanism.

Due to the lack of body stability of emergency rescue vehicles, their attitude stability is insufficient and they are unable to realize working while driving, resulting in low rescue efficiency. Aiming at the water tower fire truck, which is equipped with an active suspension system, the vehicle attitude stability is studied. First, combined with the active suspension system and spray system, a 13-DOF integrated dynamic model for the water tower fire truck is established. Using the model-assisted active disturbance rejection control method, the controllers are designed for the vertical displacement, pitch angle, and roll angle of the vehicle attitude. Then, the computer simulation is carried out to verify the effectiveness of this control method. Finally, the water spray obstacle crossing experiment is carried out with a JP32G water tower fire truck. The results show that when the vehicle runs over the triangular obstacle on one side and two sides in the integrated spray-active suspension mode, the peak–peak values of body pitch angle and roll angle are reduced by 10.9% and 23.2%, and 23.7% and 16.3%, respectively, compared with the passive hydro pneumatic suspension.

Capacity is the important indicator of the cone crushers, which is determined by the motion characteristics of particles. The spatial compound motion of the mantle, which rotates both around the central axis of the cone crusher and its central axis, was analyzed to develop motion characteristic equations of particles. The velocity distribution of particles with different motion characteristics was determined by solving the motion characteristic equations of particles using the coordinate system transformation matrix. An improved capacity model of the cone crushers based on the motion characteristics of particles considering the influence of the spatial compound motion of the mantle was established by analyzing the velocity of particles in the upward and downward direction zones of the choke-level and the influence of circumferential deflection of particles on the velocity in the radial direction. A reduced-scale cone crusher with various rotational speeds was used to simulate cone crushers with different motion characteristics of the particles passing through the choke-level. The average error between the capacity calculated by the improved capacity model and the capacity determined according to the experimental data was 5.96%. Therefore, the accuracy of the improved capacity model was verified. The improved capacity model was used in the capacity calculation of the ZS200MF cone crusher; the error was 7.4% compared with the measured value at the production site; thus, the applicability of the improved capacity model is proved. The influences of four typical parameters of the cone crusher on capacity were investigated based on the improved capacity model, which provides theoretical support for the development of new high-efficiency cone crusher and the optimization of existing equipment.

The crushing chamber is the core component of a cone crusher, consisting of mantle and concave parts. Reducing the impact of crushing chamber wear on the performance of cone crushers and the quality of crushed products while extending the service life of the mantle and concave has become a significant research challenge. The impact of the compression ratio and particle size distribution coefficient on the particle crushing pressure is investigated here in order to establish the particle pressure model. The effect of the normal and tangential components of particle crushing pressure on the wear of the mantle and concave is discussed, and the wear with the increase in crushed products and accumulation of operating time is explored in order to develop a wear model of the crushing chamber. By evaluating the compensation of the worn crushing chamber according to the adjustment mechanism of the mantle, a constant wear criterion for the crushing chamber of the cone crusher is proposed. Through analysis of industrial experimental data on an experimental prototype of a ZS200MF cone crusher with an optimized mantle and concave, the capacity was found to fluctuate at 83.45 t/h with no apparent downward trend, the calibration size production was reduced by 6.2%, and the wear similarity coefficient was 8.82%. This indicates that replacing the optimized mantle and concave based on the constant wear criterion maintains the performance of the cone crusher, delays the decline in the quality of the crushed products, and ensures similarity between the adjusted worn crushing chamber and the initial crushing chamber, which verifies the feasibility and effectiveness of the constant wear criterion for the optimization of crushing chamber. Based on the constant wear criterion, cone crushers can be optimized to obtain a crushing chamber with constant wear characteristics, which provides theoretical support for the development of new high-efficiency cone crushers as well as the optimization of existing equipment.

The cone crusher is the main equipment in the particle crushing process. The productivity of the cone crusher is determined by the motion characteristics of particles passing through the crushing chamber. In order to accurately describe the motion characteristics of the particles, the influence of the spatial compound motion of the mantle rotates around the central axis of the cone crusher and its central axis on the motion characteristics of the particles is investigated, then the improved motion model is established. Through the coordinate system transformation matrix, the motion characteristics of the particles including spatial sliding, free-falling, and spatial compound falling are solved. The applicability and accuracy of the improved model in describing the motion characteristics of the particle were verified through the experiment using a reduced-scale experimental cone crusher to simulate the motion characteristics of the particle. Based on the improved model, the motion characteristics of the particles in the CF11 hydraulic cone crusher can be simulated. With the decrease in height, the motion characteristics of particles gradually change from spatial sliding to spatial compound falling and finally to free-falling. The particles deflect circumferentially around the central axis of the cone crusher. The circumferential deflection of particles is directly related to the motion characteristics including spatial sliding and spatial compound falling. The improved model provides a theoretical basis for the high energy design of the crushing chamber and productivity improvement of the cone crusher.