Impact Crusher

The impact crusher is also called impact crusher. It is mainly used in metallurgy, chemical industry, building materials, hydropower and other materials that often need to be relocated, especially for the operation of fluid stones in highways, railways, hydropower projects, etc. Different types, scales and requirements of finished materials adopt multiple configurations.

Main Purpose:

The impact crusher can process materials with a side length of less than 100-500 mm, with a pressure resistance of up to 350 MPa, with a large crushing ratio, and the crushed materials are cubic particles. Widely used in construction materials, ore crushing, railways, highways, energy, transportation, energy, cement, mining, chemical and other industries for medium and fine crushed materials. The discharge particle size can be adjusted, and the crushing specifications are diverse.

The impact crusher is named according to the working principle, that is, the principle of impact crushing is used to crush the material. It is a finer crusher device than the jaw crusher. It is mainly used for fine crushing operations in the stone production line The crusher cooperates to crush. The impact crusher has the following five advantages in the crushing process.

1. The impact crusher is more effective in processing materials with a large amount of moisture and effectively prevents the materials from being blocked.
   When the moisture content of the processed material is too large, the feed chute and impact plate of the impact crusher can be equipped with heating devices to prevent the material from sticking. The impact crusher does not need to be equipped with a bottom sieve plate to effectively prevent clogging.
2. The material hardness of the impact crusher is more extensive.
   The hammer of the impact crusher is firmly fixed to the rotor with a mechanical clamping structure, and has a large rotational inertia when rotating with the rotor. Compared with the hammer crusher (the hammer head is overhanging), the rotor of the impact crusher has greater momentum, suitable for crushing harder materials, and their energy consumption is lower.
3. It can conveniently and flexibly adjust the granularity of the discharge, with a wide adjustment range.
   The impact crusher can adjust the output particle size in various ways, such as adjusting the rotor speed, adjusting the gap between the impact plate and the grinding chamber, etc. The clearance adjustment can be adjusted by mechanical or hydraulic type. The hydraulic adjustment system can easily adjust the clearance through the local operation button or the travel control system.
4. the wear of wearing parts is small, and the metal utilization rate is high.
   The abrasion of the hammer of the impact stone breaker only appears on the side facing the material. When the rotor speed is normal, the feed will fall to the surface of the hammer (impact surface), and the back and sides of the hammer will not be worn. Even the wear on the material side is minimal. And the bottom grinding rod is also easy to replace. The metal utilization rate of the hammer of the impact crusher can be as high as 45% -48%.
5. Spare parts replacement of impact crusher is easy and maintenance cost is reduced accordingly.
   Only 6 hammers are installed on the rotor of the impact crusher. The designed special tools can be used to easily replace the hammers. It takes only one shift to replace a set of hammers.

Working Principle:

The impact crusher is a crushing machine that uses impact energy to crush materials. When the machine is working, driven by the motor, the rotor rotates at a high speed. When the material enters the area of the hammer, it strikes and breaks with the hammer on the rotor, and then is thrown to the counterattack device to be broken again, and then rebounded from the counterattack Return to the impact area of the hammer to re-crush. This process is repeated. The materials enter the first, second, and third counterattack chambers from large to small and are repeatedly crushed until the material is crushed to the required particle size and discharged from the discharge port.

Structure:

The impact crusher includes single rotor impact crusher and double rotor impact crusher. Among them, the structure of the single-rotor impact crusher is relatively simple. The material block is fed from the feed port. In order to prevent the material block from flying out during crushing, a chain curtain is installed in the feed direction of the feed port. The feed block falls on the grate screen, the small block falls through the grate to the lower part of the casing, and the large block of material slides onto the rotor along the screen surface. A hammer with a certain height is fixedly installed on the circumference of the rotor, and the rotor is rotated by a motor through a V-belt belt at high speed. The mass falling on the rotor is impacted by a high-speed rotating hammer. After gaining kinetic energy, it hits the impact plate at high speed, then rebounds from the impact plate, and collides with the material thrown by the rotor in the crushing zone. The space formed by the bar screen, rotor, impact plate and chain curtain is called the first impact zone; the space formed by the impact plate and rotor is the second impact zone. After the materials are crushed by mutual impact in the first impact zone, they then enter the second impact zone and are crushed again by impact. The crushed material is discharged through the outlet at the lower part of the casing.

One end of the impact plate is hung on the casing with a live chain, and the other end is fixed in position with an adjusting bolt. When a large piece of material or a fragile object is caught in the gap between the rotor and the counterattack plate, the counterattack plate is subjected to greater pressure to move the counterattack back.

