What are cone crushers. Cone crushers: basic types, device and principle of operation

Cone crushers are continuous devices for grinding rock, as well as ores of different levels of hardness (medium, small). The main difference between them and the jaws is that they do not have idle. After the pieces of material of different fractions enter the crusher, they are crushed between two mobile half-cones and a stationary bowl. This design is rational for grinding ore for ferrous and non-ferrous metallurgy, therefore it is in this industry that such aggregates have found the greatest distribution. Let's talk about the device, the principle of operation and the characteristics of cone crushers.

Classification of devices

Currently, cone crushers are usually divided into large (CCD), medium (KSD) and fine crushing (KMD) devices.

KKD are characterized by the fact that they are able to take pieces of rock from 400 to 1200 mm with an output gap of 75-300 mm. The capacity of such an aggregate is from 150 to 2 300 m ³ / h. Sometimes only cone crushers can cope with the tasks. Why so, you will learn a little later.

KSD have a cone size of 600-900 millimeters and can handle pieces of ore from 60 to 300 mm, and at the outlet give a fraction of 12-60 mm. The productivity of such units is not less than 12 and not more than 580 m ³ / hour.

If we talk about KMD, the receiver is designed for pieces of 35-100 mm, and at the output you can get elements of 3-15 mm. The productivity of such crushers is 12-220 m ³ / h. If we consider the principle of the action of the aggregate in a few words, then we have approximately the following. The cone rotates. Clinging to one side of the fixed bowl, it crushes the ore, and when it leaves the other side, the fraction falls into the exit slot. Then the cycle repeats.

Roller Crusher

From the name it can be understood that a cylindrical roll acts as a working member. The material to be crushed is fed from the loading device from above, then falls between the rollers and is subjected to grinding.

Such crushers are classified according to the number of rollers. There are 1, 2 and 4-roll aggregates. It is worth noting that in the latter case two two-roll crushers are mounted, which are placed one above the other. The surface of the working element can be corrugated, smooth or serrated. In some cases, different combinations are used. For example, one roller is smooth, and the other is notched or grooved. This is done to improve the crushing and obtaining the ore of the desired fraction.

The industrial roller crusher has a working body diameter of 400-500 millimeters with a length of 0.4-1.0 of the diameter. At present, such aggregates are used for grinding medium-strength rocks of small size.

Two-roll crushers are widely used, which are ideal for grinding wet and viscous materials. In the process of work on the rolls, a deposit is formed, which is removed with special scrapers. The clearance between the rollers is set depending on the diameter of the fraction to be obtained. Well, now let's return to the cone crushers and consider them in more detail.

Crusher with your own hands - it's easy and simple

As noted above, it is unrealistic to manufacture a grinding device for industrial scales. But here for the exploitation in everyday life it is possible to make something. In the course will go various improvised means.

Let's look at the simplest version of the crusher. This is the container into which the shaft is mounted on the bearings. The latter is equipped with several working elements, for example, knives. We also need a low-power electric motor - let it be a 1 kW device, with which the shaft will be driven. The connection between the shaft and the motor is best realized by a belt drive with several wheels of different diameters. So it will be possible to adjust the speed of rotation of the crusher knives.

What is the purpose of such an aggregate, you ask? Of course, it will not be possible to crush ore and other rocks, but we do not really need it. But such a crusher, made with your own hands, is quite suitable for processing cereals, grass, etc. In principle, in agriculture, the thing is necessary, especially since it is simple to make. But sometimes the simplest crushers can find their application in construction for grinding crushed stone or gravel.

As you can see, there is nothing complicated, you just need to find the right tools and details for the future unit. You can increase the power of the crusher by setting another engine, say, 5 or even 10 kW, but in this case it is better to replace the belt drive with a gearing through a simple gear.

Equipment for grinding crushed stone

Currently, the crusher for crushed stone can have some design features. What is a jaw crusher? The essence of her work is that the material falls between two cheeks (swinging plates) and is crushed. By adjusting the gap, it is possible to obtain crushed stone of different fractions. When a medium of medium and small cuboidal shape is needed, cone crushers (KMD) for crushed stone are used. This is the most common solution in construction. Do not forget about the roller crushers. With their help it is possible to obtain crushed gravel of fine fraction.

I would like to elaborate on cone crushers. The fact is that with their help you can get a cuboid crushed stone, which is used for strewing roads and in building to obtain concrete.

It is worth noting that the cone crusher for rubble is good because it uses the technology "stone to stone." It consists in creating cramped conditions under which about 30% of the rubble is crushed by rubbing against each other. But for the implementation of this method, the crusher operates under the rubble. The movable cone with this approach is completely closed with rubble ("blockage"). There is a small drawback in the form of a larger fraction at the output. For this purpose, the discharge gap is somewhat larger than the material being processed.

On the advantages and disadvantages of cone crushers

There are many pros and cons, which must be mentioned. Since the shape of the crushing surface does not form a regular cone, the crushing force can differ significantly at different stages and sections. But this forced action, which was achieved with the help of changing the angle of tilt of the cone along its height, which requires technology.

