rock crusher kinematic diagram

rock crushers

This invention relates to jaw rock crushers. In such known crushers, eccentrics or unbalanced rotors drive one or two oppositely situated swing jaws. The disadvantage of the known jaw rock crushers in comparison with known gyratory crushers lies in their cyclical work. i.e. the jaw makes one power stroke and one idle stroke during one revolution of the eccentric shaft. That requires higher strength of construction, balancing and a more powerful mechanical drive. Also, in the conventional jaw crushers, the axle of the swing jaw is situated in its rear part, the power stroke of the jaw providing a force component acting in anti-gravitational direction and braking the material.

The objectives of the present invention is to increase the efficiency of above crushers, decrease their mass and requirements to the construction strength, balancing and mechanical drive, to simplify the construction, and to reduce the drive to easily accessible and interchangeable conventional relatively cheap units.

Above objectives are achieved by executing the drive in form of hydraulic cylinder acting on the swing jaw and connected to a hydraulic pulser. The latter is made as a hydraulic reciprocating cylinder with its plunger actuated by a displacer, such as radial or axial cam, eccentrics, cranks and the like. This simplifies the drive by eliminating heavy components of the known mechanical drives and reduces it to easily accessible and interchangeable hydraulic units with lesser masses and cost.

Above cyclical work is eliminated by dividing the swing jaw into separate sections interacting with hydraulic cylinders connected to a multi-plunger hydraulic pulser. The plungers of the latter are spaced equally apart from each other and relatively to the displacer.

Such a rock crusher squeezes treated materials continuously since the jaw sections work in turn, the more sections, the more uniformly the crusher works. The different jaw sections squeeze and release the materials simultaneously. Such uniform work lessens the horsepower, dynamic load and the crushers mass and foundation. Besides, the efficiency of the breaking down of rocks is elevated since the transverse (bending) load on rocks between the different sections is probable.

Still better balancing is achieved providing opposite swings of the synchronized swing jaws, instead of the stationary one. Besides, the opposite swing counterbalanced jaws increase the crushers throughput. To facilitate the gravitational movement of the material and to provide the possibility of a much lower headroom construction (e.g. for portable crushers of underground mining), the jaws form an inclined crushing chamber. It slops downwardly from the inlet to the discharge, with the swing jaw being lower and having frontal ears for its swing axle. Such a low-profiling crusher with its dramatically reduced mass and easily disconnected hydraulic drive makes it suitable for underground mine applications.

Similar to the hydraulic cone and gyratory crushers of the previous chapter, this invention can be also made in line with the authors earlier hydraulic shock impact applications. Therein an impulse exciter/pulser of hydraulic shocks is installed in the pipeline with its length greater than a half product of the sound velocity and the impulse time.

Fig. 1 is a side elevation view of the present crusher with a stationary jaw and a double-acting hydraulic cylinder. Fig. 2 is a top plan view of the crusher with two-sectional swing jaws. Fig. 3 is a hydraulic diagram of the crusher of Fig. 2. Fig. 4 is a kinematic diagram of a hydraulic pulser of a crank type. Fig. 5 is the same as above of a radial eccentric (cam) type with parallel rocks between the different sections is probable. Fig. 6 is the same as above of an axial cam type. Fig. 7 is the same as in Fig. 1, with a single-acting hydraulic cylinder. Fig. 8 is above crushers hydraulic diagram. Fig. 9 is the same of the crusher of Fig. 1 with two opposite synchronizedswing jaws. Fig. 10 is the same as above, a swing jaw having frontal ears.

A hydraulic rock crusher of the present invention consists of a swing jaw 1 swung on an axle 2 mounted on a frame 3 (Fig. 1 and 2). An opposite jaw can be a stationary one 4 fixed to the frame 3 (Fig. 1 3. 7 and 8) or a synchronized jaw 5 swim on an axle 6 mounted either on the frame 3 (Fig. 9) or on the same axle 2 (Fig. 10). To eliminate the cyclical work of the crusher, the swing jaw 1 is divided into separate sections 7 (two such sections are shown in Fig. 2 only in way of illustration, but not in a limiting sense). The hydraulic drive consists of hydraulic cylinders 8 swung in axles 9 mounted on the frame 3 and acting upon the swing sections. The cylinders of different sections are connected to a multiplunger hydraulic pulser 10.

