Cone crusher spare parts
There are a number of different criteria to consider when selecting the right chamber for your crushing needs. There is one,however, that must always be considered. That you have well-graded feed to the chamber. A well-graded feed is generally thought to be 90-100% passing the closed- side feed opening, 40-60% passing the midpoint and 0-10% passing the closed-side setting.
A feed that is not well graded will invariably cause one or more problems with the crushing operation. If the feed is too coarse or too fine, the following problems could develop.
Reduced TPH through the crusher.
Feed too coarse = low horsepower consumption, too fine = high horsepower consumption Coarse feed will not produce as cubical a product as it should be.
Feed too coarse will cause the upper part of the crushing chamber to wear out
Feed too fine can cause upper frame movement
Oil temperature will rise if feed is too fine
Most importantly is the difference in capacity from a new liner to a worn out liner as the reduction in capacity is caused by the lower portion wearing faster than the upper portion which causes the feed operation to close off.
Choke Feeding Is A Proven Aid
In order to maintain the maximum levels of capacity, gradation and cubical product, a crusher must be choke fed at all times. The best way to keep a choke feed to the crusher is with a surge bin ( or hopper) and feeder that are located prior to the crusher. Choke feeding is almost impossible to achieve without a hopper and feeder.
When the crusher feed is reduced, the product tends to become coarse, with slivers and flats occuring.
When should you replace a liner in your crusher?
If the liner is wearing evenly throughout the chamber, you should consider changing out the manganese when it has worn down to about 25mm thick at the bottom. At about 19mm to 16mm thick, the manganese will crack, causing the backing material to begin to disintegrate. This in turn will cause the liners to break loose. If this happens, continued operation could destroy the seat on the support bowl or the head of the crusher.
Cone Crusher Manganese Mantle
The mantle is one of the actual crushing surfaces in the cone crusher It is the one that moves in a rotary pattern driven by the counter shaft to crush rock between itself and the immobile liners. The mantle doesn't actually rotate; rather it moves in a circular pattern due to an eccentric lobe on the main shaft.
Cone Crusher Concave Liner (Manganese)
The concave cone liners are the other surface that does actual crushing. The liner is shaped like an inverted cone (big side down) with the upper side have an opening that will accept the material to be crushed. These are also made of durable manganese for long life.
The main shaft is what the mantle is mounted to and is supported by bearings at its base and right below the mantle. It is driven by spiral bevel gears from the counter shaft. It does not rotate, rather it is housed in a frame that does rotate. The bearings in this frame are put off-center, creating the oscillatory motion. Depending on the model the ring gear may be located at the bottom or top of the main shaft.
Cone Crusher Counter Shaft
This shaft transfers rotary motion into the cone crusher. On the exterior end of the shaft is a sheave, on the interior side is a pinion gear that drives the eccentric main shaft housing. These assemblies are often lubricated with a oil bath system with a cooling mechanism.
The exterior end of the counter shaft has a V-groove sheave on it. Around 6 V-belts can be used to turn the countershaft. The mass of the sheave helps to keep the cone crusher gyrating, but its mass isn't as critical as that of a jaw crusher. Electric motors are typically used to turn this sheave with 200 electrical horsepower being typical.
Cone Crusher Bearings: Main & Counter
These are typically tapered roller bearings in an oil bath lubrication system. The alloys of these can often contain lead due to its effectiveness in lubrication retention.
Cone Crusher Springs
Part of the safety mechanism to prevent damage to a cone crusher during operation are large springs that put downward pressure on the upper frame (the one holding the liners). Should some piece of non-crushable piece of material enter the cone the springs can allow the liner half to rise and prevent damage.
Cone Crusher Protection: Hydraulic Cylinders
Hydraulic cylinders (typically actuated by noble gasses like nitrogen vs hydraulic oil) can collapse the springs and allow uncrushable material to exit the cone. This can be automatically actuated should the cone stop motion during operation.
Cone Crusher Beveled Gears
This gear set translates the horizontal rotary motion of the counter shaft into the vertical rotary motion of the main shaft. They are typically forged and cut for strength and low noise.
Top Cell Liners
Material to be crushed enters the cone chamber through something called the top cell, which is typically lined with manganese liners. A device called a rotary feed distributor is sometimes added to the top cell to distribute the input material evenly throughout the bowl. When feeding a cone from a screen the rock obviously is always entering the crushing chamber on one side of the bowl only, the rotary feed distributor slings the materials around both side of the cone head, filling the crushing chamber more evenly resulting in potentially a better wear pattern and even better gradation from the full choke fed feed chamber.
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