Causes And Treatment Methods Of Cone Crusher

Cone crusher is one of the commonly used crushing equipment, and various problems will inevitably occur in production.

1.Crack in the cone crusher

The unbalanced force of the moving cone caused by passing iron, uneven feeding, and the entry of large pieces of material is the main cause of cracks in the moving cone.

    (1)

  • Iron damage

    As can be seen from the figure below, there are many obvious traces of iron crossing on the moving cone liner and the fixed cone liner. After passing through the iron many times, it causes fatigue damage to the cone, especially when there is a large iron passing that cannot be discharged at one time, the iron passing through the crusher cavity and the crusher cavity can be discharged after multiple squeezes, and even the crusher is stuck. Or burned triangle belt.

  • (2) No spare parts

    Because there is no spare main shaft and upper frame on site, every time the liner is replaced, the filler does not reach sufficient strength and is put into use. This causes the crushing force to directly act on the cone, which easily causes cracks in the cone.

  • (3) The feeding is not ideal, the crusher operating pressure fluctuates greatly, and the cone is frequently impacted.

Reasons for unsatisfactory feeding:

  • (1) Feeding is eccentric. The material in the crushing cavity cannot be enriched around, causing the cone to be eccentric.
  • (2) In the feed of the crusher, there are many large materials, which exceeds the allowable value;
  • (3) The granularity of the feed is not uniform. When there is a large piece of material, the cone automatically drops, and the small piece of material immediately drops, which not only affects the crushing efficiency, but also changes the force point from multi-directional balance to partial unidirectional.

Approach:

  • (1) Install iron remover and metal detector before the material enters the crusher to avoid the occurrence of iron crossing;
  • (2) Equipped with a spare upper frame and moving cone assembly on site, the moving and fixed cone packing can be filled in advance before each liner change to ensure that the packing has sufficient maintenance time;
  • (3) Improve the feeding hopper of the crusher to avoid eccentric feeding, and at the same time, ensure that the crusher is full of feeding;
  • (4) Through prior classification, the feed size of the crusher is controlled within its design range.

2. The upper and lower frame connecting bolts often break

After the crusher is used for 1 to 2 years, the fracture of the connecting bolts of the upper and lower frames will occur to varying degrees, and in the later stage, the fracture of the connecting bolts will become more frequent.

Since the steel structure frame of the crusher and the concrete foundation are flexibly connected (spring connection), the vibration of the body is basically not transmitted to the concrete foundation. The upper and lower bodies are positioned with a tapered surface and connected with 20 M42 bolts. The upper and lower bodies are prone to wear and pitting under the action of vibration for a long time, which affects the positioning accuracy and changes the stress condition of the connecting bolt. In addition to the tensile force considered in the original design, it also bears the shear force. Force conditions are complex, so fractures are prone to occur.

Approach:

  • (1) Use a constant torque wrench to adjust the bolts so that the forces on all the connecting bolts are balanced;
  • (2) Regularly replace the connecting bolts of the upper and lower frames;
  • (3) Regularly check the wear and pitting of the joint surface of the upper and lower frames, and repair the joint surface in time when it exceeds the specified value.

3. The connection between the cone head and the main shaft is loose

Due to the threaded connection between the conical head and the main shaft, loosening often occurs during operation.

Treatment method: When the conical head is used for a certain period of time, the internal thread of the conical head is welded for assembly processing according to the actual size of the thread on the spindle. After assembly, a special bolt and a conical pressure plate are processed using the lifting screw holes on the main shaft, and the conical head is compressed again, leaving a certain gap between the two, and cushioned with a rubber plate.

4. Block the mine funnel

According to the basic theoretical analysis of powder layer mechanics, the horizontal inclination of the hopper wall must meet certain conditions (a = 450 + l / 2β) to form a logistics. However, due to the non-uniform particle size of the feed, a straight angle is formed at the transition between the feed hopper and the feed port, especially when the dryness and wetness of the ore changes, which will cause blockage and affect normal operation.

Treatment method: add an inclined arc-shaped liner to the front face of the ore funnel, so that the material shakes off onto the arc-shaped liner and slides freely along the liner into the material inlet.

5. Partial wear of rolling wall and body bushing

The main reason is that the centerline of the feeding port is consistent with the centerline of the crusher, and the geometric centerline of the flow through the feeding port is not consistent with the centerline of the feeding port, which only accounts for 2/3 of the cross-sectional area of ​​the feeding port. The materials enter the crushing chamber and flow to one side, causing partial wear.

Approach:

(1) Move the feeding port by 100-150mm so that the material flowing through the feeding port flows into the geometric centerline and the centerline of the crusher, so as to achieve a balanced ore separation;

(2) Or improve the upper feeding device to achieve uniform feeding.

6. Poor sealing, dust enters the lubrication system

Because the crushing cone has a high number of swings and a large swing stroke, coupled with the fine particle size of the product, the dust concentration is large, so that the dust can easily enter the crusher’s lubrication system, resulting in short lubricant life, tapered bushing, Body bushings and bowl bearings are often burnt out.

Treatment method: Select industrial felt with a thickness of 8-10mm, and fix the felt on the outer edge of the oil groove of the bowl-shaped bearing frame with a pressure plate. The height of the felt must ensure a compression of 3-5mm. After the felt is installed, it should be Lubricate to reduce felt wear. The advantage is that in the water seal dustproof device, most of the coarse-grained dust has been blocked by felt. This prevents dust from entering the lubrication system, and the sealing effect is better.

The reasons for the failure of the crusher include accidental damage caused by improper use and maintenance, and natural damage caused by wear and tear, corrosion and fatigue. The former can be avoided by improving the management level, while the latter is unavoidable, but if you master the rules, taking corresponding measures from design, manufacturing to use, maintenance and other links can greatly reduce the damage to parts and extend the service life.

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