Hammer:

The shape of the hammer is closely related to the tightening method and working load. The design of the hammer should meet the requirements of reliable work, easy loading and unloading, and improving the utilization rate of the hammer metal. The hammer is generally made of high chromium cast iron, high manganese steel and other wear-resistant alloy steel. There are many shapes of bar hammers, including strips, T-shapes, S-shapes, I-shapes, axe-shapes, and grooved shapes. Generally, they are strip-shaped.

Compression block：

This part is widely used in all kinds of mining machinery, with excellent materials and stable performance, and can be manufactured according to different requirements. After the load test operation is completed, the compression block should be adjusted as necessary. The compact block has the excellent characteristics of stable chemical composition, reasonable heat treatment process, good wear resistance and high strength. The automatic clamping mechanism of the compacting block adopts the cylinder drive, connecting rod mechanism and linear guide rail to realize the sequential actions of the compacting block clamping, feeding, clamping at the other end, simultaneous release and retraction.

Components:

The main components of the impact crusher are spring, railing, front impact frame, rear impact frame, impact liner, square steel, impact liner bolt, clamshell device, main shaft, hammer, rotor frame, liner, locking block Compact the block, etc.

Counterattack:

The function of the counterattack plate is to withstand the impact of the material struck by the hammer, so that the material is crushed by the impact, and the material after the impact is crushed back to the impact area, and the impact crushing is performed again to obtain the desired product size.
There are many forms of counterattacks, mainly in two types: polyline and arc. The broken line-shaped impact surface can make the materials at each point of the impact plate impact in an approximately vertical direction, so the best crushing effect can be obtained. The arc-shaped impact surface can make the material block rebound from the impact plate, and form a fierce impact crushing area in the center of the circle to increase the free impact crushing effect of the material.
The counterattack plate is generally welded with steel plates. The impact surface is equipped with wear-resistant lining, but it can also be composed of impact rollers or grate strips. The counterattack surface with grate has less fine-grained content, the production capacity of the equipment can be improved, and the power consumption is saved. However, there are defects such as complex structure, difficult to replace after the impact surface is worn, and fast wear.
The rotor of the impact crusher is mostly made of integral cast steel. The structure is sturdy and durable. It is easy to install the plate hammer. Its mass is large enough to meet the crushing requirements. The rotors of small and light impact crushers can also be welded with steel plates.

Square steel:

The square steel is square and can be divided into seams and seamless. The square steel with seams is welded together by steel plates to make square steel pipes. Seamless square steel is made from seamless steel tubes. Its pressure resistance is far greater than that of a square tube with a seam. The counterattack breaking square steel plays a role of preventing the material from being discharged from the front; the counterattack breaking strictly implements the heat treatment process, uses high-strength wear-resistant parts, and the key components are imported from countries such as Torrington bearings. Square steel theoretical weight calculation formula: side length Х side length Х0.00785 = kg / m (only for reference, mainly in practice)

HC Series Impact Crushers：

HC Series Impact Crushers are built on advanced technology with a combination of domestic applications. The overall structure is simple, practical and reasonable.

Raw materials:

Granite, limestone, concrete, lime, plaster

Capacity:

50-1200t/hMax feeding size:300mm-1600mm

Application:

Mining, metallurgy, construction, highway, railroad, and water conservancy, etc.

Product Data：

Technical Data of HC Series Impact Crushers:

Model	Max Feed Size(mm)	Throughput(t/h)	Motor Power(kw)	Overall Dimension(L×W×H)(mm) ( the biggest size )	Weight(Motor not included)(t)
HC128	300	40-70	37-55	3115*1600*2932	11.8
HC139	500	50-80	55-75	3060*2048*2935	14.6
HC239	500	100-180	110-132	3095*2048*2970	14.7
HC255	500	100-290	132-160	3095*2398*2970	17.4
HC359Ⅱ	700	180-350	200-250	3415*2666*3127	22.2
HC459	750	220-450	250-315	3717*3020*3301	27
HC579	800	250-550	400-500	3552*3547*3231	36.2
HC679	1000	400-700	560-630	4019*4064*3652	53.2
HC779	1300	500-850	630-800	4785*4338*4849	79
HC798	1300	750-1100	800-1250	4825*4838*4849	90.8
HC898	1500	1000-1500	1000-1600	5382*5445*5454	112.8
HC8118	1600	1400-1900	1400-2000	5382*5945*5454	135.5
HC8138	1600	1400-2500	1600-2100	5348*6527*5454	158.8

Technical Data of HSI Series Impact Crushers:

Model	Max Feed Size(mm)	Throughput(t/h)	Motor Power(kw)	Overall Dimension(L×W×H)(mm) ( the biggest size )	Weight(Motor not included)(t)
HSI379	350	240-460	250-280	3271*3527*2730	23.23
HSI498	400	275-560	280-355	3755*3522*2833	27.2
HSI5118	450	375-825	500-710	3552*4547*2746	36.2
HSI6118	500	600-900	800-900	3733*5272*3306	56.2
HSI7138	500	875-1490	900-1250	4785*5838*4120	78

Details Introduction：

Features and technology advantages of HC Series Impact Crushers:

1. High-quality plates and wear parts to reduce abrade and improve the production efficiency of various conditions; advanced processing technology is the basis of equipment performance.

