The jaw crusher is mainly composed of a frame, a movable jaw assembly, a movable jaw, a fixed jaw, a triangular wheel, a flywheel, a bracket, a side guard, a discharge port adjusting device and a driving device. Because of its simple structure, easy manufacture, reliable operation and convenient maintenance, it has been widely used in crushing operations in metallurgy, chemical industry and mining industries.
In the jaw crusher, the ore is crushed and reduced to the required particle size. When the moving plate moves away from the fixed plate, the ore is sliding down freely from the upper portion of the crushing chamber to the discharge port under the action of gravity. During this process, the ore slides down along the surface of the jaw plate and causes sliding friction which makes the jaw plate be worn. Therefore, the abrasive wear is an important wear type caused by the squeezed ore.
When the ore is squeezed and ground under the huge mechanical force of the jaw plate, it is easy to form hard sharp edges and corners, and continual interaction between ore and the jaw plate makes the surface of the jaw plate appear very deep scratches, dense grooves and large-area deep pits. As a result, under the strong chiseling action, the jaw plate develops plastic deformation, metal rheology, brittle fracture and spalling, causing the material of jaw plate continuously to migrate and lose, and gradually become thinner. Therefore, chiseling wear is the main form of wear.
Jaw crusher has a large crushing force and fast running speed. Under the action of the huge impact and crushing stress, it withstands long-term and periodic contact fatigue load and is prone to fatigue crack. Therefore, fatigue spalling is also one of the causes of wear.
In order to protect the environment and improve working conditions, a water spray facility is installed on the site of the jaw crusher for dust suppression. At the same time, the water directly contacts the raft which accelerates the oxidation and corrosion of the raft and causes corrosion and wear of the raft.
The wear of the jaw plate presents complexity and diversity and is affected by factors such as materials, abrasives, environmental media, and relative motion. The value of the moving motion is usually reduced to solve the wear problems. In recent years, with the rapid development of computer technology, software simulation is used to comprehensively consider various factors that cause wear, and dynamically imitate of the crushing movement of the jaw plate, so as to more comprehensively analyze the wear rules of the jaw plate and finally reduce its wear rate.
In addition to the wear problem of the jaw plate, there are many other problems caused by parts and components can not be ignored. Next, we will introduce the failure analysis and troubleshooting of the jaw crusher.
4Check the tooth gap size of the tooth plate. If it does not meet the standard, the jaw plate must be replaced, and the relative position of the fixed jaw plate and the movable jaw plate should be adjusted to ensure that the tooth top is fixedly pressed against the tooth root to prevent displacement.
6It is non-bearing temperature rising, but the sealing sleeve of the movable jaw rubs with the end cap, which causes friction heating, or the double embedded cover of the frame bearing seat and the spindle rotate together, causing friction and heat.
6Replace the end cap and the sealing sleeve, or loosen the upper bearing cap of the end of the frame bearing housing which is overheated, press the fuse and the insert cover into the bearing housing groove, and then fix the bearing cover to eliminate the cover rotation.
Crushing raw material takes its toll on your equipment. For every ounce of product that passes through your machinery, the lifespan of your equipment steadily decreases. This leads to decreased output and mounting maintenance and repair costs. We at FLSmidth have created a solution, built on more than a hundred years worth of jaw-crusher experience.
Get things up and running quickly, and keep them going longer and safer. Our TST Jaw Crushers are engineered for trouble-free operation, characterised by safe and easy serviceability. Additionally, we have included the most modern analysis techniques and features available to date ensure a strong and reliable crusher design. In order to handle the increasingly hard ores and remote locations common in the industry today, the TST is also equipped with an efficient crushing motion, modular frame and a simple, low maintenance design. All of this together results in a crushing solution that can handle almost any job, on almost any budget.
FLSmidth provides sustainable productivity to the global mining and cement industries. We deliver market-leading engineering, equipment and service solutions that enable our customers to improve performance, drive down costs and reduce environmental impact. Our operations span the globe and we are close to 10,200 employees, present in more than 60 countries. In 2020, FLSmidth generated revenue of DKK 16.4 billion. MissionZero is our sustainability ambition towards zero emissions in mining and cement by 2030.
