PC, PLC, SCADA or HMI controlled automation systems are manifactured according to general layout and motor power on the crusher plants.

Altough the investment in automation systems are a little more expensive, it recoups in very short period of time.

The capacity of the plant will be increased.

The operator faults will be reduced.

The safety of life and property will be guaranteed.

The points below can be observed, controlled and logged in the PLC and HMI based automation:

  • Sequential start timer settings,
  • Sequential stop timer settings,
  • Running info of motors,
  • Circuit breaker info of motors,
  • Contactor fault info of motors,
  • Local control states,
  • Rope switches’ state and decommissioning,
  • Misalignment switches’ state and decommissioning,
  • Zero speed switches’ state and decommissioning,
  • Voltage, current, frequency and power consumption values from energy analysers,
  • Capacity (t/h) indication and logging from belt scales,
  • Indication of crushers’ current and dosing control,
  • Crusher runtime and maintenance timers,
  • Lubrication, pressure, flow and temperature controls,
  • Silo level controls with ultrasonic sensors,
  • Gate direction states and controls,
  • User management and authorization,
  • Total material production counters and power consumption logging and reporting,
  • Remote control.


Motor Start Timer Delay: Start timers entered seperately for each motor, prevents all motors from starting at the same time and enables sequential start. Thus, from first to last, all motors will have a specific sequence and wait for previous motor to start then count its own time period before starting-up, resulting in reliable start-up. This particularly increases lifespan of crusher motors and start-up equipments by preventing the crusher motors to start at the same time.

Motor Stop Timer Delay: Stop timers entered seperately for each motor, prevents all motors from stopping at the same time and enables sequential stop. Thus every motor will count its own time period before stopping, making sure there is no material left on the equipment. This feature enables the plant’s next start-up to be smoother without any material left on the system.

Alarms: Any fault occuring in the system (Ex: circuit breaker, contactor faults, silo level alarms, temperature and pressure levels of crusher motors, etc.) cen be observed in the HMI panel or SCADA system. This greatly helps fault management.

Switch Settings: Decommissioning of rope switches, misalignment switches and zero speed switches are available. This helps system to bypass the control when false alarm occurs. Time-delay for crusher interlock signals also prevents false alarms that results in unnecessary stopping of the machinery.

Feeder Adjustment: Depending on the silo levels or the capacity that crushers operate the feeder speeds can be automaticly adjusted. The only setting on the automatic operation mode is the range of the crusher current so feeder speed can be adjusted.

Reporting: In addition to other settings, runtime timers for all plant and important crusher motors, shift runtime timers are logged and can be observed from the HMI. Production and stockpile report can be observed on the plants with the belt scale.