The cone crusher is the core equipment for fine and medium crushing of quartz
sand. If the particle size deviation after crushing is large (qualified particle
rate is lower than 80%) and the capacity drops sharply (lower than 70% of the
rated value), the subsequent sand production load will be increased and the
qualified rate of finished products will be low. Combined with years of
operation and maintenance experience, the three-step troubleshooting method is
summarized to help enterprises quickly recover equipment performance.
Step 1: Inspect the crushing chamber and liner plate - the core component
determines the crushing effect
Crushing chamber and liner plate are parts directly contacting with quartz
sand, and loss or improper fitting are main reasons.
Uneven wear of liner plate will lead to particle size fluctuation: too fast
wear of liner plate at feed end (strong impact of quartz sand) will expand the
gap of feed inlet and increase coarse particles; The liner plate at the
discharge end is worn, which will make the proportion of fine powder exceed the
standard. It is required to measure the thickness of the lining plate regularly,
and replace it immediately when the abrasion exceeds 1/3 of the original
thickness. High-chrome alloy lining plate is preferred, and the abrasion
resistance is 40% higher than that of high-manganese steel.
Wrong type selection of crushing chamber will lead to low capacity: standard
chamber is used for processing coarse quartz sand (20-50mm), and short head
chamber is used for processing fine quartz sand (10-20mm). If the chamber type
is not matched with the particle size of raw material, insufficient crushing
will be caused. When changing the cavity type, synchronously adjust the rotation
speed of the eccentric shaft. The standard cavity is 18-22r/min, and the short
end cavity is 22-25r/min to ensure the crushing force is appropriate.
Step 2: Calibrate operating parameters - parameter deviations are hidden
"productivity killer"
Improper setting of parameters such as feeding amount, discharge opening and
eccentricity will directly affect the productivity and particle size.
Overload or uneven feeding capacity: materials in the crushing chamber are
piled up and cannot be fully crushed when exceeding the rated capacity of
equipment (e.g. rated 80t/h, actual 100t/h); The feeding will fluctuate from
time to time, resulting in coarse and fine grain size. Electronic belt weigher
shall be used to control the quantity, which shall be kept at 80% - 90% of the
rated value. Material level sensor shall be installed to realize automatic
adjustment.
Unreasonable clearance at discharge outlet: excessive clearance (20% more
than the design value), increasing coarse particles; Too small (30% lower than
the design value), the capacity drops. It shall be adjusted according to the
particle size requirements of finished products. If 10-15mm finished products
are required, the gap shall be 8-10mm. After adjustment, 3 batches of materials
shall be crushed to ensure that the qualified particle ratio meets the
standard.
Excessively small eccentric distance: insufficient crushing force and
incomplete material crushing. The recommended eccentric distance of common cone
crushing is 8-12mm, and it can be adjusted to 10-14mm for the treatment of high
hardness quartz sand to enhance the crushing impact.
Step 3: Adaptation of material characteristics and maintenance - raw material
problems+lack of maintenance, easily causing equipment collapse
The characteristics of quartz sand and poor equipment maintenance aggravate
the problem.
The hardness of raw material exceeds the standard or contains impurities: the
Mohs hardness of quartz sand exceeds 7.5, or granite and metal block are mixed,
which will accelerate the abrasion of lining plate and cause uneven grain size.
Impurity removal device shall be added before feeding to pre-treat ultra-hard
raw materials with jaw crusher to reduce cone breaking load.
Lubricating system failure: insufficient or polluted lubricating oil will
cause wear of main shaft and bearing and unstable crushing force. Check the oil
level every day (keep at 2/3 of the oil level), check the oil quality every
week, and replace the anti-wear hydraulic oil every 3 months to ensure that the
lubrication system is normal.
Daily work: clean the residual materials of the equipment every day, check
the liner plate and fasteners every week and calibrate the parameters every
month. With this operation, the cone breaking capacity can be increased by more
than 15%, and the qualified particle size ratio is stabilized at more than 90%.
If the problem still exists, it is suggested to contact the manufacturer for
on-site inspection to avoid further loss of parts.