Jaw Crusher is a kind of mining equipment used for primary and secondary crushing. It is widely used in medium-sized crushing of various ores and bulk materials in mining, smelting, building materials, highway, railway, water conservancy, and chemical industries. It has a wide variety and a wide range of uses, making it the perfect choice for mining and quarrying.
Of course, for the customers, in addition to the brand and quality of jaw crusher, the installation and use methods also make them particularly concerned. In order to meet the needs of users and help them solve the most concerned issues, we will talk about how to install and use it next.
From its basic structure, we can easily see that its structure is complicated with many parts. Therefore, during the installation, the user should pay more attention to it and must be installed under the guidance of the manufacturer's technical personnel and in conjunction with the installation and use instructions of the equipment. Pay more attention to the details to ensure that nothing is lost.
Since the working area of the jaw crusher is mostly mountainous, it is necessary to thoroughly investigate whether the topography of the mine is suitable for concrete piling before installation, and according to the site topographic conditions, foundation soil conditions, pile arrangement, and length, and pile frame factors such as ease of movement determine the piling order, and it should also be considered that the depth of the piles should be basically the same, and the foundation soil is even and tight.
The jaw crusher is mainly installed on the concrete foundation. Therefore, the stability of the foundation will affect the stability of the machine. If the foundation is stable, the vibration will be less during the production process, and the equipment can stably run. If not, the jaw crusher will easily generate loud noise and vibration when it is working, which not only affects the production process but also causes the equipment to break away from the foundation. It will have a bad influence on service life, and more importantly, cause personal safety hazards for workers, so the pouring of the foundation is very important.
The jaw crusher is installed on the concrete foundation. In order to reduce vibration and hum, a layer of hardwood, rubber or other vibration-absorptive material should be placed between the frame and the concrete. The horizontal and vertical levels of the frame mounted on the wooden base shall be in accordance with the requirements, and the backing between the frame foot and the soil shall be flat, uniform and stable. Before installing, the sliding bearing is researched and placed and then placed in the bearing housing. The horizontal value and the eccentricity deviation value are measured by the level meter. If the inner diameter is within the allowable range, the eccentric shaft can be placed on the bearing.
Before the shaft and bearing assembly, the sliding bearing needs to be researched and then placed in the sliding bearing housing, and the horizontality and coaxiality of the placement are detected by the level meter. If the measurement result meets the requirements, then install the eccentric shaft on the bearing and check the fit between the shaft and the bearing by applying red dan powder on the journal.
If the surface of the plain bearing is too high, further scraping is required until the high point between the contact surfaces disappears. Finally, a certain amount of lubricating oil is applied between the bearing housing and the bearing to reduce shaft wear. The contact area between the eccentric shaft sliding and the frame should be no less than 80%, and the gap between them should be less than 0.07 mm.
The rod bolt should be assembled after the main bearing and the eccentric shaft are ground. Before assembly, check it carefully, and then use the crane to place the rod bolt slightly lower than its normal position in the crusher. Wash the upper and lower bearings of the rod bolt and lubricate them with thin oil, and then install the bearing, main shaft, upper bearing, and upper shell. Lifting the rod bolt, then install the bolts and tighten them. The bracket should be added when the oil leakage occurs due to poor fitting. When conditions permit, it is best to assemble the complete set of rod bolts and main shaft outside and load them into the frame once with the crane.
The smash or installation of toggle plate can be removed by loosening the tension spring nut, removing the spring, and then using a chain or a wire rope to tie the lower part of the movable jaw plate, and then pulling the wire rope with the driving, so that the movable jaw is close to the fixed jaw, and the rear toggle plate automatically drop off, just inverted repeat the above steps in the installation.
The movable jaw plate is assembled by using the pre-assembled parts, that is, the movable jaws, the movable shaft, the movable dental plate, and the bracket are assembled in advance, and then hoisted in the frame by a crane. The sliding bearing is first ground and placed in the frame bearing housing to measure the deviation of the slope and the coaxiality. Then apply oil to the bearing and journal surfaces and place the movable jaw in the bearing.
