cone crusher drawings

nordberg mp series cone crushers - metso outotec

nordberg mp series cone crushers - metso outotec

The MP crushers' availability is further enhanced by the hydraulic clearing system. With a large vertical stroke, material can fall easily and this provides consistent stroke capabilities throughout the entire liners life.

Get the maximum potential out of your size reduction process to achieve improved crushing performance and lower cost per ton. By using our unique simulation software, our Chamber Optimization experts can design an optimized crushing chamber that matches the exact conditions under which you operate.

nordberg hp500 cone crusher - metso outotec

nordberg hp500 cone crusher - metso outotec

Nordberg HP500 cone crusher is one of the largest models in the worlds most popular cone crusher family, Nordberg HP Series. It is frequently utilized in aggregates production, quarrying applications, and mining operations in the second, third, or fourth step of size reduction process.

Nordberg HP500 cone crusher features a unique combination of crusher speed, throw, crushing forces and cavity design. This combination is renowned for providing higher capacity and superior end-product quality.

Increasing the stroke, the power and the retaining force while improving crusher body design and weight to withstand the force are principles of kinematics. A higher density in the crushing chamber improves the inter-particle crushing action, resulting in superior product shape, high reduction ratio and high capacity.

In a size-class comparison, Nordberg HP500 cone crusher has a higher output capacity, higher density in the crushing chamber and better reduction ratio, producing higher on-spec yield end products with the same energy consumption. It is equipped with the latest high-efficiency motors, making it an efficient and ecological crushing machine.

Nordberg HP500 cone crusher produces finer products by limiting crushing stages, which lowers your investment cost and saves energy. This is achieved through a combination of optimized speed, large throw, crushing chamber design and increased crushing force. The efficient crushing action of Nordberg HP500 cone crusher gives it the best power utilization per cone diameter.

Designed for your needs, Nordberg HP500 cone crusher is safe and easy to maintain. Fast and easy access to all the main components from the top and dual-acting hydraulic cylinders significantly reduce downtime.

Nordberg HP500 cone crusher is engineered to ensure maximum operator safety and easy maintenance. Accessibility from the top of the crusher to the principal components, easy access for liner maintenance, mechanical rotation of the bowl for removal with a simple press of a button, and no backing compound on liners make Nordberg HP500 cone crusher safe to maintain.

Nordberg HP500 cone crusher delivers less downtime and increased operator confidence. Dual-acting hydraulic tramp-release cylinders are used to let the crusher pass tramp iron and to provide a large clearing stroke if needed. The double accumulator combination provides better reactivity of the hydraulic system.

With Metso IC70C you can control maintenance, setting modifications, production follow-up and data extraction. All parameters can be adapted to your plant characteristics, and you can easily do all this close to the crusher or remotely from the control room.

You set the goals and Metso IC70C helps you reach them. It allows you to monitor the feeding, change the settings automatically depending on the load or liners wear, and select the product size distribution according to your preference of coarse or fine aggregate production.

cone crusher parts

cone crusher parts

The cast steel spider cap has been designed to serve as a feed distribution plate for coarse materials. It is recessed on the 22, 30, 36 and 48-in. crushers. For fine materials, the wobble plate feeder a more effective means of distributing the feed is recommended.

The annealed cast steel top shell and spider are made in one piece. The spider is of the three arm type, equipped with a self-aligning, Scor-Proof plastic ball and socket bearing in crusher sizes 22 to 48-in., and with an hourglass type bearing in sizes above 48-in. The lubricant is sealed in with a garter type oil seal. Bearings can be lubricated from outside the topshell on the 51, 60 and 84-in. crushers through oil holes in spider caps of the four smaller sizes.

The mainshaft is of high grade forged steel, annealed for stress relief. It is tapered to gauge for head center fit. The bottom of the shaft is fitted with a polished bronze step bearing. The journal for the spider bearing is formed by a sleeve shrunk on the shaft on the 51, 60 and 84-in. crushers. Short, heavy mainshaft design results in long life.

The step bearing consists of a bronze mainshaft step, a bronze piston wearing plate, and an alloy steel washer between the two. The washer is drilled for oil cooling and lubrication. Both the mainshaft step and the piston wearing plate are made of high lead bronze, selected to give the best bearing surface. The washer and plate are pinned in place, and the bearing surfaces are grooved to permit distribution of the lubricating oil.

The Mantalloy head mantle of this cone crusher is a replaceable wearing surface. It is made of alloyed manganese steel, and is held in place with a self-tightening head nut. On the 51-in. Hydrocone crushers and larger, the bottom portion of the mantle is ground to gauge to fit the head center, and the top portion is zinced. For crushers smaller than 51-in., the entire inner surface of the mantle is ground to gauge and no zincing is required.

The Mantalloy concave ring, or the stationary crushing surface, is available in three standard types, coarse, intermediate and fine. Helices, cast into the bottom of the concave ring, engage similar helices on the top of a cast steel concave support ring. The support ring is held by a key to the top shell to facilitate assembly, after which it is supported on the bottom shell. The helical surfaces make the concave ring self-tightening; no zincing is required.

The dust seal is a plastic ring suspended in a housing from the head center and encircling the dust collar. It is designed to accommodate the vertical adjustment and the gyrating and rotating motion of the head. All wearing parts are replaceable. The crusher is fitted with a connection for introducing low pressure air inside the seal for additional dust protection.

The eccentric is made of high carbon cast steel and fitted with a bronze inner wearing sleeve. The eccentric turns in a bronze bottom shell bushing. Both sleeve and bushing are replaceable. The eccentric throw can be changed in the field by installing a different sleeve.

The alloy steel pinion is mounted on a turned shaft. The cast steel pinionshaft housing is bolted to the machined opening in the bottom shell. It is equipped with anti-friction bearings sealed inside and out, and has separate pool lubrication in all sizes except the 36 and 48-inch machines. The 36 and 48-inch Hydrocone crushers have sleeve type counter-shaft bearings which are lubricated by the external oiling system.