In double-acting cylinders (Fig. 1, 3, 9 and 10), their rods are hinged tothe sections with axes 11. In single-acting cylinders (Fig. 7 and 8), their rods are provided with spherical supports 12 fixed to the sections, although hinges can be also used as above. With single-acting cylinders, tension rods 13 are mounted on the frame 3 and have threaded ends carrying springs 14 and nuts 15. Said ends extend through suitable holes in the frame 3. The springs 14 provide the backstroke. Such a tension arrangement holds a single-acting cylinder with an unhinged rod in place. The hydraulic pulser 10 consists of a rotating member 16. such as a radial eccentric (Fig. 3, 5 and 8) or a cam (not shown), a crank, an axial cam, (Fig. 6) and the like, acting on plungers 17.

To replenish leakages, the cylinders are connected to a hydraulic accumulator 18 via a two-way valve 19 and non-return valves 20. The pressure chambers of the cylinders have safety valves 21. To adjust the positions of jaws, (to vary the discharge opening between them) and to release trapped unbreakable materials, the cylinders are connected to pressure and drain lines by four-way valves 22 (Fig. 3) or three-way valves 23 (Fig. 8).

In the rock crushers with both swing jaws Fig. 9 arid 10), the cylinders of the opposite sections have parallel connections to the pulser 10. To provide a downward component of the power stroke, the lower swing jaw has frontal ears 24 for its swing axle (Fig. 10).

Rocks are fed from the top crushed by the jaw sections moving to the opposite jaw and fall down when the sections are moved back. The rocks are crushed again by the next power stroke until they drop through the discharge opening. The resistance of the motion of the moving section increases sharply on the power stroke and diminishes on the return one. That is why the sections of the present crusher distribute the load on the mechanical drive of the pulser, frame and foundation more uniformly and ensure the smooth running. For assistance to the distribution, a hydraulic accumulator can be used in a conventional manner (not shown), storing the surplus energy during the idle stroke and releasing it for crushing on the power stroke.

Big rocks are subjected to transverse (bending) load between sections. That elevates the efficiency still more. The crusher with oppositely swing jaws is counterbalanced almost completely and therefore, its dynamic load on the foundation is considerably decreased. Since the pulser serves as an intensifier too, the hydraulic drive of the present crusher is not as cumbersome as the conventional eccentric drive of the known crushers.

jaw crusher model diagram with photo

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jaw crusher working principle

A sectional view of the single-toggle type of jaw crusher is shown below.In one respect, the working principle and application of this machine are similar to all types of rock crushers, the movable jaw has its maximum movement at the top of the crushing chamber, and minimum movement at the discharge point. The motion is, however, a more complex one than the Dodge motion, being the resultant of the circular motion of the eccentric shaft at the top of the swing jaw. combined with the rocking action of the inclined toggle plate at the bottom of this jaw. The motion at the receiving opening is elliptical; at the discharge opening, it is a thin crescent, whose chord is inclined upwardly toward the stationary jaw. Thus, at all points in the crushing chamber, the motion has both, vertical and horizontal, components.

It will be noted that the motion is a rocking one. When the swing jaw is rising, it is opening, at the top, during the first half of the stroke, and closing during the second half, whereas the bottom of the jaw is closing during the entire up-stroke. A reversal of this motion occurs during the downstroke of the eccentric.

The horizontal component of motion (throw) at the discharge point of the single-toggle jaw crusher is greater than the throw of the Dodge crusher at that point; in fact, it is about three-fourths that of Blake machines of similar short-side receiving-opening dimensions. The combination of favorable crushing angle, and nonchoking jaw plates, used in this machine, promotes a much freer action through the choke zone than that in the Dodge crusher. Capacities compare very favorably with comparable sizes of the Blake machine with non-choking plates, and permissible discharge settings are finer. A table of ratings is given.

