Optimization of Moving Cone Liner Dynamics and Health Status Prediction for Cone Crushers

As a core crushing equipment in mining, building materials, and related industries, the cone crusher relies heavily on the optimal design and health state prediction of its mantle liner to enhance equipment reliability and reduce maintenance costs. This paper proposes a comprehensive approach integrating dynamic modeling, intelligent optimization, and health prognosis. First, a virtual prototype model is established based on laminated crushing theory and multibody dynamics simulation to analyze the motion and force characteristics of the mantle liner. Second, for the two key parameters—counterweight mass and motor speed—an improved butterfly optimization algorithm (IBOA) incorporating Cauchy mutation and an adaptive weight is proposed to achieve efficient global optimization. Furthermore, vibration signal features are extracted at different wear stages; a comprehensive health indicator curve is constructed by combining PCA dimensionality reduction with adaptive feature fusion (ASFF), and the Weibull degradation model is employed for life extrapolation prediction. Finally, fuzzy C-means (FCM) clustering is applied to autonomously partition the health states. Parameter optimization reduces the standard deviation of the force acting on the mantle liner by approximately 15.4%, markedly improving system operational stability. Health prognosis reveals that the liner enters a faulty state after 785 h, and the health condition is effectively classified into four stages: healthy, good, degraded, and faulty. The results demonstrate that the proposed optimization and health prognosis methods can effectively improve the operational efficiency and reliability of cone crushers, exhibit favorable engineering applicability, and provide a quantitative basis for condition monitoring and maintenance decision-making.