The annealed cast steel bottom shell is of the three arm, open discharge type, bored to gauge for the top shell and eccentric bushing. It is bored and faced for the bottom plate, pinionshaft bearing and dust collar.

The external oil conditioning system furnished with Hydrocone crushers consists of a large oil storage tank on which are mounted a condenser type cooler, pressure type filter, motor, and a pump which pumps the lubricant to the crusher automatically. These units both cool and filter the oil. The accumulator and tank for the Automatic Reset are mounted separately from the oil storage tank.

All oil conditioning systems are equipped with oil flow and temperature safety switches which are adjusted to open the motor circuit and stop the crusher if the temperature becomes too high or if there is not a sufficient flow of oil. Flexible hose connects the lubricating unit to the crushers, greatly reducing the number of pipe fittings required and simplifying the installation.

Oil for the tank is pumped through the filter and cooler to the step bearing and up the inner eccentric bearing. It flows down the outer eccentric bearing, lubricates the gear and pinion, then returns to the tank. Tank capacities vary from 30 gallons for the 22-in. Hydrocone crusher to 240 gallons for the 84-in. machine.

23. Feed Plate 24. Screw 25. Torch Ring 26. Locking Bolt 27. Dust Shell 28. Clamp Ring 29. Adjustment Ring 30. Mainshaft Pin 31. Pin 32. Socket Liner 33. Socket 34. Eccentric 35. Eccentric Bushing 36. Counterweight 37. Counterweight Guard 38. Gear 39. Thrust Bearing 40. Countershaft Box 41. Countershaft Box Guard 42. Oil Finger Cover 43. Oil Finger 44. Countershaft Bushing 45. Countershaft 46. Pinion

CRUSHING CHAMBER may be any one of three standard types (Fine, Intermediate and Coarse) designed to assure a cubical, well-graded product. Shape of mantle and concave ring, and the range of adjustment available, results in maximum life and minimum scrap when replacing parts. Special crushing chambers also available.

BEVEL PINION AND GEAR are of the spiral design in the larger sizes provide greater tooth contact and smooth, trouble-free operation under most severe conditions. Bevel spur and pinion gears are used on smaller size Hydrocone crushers.

INNER CRUSHING CONE or mantle is one-piece Mantalloy casting held in place by a self-locking head nut. Complete contact of the ground inner surface with steel head center eliminates need for zincing in all but the larger sizes.

OUTER CRUSHING RING or concave ring is one-piece Mantalloy casting. Necessity of zincing or clamping concave ring in place is eliminated by ground-to-fit finish on outer surface and the use of an effective self-locking device.

3-PIECE STEP BEARING accommodates gyrating motion of main shaft and transmits crushing pressure to hydraulic piston. Designed to withstand bearing pressures much greater than those encountered in actual service.

While it is one of the major parts in the machine, there are few essential differences between the adjustment ring in the 10 ft. crusher and in the smaller machines, except as to size. Material of the ring which weighs 70,000 pounds is cast steel. Rigidity of the adjustment ring cross-section is essential. In this case, increased section thickness, with ordinary carbon steels, results in a reduction in deflection.

This part, which is screwed into the adjustment ring, is the means of setting of the machine. Adjustment is performed by rotating the bowl relative to the adjustment ring. In the 10 ft. machine provision has been made to adjust the setting during crushing. This increases the availability of the crusher substantially. Past practice had been to stop feed to the crusher during adjustment.

During crushing the position of the bowl and adjustment ring is maintained on the slant flank of the threads by means of the crushing force. The slant flank helps in centering the two elements. The clamp ring acts somewhat like a locking device to take up clearances. Ideally, the clamping cylinders do not have to have any greater capacity than is necessary to overcome the weight of the bowl. Practically, the clamp ring capacity is many times higher to withstand tramp passage.

To adjust the setting of the machine, hydraulic rams are used to rotate or counter-rotate the bowl in the adjustment ring. The seal between the adjustment cap and hopper is a simple, continuous, tightly fitting flap which allows free, relative rotation but prevents intrusion of dust into the thread area. The lower end of the thread connection between bowl and adjustment ring is also sealed. The hopper assembly, which is actually a part of the bowl assembly, including the hopper, hopper liner and cap closure, comprises the section in which the feed is introduced. It includes a dead bed, reducing wear and shock from the fall of the feed from the feeder above.

The adjustment rams are pressurized hydraulically and provide a setting adjustment. For normal adjustment of setting due to wear, installation and removal of the bowl is made through a swivel sheave and a cable turn applied around the adjustment cap. The bowl is then rotated by use of the maintenance crane.

The crushing head, similar in section to that of the 7 ft. machine, had three-dimensional photoelastic studies made using the technique of freezing stresses into a loaded plastic model, sectioning the model and examining the slices under polarized light. As a result of these techniques, stresses have been reduced. The core of the head consists of six massive ribs to support the crushing forces on the surface of the head. The head is cast steel.

The main shaft is of turbine rotor steel of high quality and refinement, the chemistry of which is low carbon to reduce the possibility of heat checking. It includes chrome nickel additions for deep hardening, notch toughness and resistance to fatigue. The shaft extension is provided to reduce the relative strain between the head and shaft and thereby reduce fretting in the fit, which has a heavy press. The shaft diameter is 50 percent greater than the 7 ft. crusher shaft. As a result, the shaft operates at lower values of bending stress and deflection. Reduced deflection produces distinct benefits in bearing behavior because of uniformity of oil film under load. Reduced stresses assure longer life and resistance to overloads.

The head-shaft assembly is supported by the socket and socket liner which is, in essence, a spherical thrust bearing. The function is to carry the vertical component of the crushing force while allowing the head to oscillate around the theoretical center of rotation.

