Data Collection: The Core Enabler of Crusher Automation Control
Wen Zhi Neng Shu (All members of the Intelligent Technology Department)
In the crusher‑equipment manufacturing industry, automated control has become a key driver of product competitiveness, and at the heart of this lies data collection—seemingly simple yet critically important. For equipment manufacturers, data collection is not an unnecessary technological add‑on; it is the essential foundation that enables automated control to take root, making machinery smarter, more efficient, and more reliable. Put simply, it equips machines with “eyes” and “ears,” allowing them to accurately capture every nuance of their operation.
The core function of data collection is to capture, in real time, a wide range of critical parameters during equipment operation, providing accurate decision‑making support for automated control and serving as an essential data source for product design. Unlike traditional manual operations that rely on experiential judgment, the essence of automated control lies in “letting the data speak,” with data collection furnishing the system with the evidence it needs to make informed decisions. For example, our flagship products require the acquisition of data such as feed level, particle size, crushing pressure, rotor speed, bearing temperature, current and voltage, and equipment vibration. Mobile crushing stations may also need to collect additional dynamic metrics, including generator speed, coolant temperature, oil pressure, fuel level, operating hours, and fuel consumption. These seemingly trivial data points are, in fact, the vital “driving force” that enables automated control to function effectively.
Implementing data collection is not complicated; the key lies in installing various sensors at critical points on the equipment and using a transmission module to aggregate the collected data in real time at the control terminal. Here’s a simple practical example: a jaw crusher is equipped with a particle-size sensor at the feed opening, a pressure sensor in the crushing chamber, and a temperature sensor near the main shaft bearing. During operation, the particle-size sensor continuously monitors the size of incoming material; if the particles exceed a certain size, the automated system automatically reduces the feed rate to prevent blockages. When the pressure sensor detects that the crushing pressure surpasses a preset threshold, the system adjusts the jaw‑plate gap to lighten the load on the equipment. And when the temperature sensor registers that the bearing temperature exceeds its set limit, the system boosts the cooling efficiency of the lubrication station to prevent overheating and damage to the bearing. This closed-loop process—“collection–transmission–analysis–control”—constitutes the core logic of automated control, with data collection serving as the very first step in this cycle.
For equipment manufacturers, data collection not only enables automated control of machinery, enhances product quality, and reduces operation‑and‑maintenance costs, but also delivers irreplaceable benefits to the design and manufacturing of the host equipment itself. By providing precise, real‑world operating data, it ensures that designs better align with actual usage requirements and are more scientifically grounded, thereby overcoming the limitations of traditional approaches that rely on experience and rough estimates. Conventional host‑machine design often depends heavily on engineers’ past experience, making it easy for designs to become disconnected from real‑world performance. By gathering operational data from similar machines, manufacturers can accurately capture critical information—such as load, vibration, and wear—under various operating conditions, allowing them to optimize the machine’s structure, material selection, and parameter settings. For example, based on force‑measurement data collected from a crusher’s main shaft, they can refine the frame’s thickness and material to enhance its load‑bearing capacity. Moreover, analyzing runtime data helps quickly identify design flaws, enabling timely refinements and reducing rework costs, shortening the R&D cycle, accelerating product iterations to better meet market demands, and boosting competitiveness. In addition, continuous data collection allows manufacturers to precisely characterize equipment operating patterns, refine automation control algorithms, and fine‑tune the optimal configuration of mechanical components, hydraulic systems, and electrical subsystems, resulting in more stable operation and lower energy consumption. For instance, our crawler‑mounted jaw crusher mobile station, produced in March 2026, underwent thorough analysis by engineers from both Reike Company and Intelligent Technology. Due to cost constraints and overarching design philosophies, this project limited data collection and analysis to manual processing for certain parameters. As a result, not only was the host’s hardware architecture optimized, but several hydraulic designs were improved, and the electrical control system was reconfigured for greater efficiency. Following repeated testing, the final product demonstrated outstanding overall performance.
In the past, automated control in equipment manufacturing often fell into the trap of prioritizing control over data collection, resulting in imprecise control systems and unstable equipment operation. Today, with the widespread adoption of IoT technologies, data collection has become both simpler and more cost‑effective. For large‑scale equipment such as crushers and mills, even minor data deviations can trigger malfunctions and halt production; a robust data‑collection framework, by contrast, enables early fault detection and precise parameter adjustments, allowing automated control to deliver its full potential.
Data collection is the foundation for equipment manufacturers to achieve automated control and a key enabler of intelligent upgrades. It requires no complex operations yet transforms equipment from “passive operation” to “proactive regulation,” and from “experience‑driven” to “data‑driven.” In the future, as data‑collection technologies continue to mature, they will undoubtedly elevate the level of automated control in crushers, mills, and other equipment, creating greater value for our company and providing more reliable equipment support across industries.
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