The single-toggle type jaw crusher has been developed extensively. Because of its simplicity, lightweight, moderate cost, and good capacity, it has found quite a wide field of application in portable crushing rigs. It also fits into the small, single-stage mining operation much better than the slower Dodge type. Some years since this type was developed with very wide openings for reduction crushing applications, but it was not able to seriously challenge the gyratory in this field, especially when the high-speed modern versions of the latter type were introduced.

Due to the pronounced vertical components of motion in the single-toggle machine, it is obvious that a wiping action takes place during the closing strokes; either, the swing jaw must slip on the material, or the material must slip along the stationary jaw. It is inevitable that such action should result in accelerated wear of the jaw plates; consequently, the single-toggle crusher is not an economical machine for reducing highly abrasive, or very hard, tough rock. Moreover, the large motion at the receiving opening greatly accentuates shocks incidental to handling the latter class of material, and the full impact of these shocks must be absorbed by the bearings in the top of the swing jaw.

The single-toggle machine, like the Dodge type, is capable of making a high ratio-of-reduction, a faculty which enables it to perform a single-stage reduction of hand-loaded, mine run ore to a suitable ball mill, or rod mill, feed.

Within the limits of its capacity, and size of receiving openings, it is admirably suited for such operations. Small gravel plant operations are also suited to this type of crusher, although it should not be used where the gravel deposit contains extremely hard boulders. The crusher is easy to adjust, and, in common with most machines of the jaw type, is a simple crusher to maintain.

As rock particles are compressed between the inclined faces of the mantle and concaves there is a tendency for them to slip upward. Slippage occurs in all crushers, even in ideal conditions. Only the particles weight and the friction between it and the crusher surfaces counteract this tendency. In particular, very hard rock tends to slip upward rather than break. Choke feeding this kind of material can overload the motor, leaving no option but to regulate the feed. Smaller particles, which weigh less, and harder particles, which are more resistant to breakage, will tend to slip more. Anything that reduces friction, such as spray water or feed moisture, will promote slippage.

Leading is a technique for measuring the gap between fixed and moveable jaws. The procedure is performed while the crusher is running empty. A lead plug is lowered on a lanyard to the choke point, then removed and measured to find out how much thickness remains after the crusher has compressed it. This measures the closed side setting. The open side setting is equal to this measurement plus the throw of the mantle. The minimum safe closed side setting depends on:

Blake (Double Toggle) Originally the standard jaw crusher used for primary and secondary crushing of hard, tough abrasive rocks. Also for sticky feeds. Relatively coarse slabby product, with minimum fines.

Overhead Pivot (Double Toggle) Similar applications to Blake. Overhead pivot; reduces rubbing on crusher faces, reduces choking, allows higher speeds and therefore higher capacities. Energy efficiency higher because jaw and charge not lifted during cycle.

Overhead Eccentric (Single Toggle) Originally restricted to sampler sizes by structural limitations. Now in the same size of Blake which it has tended to supersede, because overhead eccentric encourages feed and discharge, allowing higher speeds and capacity, but with higher wear and more attrition breakage and slightly lower energy efficiency. In addition as compared to an equivalent double toggle, they are cheaper and take up less floor space.

Since the jaw crusher was pioneered by Eli Whitney Blake in the 2nd quarter of the 1800s, many have twisted the Patent and come up with other types of jaw crushers in hopes of crushing rocks and stones more effectively. Those other types of jaw crusher inventors having given birth to 3 groups:

Heavy-duty crushing applications of hard-to-break, high Work Index rocks do prefer double-toggle jaw crushers as they are heavier in fabrication. A double-toggle jaw crusher outweighs the single-toggle by a factor of 2X and well as costs more in capital for the same duty. To perform its trade-off evaluation, the engineering and design firm will analyze technical factors such as:

1. Proper selection of the jaws. 2. Proper feed gradation. 3. Controlled feed rate. 4. Sufficient feeder capacity and width. 5. Adequate crusher discharge area. 6. Discharge conveyor sized to convey maximum crusher capacity.