The socket of carbon steel is of dowelled design. The forces between the head and the socket are normal to the spherical surface of the head and pass through the theoretical center. The line of action of these forces is such that practically pure compression is applied to the socket and liner, reducing deflection and stress to a minimum and promoting good bearing performance.

The force distribution throughout the crusher is based on a vector diagram of the cavity forces during crushing and the reactions at various associated loading points in the crusher. The vector diagram establishes their relative magnitude, direction and points of application. The actual magnitude of these forces is established by the crushing force necessary to lift the adjustment ring off the frame seat. This condition represents the maximum allowable force for normal crushing.

A baffle ring attached to the head is sub-merged around its entire periphery in a water trough resting on the socket. Dust tends to settle into the trough and must be continuously removed to prevent caking. For this reason, water is continuously fed through specially designed nozzles which scour the trough. Overflow water is carried off by internal piping and passages. The seal chamber is vented to atmosphere to prevent siphoning which may cause oil contamination of the water or vice versa.

The gears are straight tooth bevel gears and are designed to AGMA standards using a computerized program which, upon input of the basic information, such as DP, diameters, gear ratio, material properties, tooth type, provides a complete printout of the rated power on the basis of tooth strength and surface durability of the gear. The factor of safety on the gear is in excess of three on the strength basis and in excess of two on the durability basis.

symons cone crusher

symons cone crusher

For finer crushing or reduction a Symonscone crusher the norm. Symons are commonly used for secondary, tertiary or quaternary crushing. They do this by a different chamber design which is flatter and by operating at about twice the rotational speed of a primary type gyratory crusher.

One of the first cone crushers had a direct drive vertical motor mounted above the spider with the drive shaft passing through the hollow bored main shaft. With relatively high speeds of 480 to 580 rpm and small eccentric throw, the machine produced a uniform produce with minimum fines.There are numerous Symonscone crusher manufacturers of modern crushers each promoting some unique aspect.

The Allis Chalmers Hydrocone selling point is its adjustability and tramp protection through a hydraulic support system for the headcentre. By merely adjusting the oil reservoir below the head centre the crusher setting can be changed while in full operation. Tramp metal causes a surge of pressure in this hydraulic system which is absorbed through relief valves and gas-bladder-filled accumulator bottles which allow the headcentre to momentarily drop and return to its normal operating position when the tramp has fallen through.

The Symons or Rexnord spring cone crusher is adjusted by spinning the bowl up or down manually or through hydraulic rams. A series of powerful springs give the necessary tramp protection. Several other manufacturers produce similar types and sizes of crushers but all follow the basic types described.

When the Symons brothers Invented the cone crusher, they employed the principle wherein the length of the crushing stroke was related to the free fall of material by gravity. This permitted the material being crushed to fall vertically in the crushing chamber; and in effect, caused the particles to be crushed in a series of steps or stages as the particles got smaller due to the crushing action. This also helps to reduce the rate of wear of the liners since the sliding motion of the particles is minimized.

Recognizing that the Symons principle of crushing is the most efficient means of ore and aggregate reduction in hard rock applications, the engineers used this same principle in the design on the hydrocone.

Versatility in the form of having the ability to perform in a wide range of applications without the need for a change in major assemblies was another objective in the design. Ease of maintenance and remote setting capability also were part of the design parameters the market requires.

There is no startling revelation to the fact that the mining industry as a whole is generally moving toward the use of larger equipment to process ores in quantities far greater than what was even considered a decade ago. Trucks and shovels have led the way in extra large machines and many other manufacturers have followed suit in the development of so-called supers in their line of equipment.

In order to keep pace with the industry, crusher manufacturers have also enlarged the size of their equipment. There is now on the market, a Gyratory crusher capable of accepting a 72 diameter piece of ore. Primary jaw crushers have also increased in size. It is inevitable, therefore, that larger secondary cone crushers would also be required to complement the other equipment used to process these large quantities of ore. This super-size secondary cone crusher is the SYMONS 10 Ft. Cone Crusher.

Until 1973, the largest cone crusher built was the 7 Ft. Extra Heavy Duty crusher, which is currently used in the majority of the mining operations throughout the world. The 10 Ft. crusher, when compared to the 7 Ft. Extra Heavy Duty Crusher, is approximately 1 times larger in physical dimensions; three times heavier; will accept a maximum feed size which is approximately twice as large; and will crush at approximately 2 times the rate of the 7 Ft. machine at identical closed side settings. It will be the largest cone crusher built in the world.

The conclusions of this investigation were all positive the crusher could be built and at a cost that would be in line with its size and capacity and also with other size crushers. After that preliminary study, the project became dormant for several years.

The project was reactivated and this time general assembly drawings were made which incorporated many improvements in the crusher such as pneumatic cylinders in place of the conventional, springs for tramp iron release, a two-piece main frame a dynamically balanced design of the internal moving parts of the crusher, and an automatic clearing and adjusting mechanism for the crusher. At this stage of development we felt we were ready to build a 10 Ft. crusher for any mine that was willing to try one. Unfortunately, the conservative posture of the mining industry did not exactly coincide with our sales plans. This, added to the popularity of the autogenous mill concept at the time, led to another lull in the 10 Ft. development program.

The project was reactivated again in 1970, this time primarily at the request of one of the large Minnesota Iron Range mining companies. We then undertook a comprehensive market research study to determine if there was a need for this size crusher by the mining industry in general, rather than just the iron ore industry. We talked not only to the iron ore people but to the copper people and persons connected with the other metallic ores as well. The acceptability of this large crusher was also discussed with the aggregate industry. After interviews with many of the major mining companies, the decision was made to complete the entire engineering phase of the development program and to actively solicit a customer for this new crusher. We spent approximately $85,000 on engineering work and tests on the gamble that we could find a customer. I speak of a gamble because during our market research study we continually were told my company would be very interested in buying a 10 Ft. crusher, but only after we have seen one in operation.

