How to Choose Crusher Jaw crusher is for the primary crushing. Jaw crusher is especially good for hard material crushing. Jaw crusher is not good for soft material, and the maximum humidity of material should be less than 10%. If the raw material humidity exceeds this limit, it will stick in the jaw plates which will affect the crushing capacity of jaw crusher. One import point is that, for the tile factory user, it is recommended to separate the powder before crushing; this will increase the working capacity of jaw crusher. Another point is that, it is better to feed the jaw crusher evenly and continuously. So, feeding equipment, such as vibrating feeder is highly recommended. Hammer crusher discharging outlet with screen mesh, which is to separate the required final product. Hammer crusher is good for fragile material, such as coal, and some rocks. Hammer crusher is not good for hard or sticky material. Single rotator crushing ratio can be 10-15, double rotators crushing ratio can reach 20-30. Hammer crusher has a strict request about the material humidity, normally the material humidity should lower than 8%. If the humidity is too high, the crushed material will block the screen mesh. Besides, hammer crusher cannot break steel bar, iron. So, we must check the material before crushing.
Impact crusher is the transform of hammer crusher. Such as fixed hammer instead of the flexible hammer, delete the screen mesh plate, which we also called grid plate. Without grid plate, the discharging size is big, so impact crusher is good for coarse and medium size crushing. Impact crusher with maximum humidity of 12%. Ball mill with simple structure and reliable performance, so when even metal drop down, it is also safe. Crushed material with better mixing. Ball mill can process the material to your required fineness. Besides, ball mill can grind all hardness material. Of course, ball mill has its disadvantages, such as large power consumption, big body size and heavy weight, big starting power and works with too much noise. The material humidity should be less than 3%. Cone crusher is normally for secondary crushing. Cone crusher is expensive than impact crusher, and is good for powder making. Cone crusher works more reliable, and consumes less spare parts, so its stop working time is short than impact crusher. For a complete crushing plant, normally cone crusher is recommended, because it is more reliable than impact crusher, especially for hard material. Cone crusher is also preferred by a lot of new investors. Of course, cone crusher with high purchasing cost, and it is not good for cubic size sand processing. Roll crusher crushing ratio is 3-15. Normally the feeding size is small,-25mm is recommended. Roll crusher is used in the medium and fine processing. If the raw material is middle or soft material, roll crusher is ideal choice. Such as coal, clinker, shale, etc. roll crusher disadvantage is its roller surface wears easily. Once the roller surface is heavy wear, the discharging size will lose control. So we need to check it regularly. Now, we have not solve this problem, but we are on the way.
Jaw Crusher Knowledge Wearing parts of jaw crusher: movable jaw plate made of high manganese steel, normaly it is service time is 4 months. Fixed jaw plate made of high manganese steel, service time is 4 months; Front-thrust plate is made of casting steel, service time is 2 months; Thrust plate is made of carbon steel, service time is 10 months. Bearing bush of eccentric shaft bearing adopt white alloy, service time is 36 months. Spring is made of spring steel, service time is 6 months; Bearing bush of movable jaw plate bearing is made of bronze, service time is 12 months. Common Faults of Jaw crusher: Fault 1: Fly wheel rotates but movable jaw stop moving. Reasons: 1. thrust plate break 2. connection rod break 3. spring break Solutions: 1. replace new thrust plate 2. repair the connection rod 3. replace new spring Fault 2: Jaw plate loose and with metallic sound
Reason: the screw or side wedge is loose or damaged Solution: Fasten or replace the screw or side wedge Fault 3: Output is jaw crusher is become coarse Reason: heavy abrasion of the bottom of the jaw plates Solution: adjust the discharge opening or turn round the jaw plates Fault 4: Thrust plate support pad with impact sound Reason: spring extensive force is not enough; support pad is heavy abrasive or loose Solution: adjust spring force or replace it. Fasten or repair support pad Fault 5: Spring is broken Reason: Didn’t loosen the spring when you adjust the discharge opening to be small Solution: when you adjust the discharge opening to be small, loose the spring in advance. After the new setting, fasten the nuts advisably Fault 6: Machine jumps Reason: foot screw is loose Solution: fasten or replace foot screw Fault 7: Up and down frame connection screw is loose Solution: power off the machine, and disassemble the screw, heat it to be 150℃ in the mineral ores and then install and fasten it again.
Jaw Crusher Wearing Parts In working, the regular wearing parts of jaw crusher include the followings: 1. 2. 3. 4.
