Runnable simulator field guide
Mining crusher protection PLC scenario: test checklist
Direct answer
The learner can separate start permissives, running proof, process protection and emergency stopping, preserve the first trip and prove a controlled restart in the correct equipment order.
Written for mining, bulk-material and controls learners studying how protection inputs govern a crusher, feeder and conveyor sequence.
Scenario setup
Equipment train, energy sources, guarding, pull cord, blocked chute, zero speed, lubrication, vibration, temperature, motor protection, sequence and alarm history.
I/O and state map
Start request through permissive chain and PLC outputs into feeder, conveyor and crusher motion, with independent speed, material and equipment-health feedback.
Normal run
Downstream-to-upstream startup, stable running proof, upstream-to-downstream material clearing and deliberate normal shutdown.
Boundary run
Blocked chute, belt stopped, high vibration, bearing temperature, lubrication loss, overload, pull-cord trip, sensor discrepancy and power return.
Injected fault
The first field, protection, sequence, motor, mechanical, material-flow or feedback boundary that departed from the expected state.
Target check
The cause removed, bypasses absent, guards and zones restored and stop/start acceptance cases witnessed under the site procedure.
What interlocks are commonly used on a crusher conveyor?
Examples include downstream running proof, zero-speed detection, pull cords, blocked-chute switches, lubrication state, bearing temperature, vibration, motor protection and guarding. The required set comes from the actual risk and equipment design.
Why should the first crusher trip be preserved?
A cascade may stop several machines and create many secondary alarms. The earliest time-aligned deviation is usually the strongest evidence for locating the initiating cause.