The actual building and test of the first prototype unit without a firm commitment for a sale was an economic impossibility. We were now at the point where we needed to sell at least one unit in order to prove not only the mechanical reliability of the machine, but the economic justification for its purchase as well. Needless to say, when the order for two SYMONS 10 Ft. cone crushers was received, we felt we were now on the way toward completion of the development program.

Perhaps at this point it might be apropos to examine the crusher itself. It will stand 15-6 above its foundation, the overall height will be 19-4-. At its greatest diameter, in the area of the adjustment ring, it will be approximately 17-6. It will weigh approximately 550,000 lbs. Under normal crushing conditions, the crusher will be connected to a 700 HP motor. A 50 ton. overhead crane is required to perform routine maintenance on this crusher.

The main shaft assembly will weigh approximately 92,000 lbs. and the bowl assembly approximately 95,000 lbs. The mantle and bowl liner, cast from manganese steel, will weigh approximately 13,000 lbs. and 25,000 lbs. respectively.

The throughput capacity of the Standard will be approximately 1300 TPH at a 1 closed side setting and 3000 TPH at a 2- closed side setting. The throughput capacity of the SHORT HEAD will be approximately 800 TPH at closed side setting and 1450 TPH at a 9/16 closed side setting.

Persons familiar with the design of a conventional 7 Ft. SYMONS cone crusher will recognize that the design of the 10 Ft. is quite similar to it. As a matter of fact, we like to say that the design of the 10 Ft. is evolutionary rather than revolutionary, because all the reliable features of the SYMONS cone crusher were retained and the only changes that were made were those that added to the convenience of the operator, such as automatic clearing and automatic adjustment. From a mechanical point of view the stresses generated due to crushing loads are less in the 10 Ft. crusher than in the existing 7 Ft. Extra Heavy Duty cone.

One of our senior engineers who has long since retired told me that he had the occasion many years ago to make a presentation of a newly designed crusher to a prospective customer. He carefully prepared a rather detailed description of the crusher which included all the features that his new machine had when compared to the customers existing machine. The presentation itself took about one hour and after that period the customer leaned back in his chair and said, Thats all well and good, but will it crush rock? In effect, the customer was; saying that all the features in the world were of no use to him if the crusher did not perform its basic function to crush rock and ultimately make profits for the owner. Using todays financial terminology he was asking the engineer to economically cost justify the purchase of the crusher.

The working day of the contemporary manager or project engineer evolves around making decisions to economically justify a piece of equipment or a new operation. In our development program of the 10 Ft. cone crusher, we felt that the economic justification, from the customers point of view, was just as important to develop as the engineering aspects of the program. So we developed a three-part program to examine the economics of installing a 10 Ft. crusher. First we talked in wide generalities concerning the use of a 10 Ft. crusher. Secondly, we discussed the ramifications of using a 10 Ft. crusher versus 7 Ft. crushers in a completely new plant being considered for the future. Thirdly, we examined how a 10 Ft. crusher could be used to its best advantage in a plant that is being expanded.

The first consideration was the economic generalities of installing the crusher, or more specifically, what questions regarding the installation are pertinent to every crushing plant. Usually, the initial comparison which is made between a 7 Ft. crusher and a 10 Ft. crusher is that of price versus capacity. Theoretically, the capacity of a 10 Ft. crusher is 2 times that of a 7 Ft. while the selling price is approximately 3 times that of the 7 Ft. On that basis alone, it would appear that the 10 Ft. could not be justified. However, this is an incomplete picture. Recent cost estimates show that considerable savings are realized when the entire physical plant structure is considered. Because fewer machines are required to crush an equivalent amount of ore, the size of the buildings can be reduced, thereby decreasing the capital investment of buildings and allied equipment used as auxiliaries for the crusher.

Total manpower requirements to operate and maintain the plant is another of the generalities which were considered. Fewer crushers normally require less personnel to operate and perform maintenance, Manpower requirements obviously play a large part in the profitability of a plant. Therefore, it follows that using a 10 Ft. in place of multiple 7 Ft. units should be more profitable from the standpoint of manpower. We should, however, clarify one point regarding normal maintenance of the 10 Ft. crusher which is commonly misunderstood; namely, the periodic changeout of manganese liners in the crusher. The normal time period between manganese changes would not be significantly different between the 7 Ft. and a 10 Ft. because the wear rate, that is, the pounds of liner worn away per ton of ore crushed, will remain the same. Consequently, if a set of liners in a 7 Ft. crusher, lasted six weeks, a 10 Ft. crusher in the same operation would also last approximately six weeks. However, since the total amount of ore crushed will be greater, the maintenance costs per liner changeout will be less on the 10 Ft. crusher.

Another point for consideration is that the 10 Ft., cone crusher is a secondary crusher and normally would be fed with the product of a gyratory crusher. Since the 10 Ft. can accept a larger feed than a 7 Ft. crusher, it is possible to increase the open side setting of a gyratory crusher, thereby, allowing a greater volume of feed to pass through the crusher. Because of this, it is conceivable that a smaller primary crusher could be used in order to obtain a given quantity of ore.

A good salesman could expound on a multitude of ideas for using 10 Ft. crushers in place of 7 Ft. crushers in a new plant, but in the final analysis, the deciding factor as to whether or not the 10 Ft. crushers should be used will be the anticipated over-all plant capacity. Several studies have indicated that as a general rule of thumb the break even point for using 10 Ft. crushers in place of 7 Ft. crushers is a plant which will have an overall ore treatment capacity of approximately 40,000 TPD or approximately 8,000,000 TPY. Anything less than that figure should indicate the use of conventional 7 Ft. crushers. Obviously a small four stage crushing plant in which the third stage crusher was a 7 Ft. Standard and the fourth stage consisted of two 7 Ft. SHORT HEAD cone crushers, would not improve economically by the use of one 10 Ft. Standard cone crusher and one 10 Ft. SHORT HEAD cone crusher in place of the 7 Ft. crushers.