Fixed jaw plate Movable jaw plate Side board Toggle plate
Normally, it consumes movable jaw plate than fixed jaw plate. When it is limestone, jaw plates can even work for six or eight months or longer. But when it is hardest material, such as granite or basaltic stone, jaw plates service life will be reduce.
Jaw Crusher Tips Jaw crusher regular problems and solutions: Q1: Dissatisfied capacity Probable reasons: 1. Hardness and flexibility exceeds the stipulated range in manual instruction 2. Wrong cable connection of electrical motor 3. Too small discharging opening setting 4. Jaw plates move places 5. Too low voltage
6. Bearing moves due to the bad abrasion with movable jaw Solutions: 1. change or add crusher 2. change cable connection method 3. adjust the discharging size according to the manual book 4. check teeth distance, if not good, replace the new one. Or, adjust the location of fixed jaw plate and movable jaw plate 5. Increase the voltage of the local working site 6. change bearing of movable jaw Q2: Fixed jaw plate and movable jaw plate jumps and with noise Probable reasons: 1. anchor bolt of jaw plate loose or drop 2. too small discharging outlet setting, so jaw plates impact or strike Solutions: 1. fasten the anchor bolt 2. adjust the discharging outlet to ensure correct space Q3: Toggle plate break Probable reasons: 1. too much load or too big feeding material 2. material which cannot be crushed by crusher was fed 3. toggle plate and toggle plate gasket is not parallel 4. bad artworks of toggle plate Solutions: 1. change toggle plate and control feeding size and feeding capacity 2. change toggle plate and prohibit the material which can’t be crushed to be fed again 3. change toggle plate and replace new toggle plate gasket and install them correctly 4. change quality toggle plate Q4: Jaw crusher stops work, while movable jaw is in good condition Probable reasons: 1. tension spring break 2. tension rod break 3. toggle break Solutions: 1. change new spring 2. change tension rod 3. change toggle plate or install again
Cone Crusher Knowledge Notes about cone crushers: 1. The mineral ores must be in the middle of the distribution panel. Feeding it into the crushing cavity straightly is prohibited. That is because it will cause overloading if we feed raw material to crushing cavity directly, and abrase linera plate unequally. The correct solution: 1. feed the mineral ores via the distribution panel to crushing cavity evenly and continuously. 2. cannot higher than the concave level. 2. Max. feeding size can’t same as the feed opening size. The max. feeding size should be ≤85％ of the feed opening size. Otherwise, it will cause: a. decrease the capacity of the cone crusher b. damage the spare parts of the cone crusher c. before start the cone crusher,feeding material is not allowed d. before stop the crusher, we must stop the vibrating feeder first. And after the crushed stones are discharged from the bottom, then we stop the crusher. e. Check the lock system and hydraulic station regularly 2.The capacity of the cone crusher relates to feeding methods,feeding size,discharging size,raw material hardness,temperature,etc. Capacity is a big range and is variable. 3. replacement of the concave.Fix the U-shape screw to the adjusting ring, and pour zinc alloy into it, and combine them closely. For the new-installed or replaced concave, after 6-8working hours, check the tighting condition and screw U-shape screw again. 4. Crushig walls replacement. Crushing wall is fixed by concial head to the conical body,pour the zinc alloy to fix them.So, the new-installed or replaced cone crusher crushing wall, after 6-8working hours,check the screw condition and fasten the loose ones 5.Gear meshing. To ensure the gear working well, we must add pad at the seat,the pad thicknenss should be same as abrasive value of the disc plate. 6. Bowl bearing and sealing device. In installation of the bowl bearing,to avoid the steel wire damage the retaining ring(we can use wood to suppor the steel wires). In assembly,to 0.35-0.5mm ring gap between crushing cone and bowl spherical.Bowl bearing bush is poured with white alloy to fix the bowl bearing frame, and avoid bowl bearing bush rotates circly.Use Fasten the bowl bearing bush and frame with pin. Once found any gap between bowl bearing bush and frame,handle it at once 7.Cylinder liner and frame by the third transition fit, to avoid the liner rotates,pour zinc alloy at the top chute.When replace the new liner,should match with real size of frame.Because,after long time working and loading/unloading of the crusher,fit relationship is changed.If the gap is too much,the liner will be damaged. 8. Sleeves.Sleeve should match with hollow eccentric shaft.Pour zinc alloy to avoid sleeve rotating,but zinc alloy should be pour completely, and abundantly.But, due to the hot zinc alloy will cause the sleeve transformed,so when you install the new sleeves,we should check carefully.In production of the wearing parts,pay attention to the real internal diameter of the eccentri bushing. (1)Spring.spring is to protect the crusher machine being damaged when the unbreakable objective entering the crusher.So the compressing force of the
spring should match the crushing force of the crusher. In normal working,spring is static, only when the unbreakable material(such as steel bar) enter the crusher and make the crusher overloading and up the supporter which cause the spring compressed. (2)Top cover of crusher is shaking when it is working.This is abnormal.If compress the spring unsuitably which will effect the working,or damage the spare parts.Because over-compressed spring will cause much more crushing cavity. Reasons of shaking top cover of crusher as below: 1.unevenly feeding material to the crusher or overfeeding. 2.too much percentage of small lumps or powder mineral ores or humidity of the feeding material is too higher 3.the discharging opening is too small 10. Add cover to the nude gearing parts.But this protection cover is supplied by the users.
