Enhancing Operational Efficiency in Crushers Through the Use of an Industry 4.0 Based Crusher Control System

In the aggregate and mining industry, an excessive flow rate of raw material from the feeder, caused by irregularities in the raw material being processed by crushers, can lead to blockages or excessive strain on the crusher. Conversely, a low flow rate of raw material can result in high energy consumption by the crusher, despite operating at a low capacity. The issues encountered in the first group result in excessive energy usage in the secondary and tertiary groups. The study focuses on a system that utilizes artificial intelligence and is based on industry 4.0 principles. The system aims to maintain production in the crusher within a specific range by controlling the flow rates of the feeders using an algorithm. This control is done automatically without the need for user intervention. The system optimizes energy consumption while maximizing production capacity and ensures uninterrupted operation. The system was developed during the installation phase at an aggregate pilot plant in the Kahramanmaraş Evri region. It assesses the material capacity data using a belt scale on the crusher, feeder, and output conveyor. This data is then compared to the limit values stored in the database, and the system generates an information signal to initiate the required control actions. Based on this matching result, it sends information to the inverter, coordinates the production cycle, manages and documents the process stages using a structured learning system and artificial intelligence logic.The installation procedure was conducted using two distinct density gradation inputs. As a consequence of the reporting, the records in the report were compared during both the active and inactive states of the system. The project achieved an efficiency of 22% in terms of energy consumption per unit capacity. Based on the whole yearly energy usage, a total of 368609.7 kg of carbon emissions were averted. The facility's aggregate crushing capacity was increased by 40%.