Cone crushers are widely used in mining, metallurgy, chemical, and coal industries. Shaft fracture is a common fault that can severely affect the normal operation of the crusher. Effective measures should be taken to prevent this issue.
Main Causes of Cone Crusher Shaft Fracture:
- Mechanical Fatigue: Due to the unique working characteristics of the crusher, the shaft endures frequent mechanical impacts over time, leading to fatigue damage.
- Overfeeding: Excessive feeding causes the equipment to operate beyond its capacity.
- Contaminants in Ore: During the excavation and transportation of ore, discarded metal objects may be mixed in. These objects can enter the crusher if the electromagnetic separator is weak or ineffective, causing frequent over-iron incidents. This results in frequent impacts on the shaft and other components, leading to fatigue damage and eventual shaft fracture.
Preventive Measures:
- Waste Part Recovery: Maintenance personnel should recover and properly dispose of discarded parts removed from the cone crusher. Metal waste should not be randomly discarded into the ore.
- Tool and Waste Management: During equipment maintenance, ensure that tools and debris are not left inside the equipment.
- Metal Detection Improvement: Update or modify existing metal detectors to enhance their ability to detect and remove metal contaminants.
- Feedbelt Inspection: Operators overseeing the crusher feedbelt should be more diligent in monitoring materials and promptly remove any foreign objects.
- Regular Inspections: Operators of jaw crushers should conduct timely inspections. Any abnormal electrical or acoustic conditions should be addressed and reported immediately to prevent accidents.
- Ultrasonic Testing: Regularly use ultrasonic or other testing instruments to inspect the shaft and other stress-bearing components to assess the condition of the equipment.
- Operator Training: Strengthen training for operators to improve their practical skills, enhance equipment maintenance, and ensure timely major and minor repairs, keeping the equipment in good technical condition.
- Spare Parts Inventory: Maintain an adequate inventory of critical components such as the shaft and mainframe to prevent production halts due to unforeseen issues.
By following these measures, the risk of shaft fractures can be significantly reduced, ensuring smooth and efficient operation of the cone crusher.
