There are different types of stone crushers in mining industry such as jaw crusher, cone crusher, impact crusher, and sand making machine. This article will tell you how to maintain the 4 types of rock crushers and how to efficicently improve their performance.
How to make your crushers efficiency
Many stone crusher operators have a common coception that is "don't-fix-it-if-it-isn't-broke". They may want to save cost at the begining while the consequence is that they have to spend more money on repair and face interuption on production. That's why I always say that preventive and predictive is very important for all types of stone crusher.
Preventive means that by making regular checklist and inspections to keep crushers in good condition. Maintenance checklist is usually set up on a daily (8 hours), weekly (40 hours), monthly (200 hours), yearly (2,000 hours). Only doing that, can you prolong the machine's life span and maximize its value in crushing process.
Predictive refers to mornitoring the condition of crusher when it is running. By some maintenance tools such as lubricating oil temperature sensors, lubricating oil filter condition indicator, you can timely draw the machine data so that making a comparison between the real situation and normal state. Predictive can help you find problem early then timely removing thers issues before demage occuring.
If you have missed the first two stages of preventive and predictive, don't worry, the reactive also works.
Ractive means that even if your crushers have got problems, as long as you adopt correct solutions to respond, you still can get your machine back to normal. Next, I'll introduce important skills to maintain your equipment.
Common problems you would face when operating a jaw crusher
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Premature bearing failures. That's because you haven't make a regular cleaning in the oil chamber which is full of dust and fines. If bearing cannot get efficient lubrication, it is liable to got broken, and interupt the production at least 1 hour. To protect bearing, you have to inspect to see whether the breather is knocked off, and clean the oil chamber to gurantee enough oil for bearing.2
Jaw crusher parts especially jaw plates wear badly. Materials that need be crushed is irregular and with different hardness, so it will bring constant friction and stress to the jaw plates. At the same time, moveable jaw moves up and down in vertical direction, which leads to stronger friction between material and jaw plates thus damaging the surface of the jaw plates.Although spare parts wear replacement is inevitable, you can prolong its life span by doing regular maintenance.
For example, for jaw plates,
How to replace Jaw crusher plates?
The most practical jaw crusher repair and maintenance manual
Other ways to protect your jaw crusher parts
Cone crusher
The cone crusher in the secondary or tertiary crushing proccess often fractures medium-hard or hard rocks like pebble, quartz, granite, etc. It is easy to get premature crusher failure, if operators cannot make a correct and timely inspection and maintenance.
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You must operate at a consistent closed-side discharged setting(css). It can effectively tackle problems caused by over-sized material and maintain producing high-quality, even final products.2
"Choke fed" cavity level is necessary. That means no matter what the cavity level is too low or too high has the worst impact on your final products. If the cavity level is too low, the final product will become coarser, flatter and more elongated.3
Avoid trickle feed the crusher. Trickle feed would reduce your production, productivity, and value of end products. So you have to keep rated horsepower at 40%-100%, and between 75%-95% is optimal.4
Lubricate your machine regularly. Lubricate important parts like mainshaft, bearings, mantle and concave can make the whole production smooth and minimize the downtime.5
Clean your oil tank if it is contaminated.6
Remove the fines or sticky material in the crushing chamber.
Mantle (movable cone) and concave (fixed cone)
Mantle in moveable cone and concave is fixed cone. Due to directly contacting with rock materials, the two wear parts need frequent maintenance and protection. So operators have to know the preparations and maintaining skills.
Cone crusher repair tools list PROPANE TORCH GRINDER C/W SANDING PAD 3/4"PNEUMATIC IMPACT 3/4"RATCHET 1/2"RATCHET 1/2"TORQUE WRENCH LIFTING SHACKLES W/HOOK FLINT SPARK LIGHTER 48 MM 3/4"SOCKET 19MM 1/2"SOCKET 1/2"EXTENSION HEAD LIFTING TOOL LIFTING STRAPS ABRASIVE HAND PADI FEELER GAUGE LOCTITE 243 How to maintain and replace mantle and concave video?
Impact crusher working animation
The working principle of impact crusher is that the spinning rotor under the driving of the motor can genetate strong impact force which make blow bars crush stone material into small pieces. Then the crushed material would be thrown by hammers towards, which makes another crushing process "stone to stone".
During the whole process, the parts which wear easily are hammers (blow bars), rotor, aprons, alloy steel liners.
Sand making machine
The sand making machine is also known as the vertical shaft impact crusher. Its working mode is that the material falls vertically from the upper part of the machine into the high-speed rotating impeller. The impeller is one of the important parts of the sand making machine, and it is also the most vulnerable part.
After the materials collide with each other, they will be pulverized and smashed between the impeller for multiple times and discharged from the lower part. The materials crushed by the device have an excellent particle size and are suitable for aggregate shaping, artificial sand making and highway construction.
Different Maintenance methods when running different times
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In the face of such a dazzling market, how to choose the production equipment suitable for users' actual needs among the numerous equipment brands of many machinery manufacturers is a big problem for many large and small enterprises. Here we list top 4 world's construction equipment manufacturers for you to choose:
Suitable for very large mining sites but with relatively high prices
Suitable for medium-sized mining sites, with good equipment quality, economical price and high cost performance
Factory of Fote Heavy Machinery (FTM)
Jordan is the writer of the blog with a broad knowledge of this industry. Most importantly, he hopes to help you in your projects sincerely.
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