How to improve the capacity of crawler mobile cone crusher?
The continuous improvement of equipment production capacity is the most desired wish of many sand and gravel production practitioners. As one of the commonly used equipment in many manufactured sand equipment, portable cone crusher has many factors that affect its final output and quality.
So, what should we do to effectively improve the production capacity of track mounted mobile cone crushers? Which aspects must not be done during use, and which aspects must be done? The following will be explained by Yusheng Machinery for everyone.
11 Effective Ways to Increase Portable Mobile Cone Crusher Capacity
1.Keep the tight side discharge port parameters unchanged
In order to stabilize the output, quality and production line load of sand and gravel products, the first thing to ensure is that the parameters of the mobile cone crusher tight side discharge port remain unchanged, otherwise it is easy to cause the product particle size to increase unexpectedly, which in turn affects the entire production line system and final output.
For example, the discharge port on the tight side of a certain equipment is set to 10mm, but due to neglect of inspection and equipment wear, the parameter is expanded to 13mm, then the products smaller than 10mm of the equipment will be reduced by 15%, and the target product output will be significantly reduced. The annual revenue lost by a considerable number of sand and gravel producers in this regard is astounding.
Suggestion: Check the parameters of the tight side discharge port every shift.
2. Perform "full chamber" operation as continuously as possible
If a mobile cone crusher is "full" or it is "hungry" due to factors such as unstable feeding, then its product particle size and production rate will also fluctuate. The semi-cavity operation of tracked cone crusher, its products in the grading, finished product particle size and other aspects are not ideal.
Suggestions: Ensure cone crusher operation with full cavity as far as possible in the use of it, so as to obtain better throughput and finished product particle size.
3.Do not feed to little
Less feed does not reduce the burden of mobile cone crusher; on the contrary, too little feed will lead to impaired final output, poor grain size and adverse effects on cone crusher bearings.
According to the working principle of cone crushers, the actual power of cone crushers should not be less than 40% of the rated power. In order to obtain proper "load bearing positioning" and to maximize productivity, the actual power of cone crusher should be kept between 40% and 100% of the rated power, with operation at 75%-95% of the rated power being the best choice.
Impact: Running beyond the rated power will affect cone crusher service life and cause various problems.
4.The feed drop point needs to be aligned with the center of cone crusher inlet
It is recommended to use a vertical guide plate to direct the feed drop point to the center of mobile cone crusher inlet. Once the drop point is eccentric, one side of the crushing chamber will be full and the other side will have no or little material, resulting in lower throughput of the mobile crushing and screening plant, more needle-like product, and oversized product.
Improper operation: Once this happens, the operator tends to reduce the tight side discharge opening parameters in an attempt to get the crusher to produce the target particle size, however, this will cause problems such as overloading and adjusting ring jumping on the overfed side, which in the long run will cause problems such as adjusting ring tilting, buckling and base damage, resulting in greater losses
5.Ensure uniform feeding
When feeding, it is necessary to avoid the situation that large size stones are concentrated on one side and small size stones are concentrated on the other side to ensure uniform mixing of stones.
Impact: Once the feeding is not uniform, due to the abnormal increase of bulk density, the side where the small size stone is concentrated will easily be compacted and blocked, causing the adjusting ring to jump. Faced with the jumping of the adjusting ring caused by the blockage, the operation operator will be forced to increase the parameters of the discharge port, resulting in the increase of the product particle size. In the long run, it will also cause the adjustment ring damage and other problems, resulting in greater production losses.
6.Minimize the stagnation of the buffer bin to improve the efficiency of the production line
Cone crusher buffer bin as the "enemy of production", the equipment and other related equipment also need to be carefully arranged
Suggestion: The reasonable use of buffer bin/hopper, variable speed feeding device (conveyor belt, plate vibrating feeder) can enable the operator to keep cone crusher "full" for a long time, which can easily increase the crawler cone crusher output by 10%.
7.Precise grasp of the three design upper limits of mobile cone crushers
There are three design limits for mobile cone crushers: the upper limit of throughput (capacity), the upper limit of power, and the upper limit of crushing force.
The upper limit of cone crusher capacity refers to the maximum throughput of the crusher, a mobile cone crusher running at "full cavity" has reached the maximum throughput, beyond the limit will make the feed port overflow; when the feed increases and the material is crushed finer, the actual power of mobile cone crusher will rise; the same as the power, the crushing force between mobile cone crusher bowl tile and crushing wall will also rise as the feed increases and the material is crushed finer. When the crushing force exceeds the upper limit, the adjusting ring will bounce and loosen.
Ideal operation: When the crusher is running at maximum throughput, the actual power and crushing rate are still slightly below the upper limit. Running at a state that exceeds the rated power and crushing force limits will cause overload and permanent fatigue damage to the mobile cone crusher, which is irreversible and will continue to accumulate, ultimately shortening the life of the mobile cone crusher.
8.Ensure operation within the crusher design limit
If the mobile cone crusher is operating beyond the upper limit of crushing force (adjusting ring runout) or exceeding the rated power, you can: slightly increase the tight side discharge opening parameters and try to keep the "full chamber" running. The advantage of "full cavity" operation is that there will be a "stone impacts stone" process in the crushing chamber, which will maintain the product grain size when the discharge opening is slightly larger; reduce the feed rate, but this may not guarantee good grain shape.
Reason analysis: Usually, the problem of mobile cone crushers adjusting ring jumping or exceeding rated power is caused by jamming, feeding eccentricity, uneven feeding, too much fine material in feeding, large mud content, wrong use of crushing wall and bowl liner, or simply because the operating operator set the cone crushers tight side discharge opening too small.
9.Monitor and try to ensure proper mobile cone crusher rotate speed
Impact: If proper drive belt tension is not maintained, incorrectly or drive maintenance is neglected, belt slippage and crusher rotate speed decrease can occur during work. Crusher stone throughput decreases sharply with decreasing speed, while power consumption increases sharply and unit energy consumption rises, increasing operating costs
Suggestion: A speed monitoring device can be installed in the middle shaft and other locations, connected to a PLC or directly to an alarm device, which can notify maintenance personnel to adjust the belt once the speed drops, thus extending the belt life while ensuring excellent capacity and energy consumption
10.Control the content of fines in the feed material
The fines in the feed material: the particle size of the stone material entering the crusher is equal to or smaller than the material set in the tight side discharge opening. According to experience, for secondary cone crushers, the fines content in the feed material should not exceed 25%; for tertiary cone crushers, the fines content in the feed material should not exceed 10%.
Causes and effects: Excessive fines are usually caused by vibrating screen problems. The problem may be triggered by insufficient screen hole diameter or insufficient screening capacity. Excessive fines can lead to inadequate power utilization in the crushing process and abnormal rise in energy consumption per unit
11.Feeding height should not be too big
For small and medium-sized cone crushers, the maximum suitable height of material falling from the feeding equipment to the feed opening is about 0.9m. If the feed height is too high, the stone will easily "rush" into the crushing chamber at high speed, causing impact load on the crusher, and the crushing force or power will exceed the design limit.
Impact: This problem can cause excessive pressure or tension on the crusher components, resulting in additional maintenance costs and low throughput.