High-Speed Switched Reluctance Motor for Sustainable Crushing Operation through Cone Crusher

Abstract This work presents a sustainable motor-driven solution for energy-intensive crushing operation through cone crusher by integrating a variable-speed Switched Reluctance Motor (SRM). The comminution process consumes up to 75% of a plant’s total energy, making energy efficiency a critical consideration that can be significantly improved through speed control. A novel aspect of this study is the use of high-speed crushing operation to enhance inter-particle collision and energy dissipation, thereby improving crushing efficiency of a cone crusher. An integrated computational framework combining Discrete Element Method (DEM), Finite Element Method (FEM), and Response Surface Methodology (RSM) is employed. DEM simulation reveals that high-speed operation increases throughput and energy efficiency due to enhanced inter-particle breakage within the crusher especially for smaller particles, while lower speed gives better performance for large sized particle. These insights decide the variable speed requirements and, power and speed ratings for the SRM. A scaled-down SRM is then designed using FEM and optimized via RSM for reduced torque ripple and improved performance. Optimization lowers the torque ripple of the motor from 80% to 45% and improves its efficiency from 86% to 89%, maintaining an average torque of around 7 Nm. The fabricated SRM prototype is experimentally validated. The study demonstrates the novelty and sustainability of employing variable-speed SRM in comminution through cone crusher, offering a more efficient and adaptable drive solution for modern crushing system.