2. Strong product commonality can reduce cost. Two-cavity impact crusher can becomes three-cavity machine by adding grinding racks, and no need to change other parts.

3. Heavy type rotor, finite element endurance analysis, optimized design, reasonable structure and enhancing moment of inertia lead to bigger crushing ratio and better abrasion resistance.

4. Static and dynamic balancing test for the welding rotor should be done before assembling. To make sure the rotor has a smoothly running and long working life.

5.Main shaft is finished by quality forging, adopts keyless design and world advanced cover tightening connection to ensure the reliable working and make the maintenance easier.

6.Unique locking device for hammers makes the tightening moment of force more safe and bigger. And the replacement of hammers can be more simple and convenient.

7.Standard design for liners increase the interchangeability, decrease the repertory and variety of liners.

8.Simple but practical locking device lock the shell 1 and shell 2 together. This device has a easy operation and saves locking time.

9.Unique hydraulic device design is convenient for opening the fame racks to replace wear parts and adjust the discharge size.

10.Simple structure for impact racks and grinding racks. Easy operation, long working life, convenient maintenance and low cost

Product Usage of HC Series Impact Crushers:

HC Series Impact Crushers can crush kinds of soft and medium-hard ore, for coarse, medium and fine crushing, in primary and secondary crushing process. The series can be widely used in mining, construction, chemical, cement, metallurgical industries, etc.

Common Malfunction:

A:If abnormal vibration of impact crusher is found:

1.Explain that the material is too large, you can check the feed size.

2.Uneven wear indicates that the counter-attack hammer head needs to be replaced.

3.The rotor is unbalanced and needs to be adjusted.

4.Improper foundation treatment, need to check the anchor bolts and strengthen.

B:If the bearing of the impact crusher is found to be hot:

1.Explain that the bearing is short of oil, and it is necessary to add oil in time. Of course, too much oil will cause the bearing to heat up. Always check the oil level when adding oil.

2.If the bearing is damaged, replace the bearing in time.

3.The upper cover is too tight, the bolts should be adjusted, and the tightness is appropriate.

C:If it is found that the output particle size of the impact crusher is too large:

1.It shows that the hammer head is worn, and the hammer head needs to be idle or replaced.

2.The gap between the hammer head and the counterattack plate is too large, generally adjusted to 15-20mm. 3. If the feed size is too large, it will also affect the output size.

D:If the belt of the impact crusher is turned over:

1.Explain that the belt is worn, you need to replace the V-belt.

2.Due to the problem of belt conveyor assembly, the pulley must be adjusted on the same plane.

3.Be sure to pay attention to the quality of the triangle belt itself

Repair Method:

1. The front impact plate boom and the rear impact boom of the impact crusher are combined into one, which improves the elastic vibration of the impact plate, so that the materials bonded to the impact plate can be sent to the crusher shell in time The materials afterwards enter the lower silo together.
2. Recovery and repair of high manganese steel counter hammer counter plate. For the worn hammer, use 506 electrode, No. 2 high carbon electrode and No. 5 high tungsten electrode to conduct surfacing test. The impact hammer after surfacing with No. 5 high tungsten electrode has the best wear resistance and impact resistance. The wear resistance of the impact hammer after overlay welding with 506 electrode and No. 2 high carbon electrode is also more than 2 times higher than the original high manganese steel impact hammer. However, the cost of these two types of surfacing is relatively high, which is not economically feasible. Welding with No. 5 high tungsten electrode has good wear resistance and is economical. The specific method is to use the No. 5 high tungsten electrode for 2-3 times when the impact plate wears 3 to 5 mm.
3. The impact angle of the impact crusher is increased from 1500 to 3000, which can increase the impact strength and ensure the granularity of the material after crushing.
4. Choose the appropriate method of using the impact hammer for the impact crusher. The methods for using the impact hammer include grouping method according to weight tolerance, spacing method, cross-displacement method and symmetry method.
5. The gap between the rotor of the impact crusher and the front of the shell is increased from 10mm to 85mm, which can prevent the front of the machine from being blocked.