A study was made which considered a plant to be built using three different approaches of a conventional crushing-grinding operation. The plant which was being considered would be crushing taconite similar to that found in the Iron Range. The end product of the crushing was 5/8 rod mill feed and in this example the plant capacity was to be approximately 13.5 million TPY of ore processed to eventually produce approximately 4 million TPY of iron ore pellets. The study arbitrarily chose a four-year period of operation so that operating costs would be included and also because a four-year period is the usual comparison basis for calculating return on investment. In this example the primary crusher as well as the fine crushing plant would be operated fourteen shifts per week.

In our economic analysis of the 10 Ft. crusher development program, we also studied how this crusher could be used to best advantage when planning expansion of an existing plant. Before delving into the actual dollars and cents of several variations of expansion plans, several preliminary questions must be answered in the affirmative:

Since each plant is unique, the relative merits of the 10 Ft. crusher must be examined on an individual plant basis. Again, as a general rule of thumb, it has been found that the most benefit can be achieved in those plants which presently contain a four-stage crushing plant in which the first two stages of crushing are gyratory crushers. Studies have shown that converting the second stage gyratory crusher to a 10 Ft. Standard crusher shows most potential because the major auxiliaries required for the crusher, such as crane, conveyors, etc., are already large enough to accommodate the increased capacity of the 10 Ft.

As one possible solution, we suggested that the two 30 x 70 secondary gyratory crushers be replaced by two 10 Ft. Standard cones. These crushers could then send approximately 3600 TPH of minus 3 material to the fine crushing plant. The two existing 7 Ft. Standard crushers could be converted easily to SHORT HEAD crushers and two new 7 Ft. SHORT HEAD crushers added to the existing vacant foundations.

In Summary, we feel that the Symons cone crusher has a very definite place in the future of the mining industry and we intend to move steadily ahead with its progress. However, we have learned a few lessons along the way.

Initially, the development of these super size machines is an extremely expensive proposition. We know that if our company alone, attempted to completely design, manufacture, erect, and test a machine in this size range, it would severely tax our financial resources.

We found that super size equipment also presents some problems for our manufacturing facilities. The manufacture of one of these units puts a large dent into the production schedule of many of the smaller conventional units. In our enthusiasm to build a bigger newer machine, we continually remind ourselves that the smaller conventional units are still our bread and butter units.

On the positive side, we found that our reputation as a crusher manufacturer was enhanced because of what our customers refer to as progressive thinking. We listened to the suggestions of the mining industry in attempting to give them what they wanted.

Perhaps you will allow me to close with a bit of philosophizing from a manufacturers point of view. The 10 Ft. crusher is here ready to go into operation. Where do we go from here? A 15 Ft. cone crusher? A 20 Ft. cone crusher? Who knows? We do know that we have reached the financial limit of a development program on a machine of this size. We also know that as the size of a machine grows larger, the developmental and manufacturing risks grow larger along with it and any allowable margin for error must be minimized. We, like you, are in business to make a profit. Since larger crushers usually mean a fewer number of crushers, we must examine the profit picture from aspects of the sale. I think I speak for other manufacturers as well when I say that bigness in machines reflects bigness in development costs as well. If the mining industry wants still larger equipment in the future, the industry should prepare itself to contribute to the development program of those machines.

A multi-cylinderHydraulic Cone Crusher, theHydrocone Cone Crushercan be used in either the second or third stage of crushing by merely changing liners and adaptors.It can produce the full product range that the combination of a comparable sized Standard and Short Head can produce. It makes the machine much more versatile. It allows for much more standardization. The value of this feature is one where spare parts investment in the form of major assemblies is minimized.

All operator controls are conveniently mounted on a remote control console to eliminate the need for an operator to approach the crusher during operation.Over a period of years we have developed a unique engineering knowledge about the effects of cone crusher design parameters such as speed, throw and cavity design on crusher productivity.

Each Hydrocone Cone Crusher features dual function hydraulic cylinders that provide overload protection and a safe and fast way to clear a jammed cavity. Should the crusher become plugged, the operator merely pushes levers on the remote control console to clear the cavity.

It can produce the full product range that the combination of a comparable sized Standard and Short Head can produce. It makes the machine much more versatile. It allows for much more standardization. The value of this feature is one where spare parts investment in the form of major assemblies is minimized.

All operator controls are conveniently mounted on a remote control console to eliminate the need for an operator to approach the crusher during operation.Over a period of years we have developed a unique engineering knowledge about the effects of cone crusher design parameters such as speed, throw and cavity design on crusher productivity.

Each Hydrocone Cone Crusher features dual function hydraulic cylinders that provide overload protection and a safe and fast way to clear a jammed cavity. Should the crusher become plugged, the operator merely pushes levers on the remote control console to clear the cavity.

TheHydraulic Cone Crusheruses hydraulic tramp release cylinders and accumulators to hold the adjustment ring against the main frame seat. There is only one angular surface between the main frame and the adjustment ring which also has a radial contact point in the lowermost area. When a piece of tramp goes through the crusher, the oil is forced into the accumulators allowing the adjustment ring to raise and pass the tramp.

The tramp release cylinders are secured to the adjustment ring and the lower portion of the main frame through clevises. This allows the crushing forces to be transferred directly from the frame arm locations to the adjustment ring. This relieves the main frame shell and upper flange from carrying heavy loads.