Although the image below is of a single-toggle, it illustrates the shims used to make minor setting changes are made to the crusher by adding or removing them in the small space between the crushers mainframe and the rea toggle block.

The jaw crusher discharge opening is the distance from the valley between corrugations on one jaw to the top of the mating corrugation on the other jaw. The crusher discharge opening governs the size of finished material produced by the crusher.

Crusher must be adjusted when empty and stopped. Never close crusher discharge opening to less than minimum opening. Closing crusher opening to less than recommended will reduce the capacity of crusher and cause premature failure of shaft and bearing assembly.

To compensate for wear on toggle plate, toggle seat, pitman toggle seat, and jaws additional shims must be inserted to maintain the same crusher opening. The setting adjustment system is designed to compensate for jaw plate wear and to change the CSS (closed side setting) of the jaw crusher. The setting adjustment system is built into the back frame end.

Here also the toggle is kept in place by a compression spring. Large CSS adjustments are made to the jaw crusher by modifying the length of the toggle. Again, shims allow for minor gap adjustments as they are inserted between the mainframe and the toggle block.

is done considering the maximum rock-lump or large stone expected to be crushed and also includes the TPH tonnage rate needing to be crushed. In sizing, we not that jaw crushers will only have around 75% availability and extra sizing should permit this downtime.

As a rule, the maximum stone-lump dimension need not exceed 80% of the jaw crushers gape. For intense, a 59 x 79 machine should not see rocks larger than 80 x 59/100 = 47 or 1.2 meters across. Miners being miners, it is a certainty during day-to-day operation, the crusher will see oversized ore but is should be fine and pass-thru if no bridging takes place.

It will be seen that the pitman (226) is suspended from an eccentric on the flywheel shaft and consequently moves up and down as the latter revolves, forcing the toggle plates outwards at each revolution. The seating (234) of the rear toggle plate (239) is fixed to the crusher frame; the bottom of the swing jaw (214) is therefore pushed forward each time the pitman rises, a tension rod (245) fitted with a spring (247) being used to bring it back as the pitman falls. Thus at each revolution of the flywheel the movable jaw crushes any lump of ore once against the stationary jaw (212) allowing it to fall as it swings back on the return half-stroke until eventually the pieces have been broken small enough to drop out. It follows that the size to which the ore is crushed.

The jaw crusher is not so efficient a machine as the gyratory crusher described in the next paragraph, the chief reason for this being that its crushing action is confined to the forward stroke of the jaw only, whereas the gyratory crusher does useful work during the whole of its revolution. In addition, the jaw crusher cannot be choke-fed, as can the other machine, with the result that it is difficult to keep it working at its full capacity that is, at maximum efficiency.

Tables 5 and 6 give particulars of different sizes of jaw crushers. The capacity figures are based on ore weighing 100 lb. per cubic foot; for a heavier ore, the figures should be increased in direct proportion to its weight in pounds per cubic foot.

The JAW crusher and the GYRATORY crusher have similarities that put them into the same class of crusher. They both have the same crushing speed, 100 to 200 R.P.M. They both break the ore by compression force. And lastly, they both are able to crush the same size of ore.

In spite of their similarities, each crusher design has its own limitations and advantages that differ from the other one. A Gyratory crusher can be fed from two sides and is able to handle ore that tends to slab. Its design allows a higher-speed motor with a higher reduction ratio between the motor and the crushing surface. This means a dollar saving in energy costs.

A Jaw crusher on the other hand requires an Ely wheel to store energy. The box frame construction of this type of crusher also allows it to handle tougher ore. This design restricts the feeding of the crusher to one side only.

The ore enters from the top and the swing jaw squeezes it against the stationary jaw until it breaks. The broken ore then falls through the crusher to be taken away by a conveyor that is under the crusher.Although the jaws do the work, the real heart of this crusher is the TOGGLE PLATES, the PITMAN, and the PLY WHEEL.

