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 efficiently 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.
Why are preventive and predictive crucial to crusher maintenance?
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.
The most effective maintenance skills for different stone crushers
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.
Jaw crusher
Common problems you would face when operating a jaw crusher
1. 1Premature 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. 2Jaw 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.
Cone crusher
The cone crusher in the secondary or tertiary crushing process 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.
6 Tips to help you prolong the concrusher's service life:
1. 1You 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. 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. 3Avoid 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. 4Lubricate your machine regularly. Lubricate important parts like main shaft, 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 and concave
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.