The Hydraulic Cone Crusher is equipped with hydraulic clearing. The tramp release cylinders which hold the adjustment ring in place are double acting cylinders. These cylinders can be pressurized in the opposite direction, after the clamping pressure has been released, to raise the adjustment ring and bowl assembly for clearing; only the weight of the adjustment ring, clamp ring, and bowl assembly, plus any residual material in the bowl hopper raises.

maximize your cone crusher productivity : pit & quarry

maximize your cone crusher productivity : pit & quarry

Cost-effective aggregate production begins with employees who are knowledgeable about the maintenance requirements and operational parameters of the cone crushers they operate. There are certain proven methods and practices industry experts use to ensure a smooth crushing operation. This article presents key tips that will help you maximize your cone crushing operation.

1. Operate at a consistent closed-side discharge setting. Producing a consistent product quantity, quality, uniformity and attaining a balanced circuit begins with operating the cone crusher at a consistent closed-side discharge setting. If a crusher is allowed to operate at a wider-than-optimum setting for even a short period of time, the result will be less product and an increase in oversized material.

Keep in mind that oversized product almost always creates circuit flow problems within the aggregate plant. An example of the effect that crusher setting has on the product gradation is as follows: If the target crusher setting is 3/8 in. (10 mm) but the setting is not checked and it wears open to 1/2 in. (13 mm), then the end result is a 15 percent decrease in the minus 3/8-in. (10 mm) material size. This is a substantial decrease in productivity.

Most aggregate producers would be amazed at the revenue lost each year due to the simple fact that crushers are not being operated at consistent closed-side settings. The crusher setting should be checked on a per-shift basis.

2. Operate at a consistent choke-fed cavity level. If a crusher operates at varying cavity levels throughout the shift, the result will be an inconsistent product shape and inconsistent production rate. Operating a cone crusher at a low cavity level (half cavity) will result in a significantly coarser product gradation, and this low cavity level will also produce more flat and elongated product particles.

Efforts should be made to operate the crusher at a proper choke-fed cavity level, as the favorable end result will be increased crusher throughput tonnage and a more cubical-shaped product. This tip is particularly important for the tertiary (short head) crushers in the circuit, as they produce the vast majority of an aggregate operations salable products.

3. Do not trickle feed the crusher. Trickle feeding a cone crusher should be avoided because it not only results in poor productivity and poor product shape, but it can also adversely affect bearing alignment within said crusher. Due to the operational characteristics of a cone crusher, when crushing, it should never be operated below 40 percent rated horsepower. To obtain a proper loaded bearing alignment and to maximize productivity, the crusher should be operated above 40 percent rated horsepower yet below 100 percent rated horsepower of the drive motor.

A power draw of 75 to 95 percent is a great target range to stay within while crushing. Excessive power peaks, particularly above 110 percent rated horsepower, should be avoided as this could lead to premature crusher failure.

4. Ensure the feed is evenly distributed. The incoming feed material should be directed on a vertical plane into the center of the crusher. When the incoming feed is not directed into the center of the cone, one side of the crushing cavity could be quite full while the opposite side of the cavity could be low or empty. This will always result in a low crusher throughput tonnage, the production of more flat and elongated product particles and oversized product.

This typically prompts crusher operators to tighten the crusher setting in order to get the crusher to make the smaller product size that they are trying to produce. This in turn can result in an overload condition in the form of adjustment ring movement on the side of the crusher that is heavily loaded. Over the long term, this can cause the adjustment ring to become tilted on the main frame, resulting in an even larger loss of productivity.

5. Ensure the feed is not segregated. All incoming feed material should be well mixed and homogeneous. A segregated feed condition exists when large stones are directed to one side of the crushing cavity and small stones are directed to the opposite side.

The side of the crusher receiving the small stones will have a higher-than-normal bulk density, and this can lead to something known as packing or pancaking. This in turn leads to adjustment ring movement on the side of the crusher receiving the smaller feed stones. Adjustment ring movement forces the operator to open the crusher setting to avoid this overload condition. This results in the production of oversized product due to the increase in crusher setting. In addition, segregated feeding and the resultant adjustment ring movement can lead to a tilted adjustment ring, resulting in larger loss of productivity.

6. Minimize surge loading for a more efficient circuit. Surge loading of any crusher is a production enemy. Surge piles or feed hoppers, along with variable-speed feeding devices, can be used to provide a better and more consistent feed control to the crusher. This allows the operator to run the crusher at a very consistent cavity level for extended periods of time. Providing better crusher feed control for the cone crusher through the use of surge piles, hoppers and variable-speed feeding devices such as belt conveyors or vibrating pan feeders can easily increase crusher productivity by a minimum of 10 percent.

Regarding the volume limit, each crushing cavity has a volumetric limit that determines maximum throughput, and a choke-fed crusher is operating at its volumetric limit. The volume limit is exceeded when feed material overflows the top of the crusher. As for the horsepower limit, each crusher has been designed to operate at maximum power draw, and power draw will increase as the feed rate increases and as the feed material is crushed finer. The horsepower limit is exceeded when the crusher draws more power than it is rated for.

Lastly, dont forget about the crushing force limit of the crusher. As with the horsepower limit, crushing forces being applied between the mantle and bowl liner increase as the feed rate increases, and as the feed material is crushed finer. The crushing force limit of the crusher is exceeded when the adjustment ring bounces, wiggles or moves on top of the main frame.

An ideal operational condition exists when the crusher is operating at its volumetric limit while still being slightly below both the horsepower limit and crushing force limit. Operating any crusher outside of its designed parameters with either excessive power draw or excessive crushing force results in a very serious crusher overload. These overloads create something known as fatigue damage, which is permanent, irreversible and cumulative. Without a doubt, frequent overloads will shorten the life cycle of any cone crusher.

8. Operate within the crusher design limitations. If you find the crusher operating in a crushing force overload condition (ring movement) or a power overload condition (excessive amperage), open the crusher setting slightly, but try to stay choke fed. The advantage of staying choke fed is the fact that there will still be rock-on-rock crushing and grinding taking place in the crushing cavity. This helps to maintain good cubical product even though the setting is slightly larger than optimum.

