Laser Scanning Device for Crushing, Designed by ME Elecmetal
Compared to traditional measurement systems, real-world results (VAES) demonstrate that QuickScan Crusher delivers significant improvements in data reliability and crushing efficiency.
ME Elecmetal's QuickScan Crusher (QSC): Revolutionizing Measurement in Crushing Operations
ME Elecmetal's QuickScan Crusher (QSC) is designed to tackle the long-standing challenge of accurately measuring crushing equipment, which is often difficult to access from within the chamber. Traditional methods typically require multiple scans from various angles, resulting in only partial views of the liners. In addition to the inherent safety risks associated with laser measurements and equipment movement, these procedures lead to significant process interruptions, often taking up to two hours per session.
Limited Options for Accurate Measurement
Traditional 3D Laser Scanning: This approach involves a field team positioning a 3D laser scanner on a tripod at various locations around the crusher chamber. These scans are typically performed during a scheduled maintenance window to record as much of the surface as possible. However, the process is time-intensive and requires careful planning to minimize downtime.
Top-of-Crusher Measurements: A faster alternative is to take scans from the top of the crusher cup. While this method reduces time, the quality and reliability of the scans are compromised due to limited visibility and incomplete surface coverage.
A Safer, Faster Approach to Gyratory Crusher Scanning
ME Elecmetal has introduced a groundbreaking technology and methodology, QuickScan Crusher (QSC), that enables the scanning of gyratory crushers without exposing workers to direct hazards. By leveraging the temporary blocking of the rock breaker, QSC provides significant improvements in safety, inspection time, and data reliability.
The QSC solution uses the crusher's rock breaker to position laser measurement equipment anywhere within the crusher chamber. This flexibility enhances the visibility of liners, resulting in more accurate reports for estimating the equipment's useful life and ensuring operational reliability. The QSC system comprises an electromechanical device that is remotely operated to attach a 3D laser scanner to the tip of a primary crusher breaker, allowing for safe and efficient analysis without requiring significant production interruptions.
Key features include:
- Quick Mounting: A quick-release system enables rapid attachment to the breaker's arm.
- Remote Operation: Scanning can be controlled via a cell phone from a safe distance.
- Comprehensive Coverage: Four scans from different positions ensure maximum surface area coverage of mantles and concaves.
- No Pre-Cleaning Required: Eliminates the need for cleaning the crusher cup before scanning.
Proven Results: Client Success with ME Elecmetal's QuickScan Crusher Solution
The following data presents the improvements recorded by one of our clients after implementing the QuickScan Crusher solution. As per the data collected using the VAES methodology, a 19% reduction in measurement time and an 84% reduction in operator exposure time were observed. This solution is currently being utilized by several clients in both Chile and Peru.
Benefits
Reduced Personnel Exposure to Risks
No personnel are required inside the crusher chamber, ensuring safety. Additionally, operators must stay clear of the sump edge during the scanning process.
Efficient Scanning in Just 30 Minutes
The QSC solution does not require a crusher lockout — only a rock breaker lockout is necessary — enabling an effective scan in as little as 30 minutes.
Enhanced Data Quality
The QSC system allows scanning from closer proximity to the crushing area, improving the quality of captured data.
Greater Data Coverage
With optimal camera angles, the system captures a significantly larger amount of data, ensuring comprehensive monitoring of the crusher.
Compatibility with Industry-Standard Scanners
QSC is compatible with various market-leading scanners such as Faro, Trimble, and Leica, providing the same image resolution as traditional methods and guaranteeing accurate, reliable results.
Quick Assembly and Disassembly
The system can be assembled in just five minutes without disrupting crushing operations, and dismantling takes under two minutes, minimizing downtime and maximizing efficiency.
Remote Operation
Scanning can be controlled via a cell phone from a safe distance, providing greater safety for operators.