PYS Cone Crusher Tips Please pay attention to the following points before operating PYS cone crusher PYS series(symons type) cone crushers have standard type and short-head type. Standard type is for secondary crushing. Short-head type is normally used for tertiary crushing. PYS series cone crushers normally have four type cavities: fine cavity, medium cavity and coarse cavity,ultra coarse cavity. Choosing cavity depends on the input and output size. If the feeding material is big and output size is coarse, choose coarse or ultra coarse cavity. If the input size is small, required output size is fine, fine or medium cavity is recommended. Standard type cone crusher is mostly used in open circuit processing, while short-head cone crusher is mostly used in close circuit processing. When you operate PYS cone crusher, the users should pay attention to the followings: 1. the ideal and recommended max. moisture of feeding material is 5%. If too much humidity, it will affect the discharging capacity, or even stop the cone crusher 2. eliminate the steel bars or iron before feeding. Otherwise, the shaft will be damaged one day 3. full-loading production is recommended. Otherwise, the discharging product size will be coarse 4. reasonable configuration of the crushing machines contribute to perfect performance and productivity 5. degree of tightness of spring should be reasonable. Too tight will cause shaft broken. On the contrary, spring will jump frequently if it is too loose. And, if the spring is too loose, the final product will be coarse too 6. temperature of lubricating oil should be reasonable 7. change the lubricating oil regularly. Lubricating oil should not be dirty. Too dirty lubricating oil will cause heavy abrasion of wearing parts, such as socket liner, shaft busing,etc. 8. Transmission belt can not too tight. Otherwise, the transmission belt rotates inflexible or break. On the contrary, if it is too loose, cone crusher will stop working
PYS (symons) cone crusher Tips
PYS series (symons type) cone crushers have standard type and short-head type. Standard type is for secondary crushing. Short-head type is normally used for tertiary crushing. PYS series cone crushers normally have four type cavities: fine cavity, medium cavity and coarse cavity, ultra coarse cavity. Choosing cavity depends on the input and output size. If the feeding material is big and output size is coarse, choose coarse or ultra coarse cavity. If the input size is small, required output size is fine, fine or medium cavity is recommended. Standard type cone crusher is mostly used in open circuit, while short-head cone crusher is mostly used in close-circuit processing. When you operate PYS cone crusher, the users should pay attention to the followings: 1. The ideal and recommended max. Moisture of feeding material is 5%. If too much humidity, it will affect the discharging capacity, or even stop the cone crusher 2. Eliminate the steel bars or iron before feeding. Otherwise, the shaft will be damaged one day 3. Full-loading production is recommended. Otherwise, the discharging product size will be coarse 4. Reasonable configuration of the crushing machines contribute to perfect performance and productivity 5. Degree of tightness of spring should be reasonable. Too tight will cause shaft broken. On the contrary, spring will jump frequently if it is too loose. And, if the spring is too loose, the final product will be coarse too 6. Temperature of lubricating oil should be reasonable 7. Change the lubricating oil regularly. Lubricating oil should not be dirty. Too dirty lubricating oil will cause heavy abrasion of wearing parts, such as socket liner, shaft busing, etc. 8. Transmission belt cannot too tight. Otherwise, the transmission belt rotates inflexible or break. On the contrary, if it is too loose, cone crusher will stop working
Hydraulic Cone Crusher Tips Hydraulic Cone Crusher is a new and advance type of cone crusher. Here is some key problems and probable solutions for users's reference. Problems and Solutions: Q1: Eccentric copper bushing burn down Probable Solutions: 1. maybe some material which can not be process by cone crusher, such as iron, or steel was fed into the chamber. 2. to fine feeding material or the max. moisture of feeding material exceeds the limit 3. discharging opening is too small 4. bad lubricating. For example, wrong oil number, dirty oil or the oil is not enough Q2: Movable Cone damaged Probable Solutions:
1. feeding is not evenly or continuously. Non- evenly or continuously feeding will cause damage to the cone. Because when the cone crusher work without feeding material, this will cause the movable cone copper bushing strike with eccentric cooper bushing. If this happens frequently, the cone will be damaged. Besides, working without material also damaged the cooper bushing of movable cone. Because the movable cone will swing or waver when it works without feeding material. 2. bad lubrication. Such as oil number is wrong, oil is dirty, oil is not enough,etc. Due to the above problems, the users should pay attention to the following points: 1. evenly and continuously feeding to the cone crusher 2. check the material before feeding to cone crusher carefully, eliminate the steel bar, or irons. 3. feeding capacity match with the cone crusher processing capacity 4. if the material is too humid, it is better to dry it before processing. Otherwise, the humid material will block the cone crusher. Recommended humidity is less than 6% 5. choose the suitable model of cone crusher 6. other auxiliary equipment should match with cone crusher for a complete crushing plant processing, such as vibrating feeder, jaw crusher, screen, conveyors, etc.