The other option, of course, is to decrease the feed rate to the crusher. But the downside is that product shape tends to suffer. Typical reasons for adjustment ring movement or excessive power draw are tramp events, poor feed distribution, segregation of the feed, too many fines in the feed, high-moisture content, wrong mantle and bowl liner being used or simply trying to operate at an unrealistically small closed-side setting.

9. Monitor and maintain a proper crusher speed. If proper drive belt tension is not maintained, the belts will slip and the crusher will slow down. A slowing crusher will cause incredibly high power peaks at a very low crusher throughput tonnage. Improper or neglected drive maintenance will result in a high-horsepower consumption at a low crusher throughput tonnage, and this inefficient use of connected horsepower will result in a higher-than-normal energy cost per ton of material crushed.

A speed sensor can be used to monitor the crusher countershaft speed, which will send a warning signal of a slowing crusher to the programmable logic controller, or it could be wired to simply turn on a warning lamp. When a warning is detected, the maintenance department can be dispatched to re-tighten the drive belts. When a speed sensor is used, drive belt life is extended and proper production levels can be maintained.

10. Determine the percentage of fines in the feed. Fines in the crusher feed is defined as material entering the top of the crusher, which is already equal to or smaller than the crushers closed-side discharge setting. As a rule of thumb, the maximum number of fines in the crusher feed should not exceed 25 percent for secondary crushers or 10 percent for tertiary crushers.

When there is an excessive quantity of fines in the feed, it is typically the result of a vibrating screen problem. This problem could be due to the fact that the screen is insufficient in size, or a screen that is sufficient in size yet is inefficient in operation. Re-crushing and re-handling product size material due to an insufficiently sized screen, inefficiencies due to the way the screen is set up or due to improper vibrating screen maintenance will lead to an excessive quantity of fines in the crusher feed. This will lead to inefficient use of connected crusher horsepower and a higher energy cost per ton of material crushed.

11. Limit the height from which the feed material drops. The maximum distance from which the feed material should fall from into the top of a small to mid-size cone crusher is 3 ft. When the feed material drops from a much greater distance, the stones tend to slam into the V-shaped crushing cavity with such velocity that it subjects the crusher to shock loads and extremely high stress levels. This situation is referred to as high-velocity wedging, and it can result in power overloads or force overloads or both. This action puts undue stress and strain on the crusher components, and it results in increased maintenance repair costs and poor productivity.

hidrocone crushers 4800 cone crusher sandvik complete engineering drawings|autodesk online gallery

hidrocone crushers 4800 cone crusher sandvik complete engineering drawings|autodesk online gallery

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cone crushers | mclanahan

cone crushers | mclanahan

A Cone Crusher is a compression type of machine that reduces material by squeezing or compressing the feed material between a moving piece of steel and a stationary piece of steel. Final sizing and reduction is determined by the closed side setting or the gap between the two crushing members at the lowest point. As the wedge or eccentric rotates to cause the compression within the chamber, the material gets smaller as it moves down through the wear liner as the opening in the cavity gets tighter. The crushed material is discharged at the bottom of the machine after they pass through the cavity.

A Cone Crusher will deliver a 4:1 to 6:1 reduction ratio. As we set the closed side setting tighter to create a finer output, we also reduce the volume or throughput capacity of the machine. Generally speaking, multiplying the closed side setting by two is a good guide to the top size of the gradation exiting the machine.

The technology that makes a MSP Cone Crusher outperform competitive cones on the market is the combination of all of the factors of performance i.e. balanced eccentric, higher speeds, fulcrum point position, and stroke. By using sound engineering with years of field testing a truly tried and tested new Cone Crusher has emerged.

A balanced eccentric coupled with a fulcrum point ideally placed over the crushing chamber yields highly effective compression crushing. This allows higher eccentric speeds to maximize performance without disruptive forces. The eccentric stroke is designed to work with the eccentric speed and fulcrum position to produce higher yields and minimize recirculating loads. The torque and resultant crushing forces are as effective as virtually any Cone Crusher on the market.

Spiral bevel gears provide the turning force to the eccentric. The spiral gear is mounted on a sturdy countershaft of the Cone Crusher, which rides in bronze bushings. The gears are precision cut for quiet operation. Misalignment problems are eliminated.

The MSP Cone Crusher features one of the largest volume displacements by a crusher head. When there is a large volume of material displaced this way, it means that more material is crushed in each cycle, more material can be fed to fill the larger void left when the crushing head recedes, and more material flows through the crusher due to the larger throughput and gyrating cycles allowing material to drop further. The benefits of high efficiency, greater crushing force and high capacity coupled with the durability the market expects are the reasons why this design is the best way to increase your productivity and profitability.

Sleeve bearings make removal and installation of the MSP Cone Crusher head and main shaft simple. The tapered main shaft fits into a large opening at the upper end of the tapered eccentric bushing. The shaft does not require precise alignment. It can be inserted from a vertical position and will self-align.

With the MSP Cone Crushers automatic hydraulic overload relief system, the crusher immediately opens in the event of an overload. This action reduces the crushing pressure, allowing the obstruction to pass through the chamber. After the chamber has been cleared, the hydraulic control system automatically returns the crusher to its original setting. Shock loads on the crusher are reduced for longer component life.

MSP Cone Crushers are built to make your operations run more smoothly and easily. Its simple and easy to read control panel provides you with the necessary information to properly run your crusher. For example, the MSP Cone Crusher shows you the exact cone setting to allow the operator to stay on top of a critical set point.

To enhance your Cone Crusher's life and maintain optimal crushing capacities, an automatic liner change reminder is included for your convenience. When the new mantle and liners are installed, the automated reminder is reset. As the crusher operates, the system will track production capacities and calculate the liner wear rate. When the cone liners reach the maximum wear point, it sends a flashing reminder to 'change cone' on the cone setting meter. After the wear parts are changed, simply reset the automated reminder system and continue efficient, reliable crushing.