It is necessary to draw your attention to the fact that the main disadvantage of the cone crusher (KD) is its increased energy intensity. A little earlier it was said about how to achieve some savings during the operation of the device. In addition, the design itself is quite capacious and cumbersome, which in some cases makes it difficult to operate.

Previously, often faced with such problems as jamming the crusher due to hard rock. Today, this defect was eliminated by installing the spring suspension of the bowl to the frame. If necessary, the outlet gap increases in size, and the solid piece of rock falls down.

In recent years, the cone crusher has been slightly improved. Drawings of innovators had one distinctive make - vibrators of the unbalanced type. The latter provide the mobile cone with additional vibration, which makes the crushing more qualitative. In addition, the benefits of CDs are high performance. An important role is played by the continuity of the process, and the possibility of launching "with a blockage," that is, with a filled mobile cone.

CD with hydraulic slit adjustment

We said that the imbalances are considered innovative solutions. Despite the fact that the design of the crusher has become somewhat more complicated, it was possible to reduce the vibration of the unit during operation, and there is no need to erect large foundations, since there are practically no dynamic loads. All this improved the quality of crushing and productivity, however, the issue of energy consumption remained at the same level.

As for the hydraulics in the CD design, this innovation has already taken hold. This approach helped to achieve easier adjustment of the slot size at the output.

The hydraulic device can also be used as a compensator, i.e. a fuse. It is necessary when the hard body gets a hard piece of rock. Hydraulic closures, protecting bushings and drive units from getting dust and dirt, and, as a result, from increased wear have also found their application. But today not every company can produce such an assembly. The most widespread cone crusher (KSD) with hydraulics "Esh-Verke", "Vedag" and other leaders in the production of such equipment. Well, now let's look at some more interesting nuances.

Cone-Jaw Crusher

Separate few words should be said about the development of the designers of the company "Ash-Verke". The fact is that in the process of operation, the CD faced a problem - it is impossible to load large pieces of rock. To do this did not allow the insufficient diameter of the loading hopper. The design solution consisted in the creation of a unique form of a movable cone and a fixed cup of CD. So, the upper part of the installation turned out to be flat, which allowed loading a large fraction rock there.

In the first section the device works like a classic jaw crusher. In the middle and lower parts of the unit, a gradual narrowing of the slit can be seen. As a result, it is a standard cone crusher (600).

From all of the above, it can be concluded that this approach allows the use of large pieces of rock, as in jaw crushers, and get a cubical crushed stone at the output, which is inherent only in CD.

Jaw Crusher: principle of operation and advantages

The essence of crushing in such an aggregate is that the rock or ore is compressed between the cheeks, that is, the working organs. One cheek is fixed and rigidly fixed, the second makes a rocking motion with the help of a connecting rod. Such crushers are classified in the same way as cone crushers, and there are large, medium and fine crushing. The size of the fraction at the outlet depends on the size of the outlet slit, which can be adjusted from a mechanical or hydraulic drive.

The working chamber has a wedge shape, and there is a grinding of the ore. The material is loaded, crushed, and falls under gravity to the discharge port.

Currently, several types of jaw crushers are used, which differ from each other in the trajectory of swinging the cheek. They are divided into simple and complex. The latter are more effective in crushing rock and ore. But it is worth paying attention to the fact that it is extremely important to observe the optimum moisture content of the material. So, the SMD crusher can work with ore, the amount of moisture in which - no more than 6-8%. If this indicator increases by at least a few percent, then the performance deteriorates several times.

Inertial CDs and their scope

We have already talked a little about such crushers in this article.

They are also called unbalanced and have a vibrating device. These units play an important role in the construction of roads (both road and rail). From this it can be concluded that this decision is extremely relevant in construction organizations.

A CD with an eccentric drive is used all over the world, which makes it possible to simplify the adjustment and limit itself to changing only the discharge slot. This approach allows you to get crushed stone, which is 85% of the total output is cuboid, which is considered a very good result.

The main problem is the low frequency of oscillation of the mobile cone. If the frequency is increased, then the dynamic oscillations increase, which leads to the destruction of the foundation. Constructors are constantly striving to increase the cuboid character of the rubble, since this directly affects the quality and durability of roads.

Conclusion

So we talked about what kind of CDs are, what are their design differences, etc. You already know how to make a crusher, so if you need it, you can make an assembly that, although not suitable for industrial scale, but for consumer needs is quite suitable.

There are also alternative solutions, for example, a cone crusher, which will be ideal when conventional CD is not suitable. A separate issue is the price of the crusher. It is difficult to name specific figures. The fact is that the more complex the unit, the more there is the cost. Naturally, the unit of lower productivity, for example, KMD 600, will cost less than KMD 1200. On average, you will have to pay about 5,000 euro for the crusher.

Well, that's all that can be told about cone crushers, which are indispensable for obtaining cube-shaped crushed stone, crushing rock and ore of various sizes and hardness.