HP-WCSA: Automatic crusher / splitter

Designed for the Requirements of the Extractive Industry

The HP-WCSA combines automatic weighing, crushing and representative sample splitting in a single machine. It is designed for the preparation of large samples of coarse ores, minerals and comparable materials. Its modular design allows the machine to be adapted to different applications and integrated with additional sample preparation equipment.

The machine is based on a modular building-block principle and comprises a weighing device, sample lift, double-acting HSC 650D jaw crusher and linear splitter. Processing parameters, including the crushing gap, splitting ratio and number of aliquots, can be configured via the machine control system in accordance with the relevant application requirements and standards.

Flexible Automation and Integration Options

The HP-WCSA can be operated as a stand-alone machine, either with manual sample loading or in combination with an automatic feed magazine. It can also be integrated into robot-based automation systems. Depending on the laboratory layout and required sample flow, the machine may be installed as the input unit of a robot cell, positioned between two robot cells or incorporated into a linearly arranged system.

In linear automation concepts, sample containers can be transported and handled by a gantry system or conveyor-based handling system. An upstream feed magazine can supply samples automatically, while downstream robots or handling systems can transfer the processed fractions to subsequent preparation or analysis steps.

Integrated electrical and pneumatic control cabinets, a PLC-based control system and suitable communication interfaces enable the HP-WCSA to exchange data with higher-level automation and laboratory information systems. This allows the machine to be integrated into both new installations and existing sample preparation workflows.

Fully Automatic Sample Preparation

Coarse samples are loaded to the machine either as a single sample or in a cup via an automatic feed magazine. Once the processing parameters have been selected on the integrated HMI panel or the PrepMaster SCADA system, the HP-WCSA performs the complete weighing, crushing and splitting sequence automatically.

The machine control system coordinates all process steps and monitors the operating status. Sensors detect when the sample has passed through the individual processing stages (option), while the HMI panel displays the current process status and any operating or fault messages. Normal operation therefore requires no manual intervention.

Intelligent Crushing with the HSC 650D

The double-acting HSC 650D jaw crusher is equipped with servomotor-driven jaw adjustment. This allows the crushing gap to be set precisely according to the material properties and required final particle size. Automatic wear compensation maintains the selected gap as the crushing jaws wear, ensuring consistent and reproducible crushing results (option).

Sensors monitor the crushing process and detect when the complete sample has passed through the crusher (option). The process is therefore controlled according to the actual material flow rather than a fixed processing time, reducing cycle times and avoiding unnecessary crusher operation.

If a blockage occurs, the crushing jaws can be opened automatically to release the obstructing material. The material is then discharged via the vibratory chute. This reduces the need for manual intervention, improves operator safety and allows the machine to be returned to operation quickly.

Representative Sample Splitting

After crushing, the material is conveyed continuously to the linear splitter by a vibratory feeder. A scraper distributes and levels the material flow to prevent accumulations and ensure uniform feeding.

The splitter consists of a moving carriage positioned above three linearly arranged sampling chambers. By repeatedly passing through the material flow, the carriage collects numerous individual increments for each active fraction. These increments form representative composite samples and reduce potential splitting errors.

The splitting ratio and number of aliquots can be configured according to the application. The two outer sampling chambers can be closed individually, allowing the splitter to produce the required number of fractions. Material-flow monitoring confirms that the complete sample has passed through the splitter. After processing, the splitter and connected material paths can be cleaned automatically with compressed air to reduce the risk of cross-contamination.

Safe and Ergonomic Operation

The HP-WCSA is fully enclosed and sound-insulated. This design reduces noise and protects operators from moving components. Safety switches monitor the access points and stop the machine automatically if a safety-related condition or malfunction is detected. The corresponding messages are shown on the HMI panel to support efficient troubleshooting.

The automated process minimizes the manual handling of large, coarse samples. Accessible machine components also simplify cleaning, inspection and maintenance.