The MSP Cone Crushers are built heavier than most competitive Cone Crushers. The extra weight means lower stress on the machine, which results in longer operational life. There is no question that the proper use of mass makes for more durable crushers. Additionally, a broad array of manganese liners is offered for each size MSP Cone. A unique and patented feature allows the Liners to fit without the use of any backing material. Improved Chamber matching with crusher feeds virtually eliminates any trial and error.

All these factors combine to give producers more effective compression crushing. This reduces liner wear, which reduces wear cost and allows higher yields, resulting in decreased overall cost per ton of finished product.

In the Symons principle, which is utilized by the MSP Cone Crusher, each cycle is timed so that the feed material and the upward thrust of the crushing head meet at the moment of maximum impact. The optimum speed of gyration and the large eccentric throw produce two important results: 1) the rapidly closing head catches the falling feed material and delivers the extremely high crushing force and 2) on the other side of the chamber the rapidly receding head allows material to fall freely to the next point of impact or exit the chamber. The combination of superior crushing force and free flow of material in the MSP Cone Crusher results in production levels that are unsurpassed and means lower power consumption per ton.

Ten years of testing went into the final combination of speed, stroke, and head angle to deliver the most efficient use of power. Greater efficiency delivers lower power consumption, reduced cost per ton, less maintenance and higher profits.

The power input imparted by the driven eccentric results in a bearing force in opposition to the crushing force at a point on the lower portion of the main shaft. The bearing force as it is transmitted to the main shaft provides the required moment to crush the rock. The distance between the bearing force and the fulcrum point is called the force arm. The longer the force arm, the greater the momentum, which produces a greater crushing force.

Crushing loads are distributed over a large spherical bearing. The socket liner keeps full contact with the crushing head ball and carries all of the vertical component and part of the horizontal. The long force arm, represented by the main shaft, reduces the load transmitted through the eccentric bushing.

Capacities and product gradations produced by Cone Crushers are affected by the method of feeding, characteristics of the material fed, speed of the machine, power applied, and other factors. Hardness, compressive strength, mineral content, grain structure, plasticity, size and shape of feed particles, moisture content, and other characteristics of the material also affect production capacities and gradations. Gradations and capacities are most often based on a typical, well-graded choke feed to the crusher. Well-graded feed is considered to be 90% to 100% passing the closed side feed opening, 40% to 60% passing the midpoint of the crushing chamber on the closed side (average of the closed side feed opening and closed side setting), and 0 to 10% passing the closed side setting. Choke feed is considered to be material located 360 degrees around the crushing head and approximately 6 above the mantle nut. Maximum feed size is the average of the open side feed opening and closed side feed opening.

Minimum closed side setting may vary depending on crushing conditions, the compressive strength of the material being crushed, and stage of reduction. The actual minimum closed side setting is that setting just before the bowl assembly lifts minutely against the factory recommended pressurized hydraulicrelief system.

Overall, industry acceptance of the Symons principle and performance, the McLanahan Cone Crusher works to deliver lower recirculating loads at higher tonnage rates with lower maintenance costs by combining:

A general rule of thumb for applying Cone Crushers is the reduction ratio. A crusher with coarse style liners would typically have a 6:1 reduction ratio. Thus, with a 34 closed side setting, the maximum feed would be 6 x 34 or 4.5 inches. Reduction ratios of 8:1 may be possible in certain coarse crushing applications. Fine liner configurations typically have reduction ratios of 4:1 to 6:1.

The difference between the volume displaced by the crushing head when it is fully closed and fully open is called the displacement volume. A large displacement volume results in greater capacity because:

In order to maintain the maximum levels of capacity, gradation, and cubical product, a Cone Crusher must be choke-fed at all times. The best way to keep a choke-feed to the ConeCrusher 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.

There are a number of different criteria to consider when selecting the right chambers for your crushing needs. However, the one that must always be considered isthat you have a well-graded feed to the chamber. A well-graded feed is generally thought to be 90 to 100% passing the closed-side feed opening, 40 to 60% passing the midpoint, and 0 to 10% passing the closed-side setting.

One thing you should never do is place a new concave liner in a crusher with a worn mantleor place a new mantle in a crusher with a concave liner. Why? If you have properly selected the replacement component, you will change the complete profile of the Cone Crusher by mating new and worn components. The receiving opening will tend to close down, restricting the feed from entering the chamber and causing a reduction in tons per hour.

If the liner is wearing evenly throughout the chamber, you should consider changing out the manganese when it has worn down to about 1" (2.5 cm) thick at the bottom. At about 3/4" to 5/8" (1.9 to 1.6 cm) 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 should happen, continued operation could destroy the seat on the support bowl or the head of the Cone Crusher.

McLanahan Symons Principle (MSP) Cone Crushers utilize a combination of improved factors of performance, which are enhanced by the Symons Principle of crushing, as well as the latest hydraulic features and electrical features that create a modern, efficient, reliable and durable Cone Crusher that ultimately leads to a faster ROI. MSP Cone Crushers are designed to make your operation run more smoothly and easily, as well as ensuring lower operating costs and minimal downtime so that MSP Cone Crushers are more frequently fully operational and processing optimal amounts of material.

Efficiency can be defined by the ratio of the work done by a machine to the energy supplied to it. To apply what this means to your crusher, in your reduction process you are producing exactly the sizes your market is demanding. In the past, quarries produced a range of single-size aggregate products up to 40 mm in size. However, the trend for highly specified aggregate has meant that products have become increasingly finer. Currently, many quarries do not produce significant quantities of aggregate coarser than 20 mm; it is not unusual for material coarser than 10 mm to be stockpiled for further crushing.

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