These jaw crushers are ideal forsmall properties and they are of the high capacity forced feed design.On this first Forced Feed Jaw Crusher, the mainframe and bumper are cast of special alloy iron and the initial cost is low. The frame is ribbed both vertically and horizontally to give maximum strength with minimum weight. The bumper is ruggedly constructed to withstand tremendous shock loads. Steel bumper can be furnished if desired. The side bearings are bronze; the bumper bearings are of the antifriction type.

This bearing arrangement adds both strength and ease of movement. The jaw plates and cheek plates are reversible and are of the best-grade manganese steel. The jaw opening is controlled by the position of an adjustable wedge block. The crusher is usually driven by a V-to-V belt drive, but it can be arranged for either V-to-flat or fiat belt drive. The 8x10 size utilizes a split frame and maybe packed for muleback transportation. Cast steel frames can be furnished to obtain maximum durability.

This second type of forced feed rock crusher is similar in design to the Type H listed above except for having a frame and bumper made of cast steel. This steel construction makes the unit lighter per unit of size and adds considerable strength. The bearings are all of the special design; they are bronze and will stand continuous service without any danger of failure. The jaw and cheek plates are manganese steel; and are completely reversible, thus adding to their wearing life. The jaw opening is controlled by the position of an adjustable wedge block. The crushers are usually driven by V-to-V but can be arranged for V-to-flat and belt drive. The 5x6 size and the 8x10 size can be made with sectionalized frame for muleback transportation. This crusher is ideal for strenuous conditions. Consider a multi jaw crusher.

Some jaw crushers are on-floor, some aboveground, and others underground. This in many countries, and crushing many kinds of ore. The Traylor Bulldog Jaw crusher has enjoyed world wide esteem as a hard-working, profit-producing, full-proof, and trouble-free breaker since the day of its introduction, nearly twenty years ago. To be modern and get the most out of your crushing dollars, youll need the Building breaker. Wed value the privilege of telling you why by letter, through our bulletins, or in person. Write us now today -for a Blake crusher with curved jaw plates that crush finer and step up production.

When a machine has such a reputation for excellence that buyers have confidence in its ability to justify its purchase, IT MUST BE GOOD! Take the Type G Traylor Jaw Crusher, for instance. The engineers and operators of many great mining companies know from satisfying experience that this machine delivers a full measure of service and yields extra profits. So they specify it in full confidence and the purchase is made without the usual reluctance to lay out good money for a new machine.

The success of the Type G Traylor Jaw Crusheris due to several characteristics. It is (1) STRONG almost to superfluity, being built of steel throughout; it is (2) FOOL-PROOF, being provided with our patented Safety Device which prevents breakage due to tramp iron or other causes of jamming; it is (3) ECONOMICAL to operate and maintain, being fitted with our well-known patented Bulldog Pitman and Toggle System, which saves power and wear by minimizing frictionpower that is employed to deliver increased production; it is (4) CONVENIENT to transport and erect in crowded or not easily accessible locations because it is sectionalized to meet highly restrictive conditions.

Whenever mining men need a crusher that is thoroughly reliable and big producer (which is of all time) they almost invariably think first of a Traylor Type G Jaw Crusher. By experience, they know that this machine has built into it the four essentials to satisfaction and profit- strength, foolproofness, economy, and convenience.

Maximum STRENGTH lies in the liberal design and the steel of which crushers parts are made-cast steel frame, Swing Jaw, Pitman Cap and Toggles, steel Shafts and Pitman rods and manganese steel Jaw Plates and Cheek Plates. FOOLPROOFNESS is provided by our patented and time-tested safety Device which prevents breakage due to packing or tramp iron. ECONOMY is assured by our well-known Bulldog Pitman and Toggle System, which saves power and wear by minimizing friction, the power that is used to deliver greater productivity. CONVENIENCE in transportation and erection in crowded or not easily accessible locations is planned for in advance by sectionalisation to meet any restrictive conditions.

Many of the worlds greatest mining companies have standardized upon the Traylor Type G Jaw Crusher. Most of them have reordered, some of them several times. What this crusher is doing for them in the way of earning extra dollars through increased production and lowered costs, it will do for you! Investigate it closely. The more closely you do, the better youll like it.