Impact Crusher Tips Common Problem and Solution of Impact Crusher Q1: bearing becomes hot Solution: 1. lubricating oil in the bearing timely and check the oil level 2. bearing is broken and change new one 3. top cover is too tight,adjust the anchor bolt to change 4. clean the bearing and change with clean lubricating grease Q2: abnormal vibration 1. feeding material is too big, and check the feeding size 2. uneven or uniform abrasion, change the impact hammer 3. rotator is uneven, need to check the anchor bot and fasten it Q3: v-belt overturn or reversal 1. change new v-belt because it is heavy wear 2. adjust the pulley in the same plane 3. v-belt quality problem Q4: too big discharging size 1. plate hammer or liner is heavy wear, so replace new ones 2. space gap between hammer and impact plate is too big,normal gap is 15-20mm 3. too big feeding size affect discharging size Q5: knocking noise in the machine 1. the material which is not workable with impact crusher was fed into,so stop the machine and eliminate the material 2. liner plate is loose,so plate hammer bump with liner plate,so fasten the loose parts 3. plate hammer or other parts broken, so replace new plate hammer or parts
Impact Crusher Tips 2
Impact crusher is one of the most popular stone crusher or Lordz company.Now, let’s introduce how to improve the impact hammer. Now,we share the experience with you hereby. One of our Sichuan cement company which buy impact crusher PF1210 as the secondary crusher in the limestone crushing plant.Due to the local limestone raw mateiral contents SiO2 with 6%, is very hard rock, so plate hammer is abrased heavily,plate hammer with service time of only 1month,and crushing capacity is only 8000tons.Desing the same size countersink holes or rabbet to ease installation.Rabbet width should be match with the countersink holes.Graphic design of the outer surface,which is easy to match the rabbet of the rotor.Plate hammer thichkness added to 120mm,the transition stage countersink hole pull out angle of the plate hammer is designed to be 90°。To light the weight,and keep the same weight with the original plate hammer.Symmetric designed groove of the reverse two sides of the plate hammer. To ensure the stability of the bolts,we design the spider which match the countersink holes.The countersink bolts length is designed from 165mm to be 220mm.The transition stage pull out angle is designed from 75°to 90°. Due to hardness of the limestone,to increase the abrasive resistance of plate hammer, we change the raw materail from ZGMn13 to ZGMn13Cr2. Double-side turnover plate hammer abrasion process:the first time turnover of the single size, two edges were abrased about 30mm,then we can turnover the side.The other two edges were abrased about 30mm,then lastly the service life of the plate hammer ended.Thus,we realize twice turnover two sizes and work with them. Then, the plate hammer service time is 2months,and crushing capacity is increased to 20000tons.
Belt Conveyor Tips If belt alignment happened when the belt conveyor transport the coal,and cause stop working which will affect the production. And, belt alignment will cause bad abrasion to the frame, The belt edges of the conveyor and frame will have abrasion, this will cause fast abrasion of the belt or damage it and cause accident.Belt conveyor was stuck, and with abnormal sound,which add the pressure to the belt conveyor, and will cause belt slip; And due to the belt alignment which will cause coal drops which add worker pressure. So, solve the belt alignment problem is very important to our production. Reason of belt alignment 1. original design defect 2. production process and installation of the belt conveyor 3. belt vulcanization connection 4.coal feeding position is wrong