The dental plate is the fastest worn part of the crusher and requires frequent replacement. The dental plate is fixed on the front wall and the movable jaw by bolts or wedges. The contact surface must be straight, and no lifting phenomenon is allowed. Otherwise, it should be solved in time. Since the inside of the front wall of the frame is not machined, it is better to lay a layer of the soft metal gasket between the back of the fixed dental plate and the forearm of the frame to ensure that the two are closely fitted.
The above is the installation method for the parts of the jaw crusher. However, in order to make the equipment run stably and maximize the benefits for the user, in addition to the correct installation of the jaw crusher, the rational use is also crucial, which is related to whether the assembled jaw crusher will run in long-term stable production and create a constant value for customers.
Before the jaw crusher is started, the equipment must be thoroughly inspected, for example, to check if the connecting bolts are loose; whether the protective cover of the pulley and the flywheel is intact; whether the tension of the V-belt and the tension spring is appropriate; whetherallthe oil is filled; whether the lubrication system is integrated; whether the electrical equipment and signal system are normal, etc. In addition, before starting the crusher, the oil pump motor and cooling system should be started first. After 3-4 minutes, when the oil pressure and flow indicator are normal, the motor of the crusher can be started.
During operation, attention must be paid to increase ore uniformly, and the ore is not allowed to be filled with crushing chambers. The maximum size of the ore should not be greater than 0.85 times the width of the ore. At the same time, the non-crushing objects such as the shovel teeth of the shovel and the drill bits of the rig are strictly prevented from entering the crusher. Once it is found that these non-broken objects enter the crushing chamber and pass through the discharge port of the machine, the relevant personnel should be immediately notified to take them out in time to avoid entering the next section of the crusher, causing serious equipment accidents;
During the operation, you should always pay attention to prevent the large nuggets from getting stuck in the feeding port of the crusher. If it happens, be sure to use iron hooks to turn the ore; if it needs to be taken out of the crushing chamber, special equipment should be used. It is strictly forbidden to carry out these tasks by hand;
If the crushing chamber is blocked, the ore should be suspended. After the ore in the crushing chamber is broken, the ore can continue to be fed, but the crusher is not allowed to stop running at this time;
Regular inspections should be taken to observe the working conditions and bearing temperatures of the various components of the crusher by means of viewing, listening, and touching. Usually, the bearing temperature must not exceed 60 to prevent the alloy bush from melting or being burnt tile accident. When it is found that the bearing temperature is very high, do not stop the operation immediately. Effective measures should be taken to reduce the bearing temperature in time, such as increasing the oil supply, forced ventilation or water cooling. After the bearing temperature drops, it can be stopped for inspection and troubleshooting;
When the crusher stops, it must be stopped in the order of the production process. First of all, it is necessary to stop feeding the mine. After the ore in the crushing chamber is completely discharged, the crusher and the belt conveyor should be stopped, and then is the motor of the oil pump. It should also be noted that the crusher suddenly stops for some reasons. Before the accident is processed and ready to drive, the accumulated ore in the crushing chamber must be removed. The installation of the jaw crusher and the method of use directly affects the quality of the finished product and the smooth progress of production. Mastering the correct installation and use of the jaw crusher is an effective guarantee for improving the efficiency of crushing work and product quality.
The series of jaw crushers produced by Rayco are widely used in mining and aggregate crushing industries. They are specially developed for crushing the hardest ores and rocks, and are mainly used as primary crushers.
When working, the motor drives the belt and pulley to move the movable jaw up and down through the eccentric shaft. When the movable jaw rises, the angle between the toggle plate and the movable jaw becomes larger, thereby pushing the movable jaw plate closer to the fixed jaw plate, and the material passes through the two jaws. The squeezing and rolling between the plates realize multiple crushing.
When the movable jaw descends, the angle between the toggle plate and the movable jaw becomes smaller. The movable jaw plate leaves the fixed jaw plate under the action of the pull rod and the spring, and the crushed material passes through the discharge port in the lower jaw cavity freely under the action of gravity Unload.
When crushing high hardness and strong corrosive materials, C6X can accomplish the task very well. Its equipment structure, manufacturing technology and material selection determine the high strength of its body. Not only can it be used for coarse crushing of the hardest rocks and ore, but also can be continuously produced in the most demanding production environment on the ground and underground to ensure the maximum production efficiency of customers.Get in Touch with Mechanic