Components: The HP800 cone crusher usually consists of an upper frame, a lower frame, a moving cone, a fixed cone, a main shaft, a horizontal shaft, a locking cylinder, an adjustment ring, a locking ring, a transmission device, a hydraulic locking and hydraulic motor adjustment system, a hydraulic and lubrication station, and a tc1000 automatic control system.
Working principle: The working part of this crusher is two truncated cones. One is a fixed cone (also known as an outer cone), and the other is a moving cone (also known as an inner cone). During operation, the rotation of the motor drives the cone part to swing around a fixed point under the action of the eccentric sleeve through the belt pulley or coupling, transmission shaft. Thus, the crushing wall approaches and leaves the surface of the rolling white wall fixed on the adjustment sleeve from time to time, allowing the ore to be continuously impacted, compressed, and bent in the crushing cavity to achieve crushing. The crushed material is discharged from the discharge port at the lower part of the crusher under the action of gravity.
The Metso HP800 cone crusher is a device widely used in fields such as metallurgy, construction, hydropower, transportation, chemical industry, and building materials industry. It is suitable for crushing various ores and rocks of hard and medium hardness or above. It is one of the ideal equipments for large stone factories and mining crushing. It has the characteristics of reliable structure, high production efficiency, convenient adjustment, and economical use.
Here is its detailed introduction:
Components: The HP800 cone crusher usually consists of an upper frame, a lower frame, a moving cone, a fixed cone, a main shaft, a horizontal shaft, a locking cylinder, an adjustment ring, a locking ring, a transmission device, a hydraulic locking and hydraulic motor adjustment system, a hydraulic and lubrication station, and a tc1000 automatic control system.
Working principle: The working part of this crusher is two truncated cones. One is a fixed cone (also known as an outer cone), and the other is a moving cone (also known as an inner cone). During operation, the rotation of the motor drives the cone part to swing around a fixed point under the action of the eccentric sleeve through the belt pulley or coupling, transmission shaft. Thus, the crushing wall approaches and leaves the surface of the rolling white wall fixed on the adjustment sleeve from time to time, allowing the ore to be continuously impacted, compressed, and bent in the crushing cavity to achieve crushing. The crushed material is discharged from the discharge port at the lower part of the crusher under the action of gravity.
Its advantages include:
Strong main shaft, small inertia force.
High production intensity, low unit power consumption, and fine product granularity.
Adopts hydraulic automatic iron passing and free adjustment, which is fast, safe, and easy to operate.
Adopts labyrinth seal with low cost and good effect.
Large eccentric angle, large swing stroke and crushing capacity of the moving cone.
The automatic control system can continuously monitor the functions of the machine.
However, during the use of the HP800 cone crusher, some faults may occur. Here are some common faults and solutions:
Wearing of the upper bushing of the moving cone:
Excessive load during the running-in period: To ensure good contact of the newly replaced upper bushing of the moving cone, the load should be gradually increased to facilitate the running-in of the steel bushing. Once the steel bushing is overloaded and burned, necking will occur and it needs to be replaced again.
Worn to the limit: When the upper bushing of the moving cone is severely worn, it will increase the swing load of the moving cone. Especially when the crusher is idling, it will increase the load on the upper bushing and burn the upper bushing. The size of the upper bushing of the moving cone should be checked in time. The wear should not exceed 2mm.
Poor quality lubricating oil: Poor oil quality can easily cause the oil film of the liner to break instantaneously and burn the upper bushing. The oil quality of the lubricating oil should be checked regularly and replaced in time.
Wearing of the lower bushing of the moving cone:
High load during the running-in period: The lower bushing of the moving cone mainly bears the force during the crushing process and requires very good contact. The running-in time of the lower bushing of the moving cone is relatively longer.
The gap between the lower bushing of the moving cone and the eccentric iron is too large or too small: The fit gap between the lower bushing of the moving cone and the eccentric iron should be 1.0 - 1.2mm. Too large or too small gaps can cause the copper bushing to burn. Therefore, the size should be carefully measured during the replacement of the lower bushing of the moving cone and during its use.
Poor quality lubricating oil: Poor oil quality will cause the oil film to break instantaneously during the operation of the moving cone and burn the copper bushing. It should be checked and replaced in time.
Insufficient oil volume: When the oil circuit is blocked or the pump capacity decreases, it will cause a lack of oil and burn the copper bushing. The oil circuit and oil volume need to be checked periodically.
Iron passing: It will cause the crusher to have an instantaneous excessive load, resulting in the rupture of the oil film and burning of the copper bushing. The metal detector installed on the feeding belt needs to be kept sensitive and reliable, otherwise, the copper bushing is prone to burning.
Large gap in the lower bushing of the moving cone: Wear of the lower bushing of the moving cone will cause a large gap, which will reduce the contact surface between the moving cone and the eccentric body and increase the swing of the moving cone, resulting in bushing burning. It should be checked and replaced periodically.
Burning of the main shaft bushing:
The load is added too quickly during the running-in period: To ensure good contact between the new bushing and the main shaft, the load should be gradually increased after replacing the bushing to avoid burning the copper bushing.
Poor quality lubricating oil: Poor oil quality will reduce the viscosity of the oil film and cause the oil film of the main shaft bushing to break instantaneously during the crushing process, resulting in burning of the copper bushing. It should be checked and replaced in time.
Insufficient oil volume: When the oil pipe is blocked or the pump capacity decreases, it is easy to cause a lack of oil in the copper bushing and unable to form an oil film until the copper bushing is burned. The oil pipeline and oil pump should be checked regularly to ensure sufficient oil volume.
Iron passing: Iron passing will cause the crusher to have an instantaneous excessive load, resulting in the rupture of the oil film and burning of the copper bushing. The metal detector on the feeding belt needs to be kept sensitive and reliable.
Unsuitable fit gap: The gap between the main shaft bushing and the main shaft should be kept between 1.0 - 1.2mm. Too large or too small gaps will cause the copper bushing to burn. During the replacement of the new bushing and the use of the bushing, the gap between the main shaft bushing and the main shaft should be carefully checked.
Bending or deformation of the main shaft: It will cause a significant reduction in the fit between the main shaft and the main shaft bushing. Especially after the crusher operates and heats up, it will cause burning of the copper bushing. The state of the main shaft should be checked regularly.
Deformation or fracture of the main shaft:
Iron passing: Iron passing will cause a sharp increase in the bending stress of the main shaft and instantaneous overload, resulting in deformation or fracture. Therefore, the metal detector on the feeding belt should be detected in time to keep it sensitive and reliable.
Burning of the main shaft bushing: Under certain conditions, when the bushing burns, a relatively high temperature will be generated, causing cracks on the surface of the main shaft. If the cracks are not eliminated in time, they will further develop and cause the main shaft to deform or fracture.
Deterioration of lubricating oil:
Damage to the tu-type labyrinth seal: It will cause a large amount of dust to enter the crusher cavity and lubrication system, deteriorating the oil quality. The tu seal should be checked regularly.
Insufficient positive pressure air volume: The HP800 crusher has a positive pressure blowing system. The air enters the crusher cavity through the pipeline to form positive pressure in the cavity to prevent dust from entering. The positive pressure air volume should be checked frequently.
Overdue use of lubricating oil: The service life of lubricating oil is 20,000 hours. After exceeding the service life, the viscosity and other indicators of the lubricating oil will significantly decrease and must be replaced regularly.
Damage to the tu-type labyrinth seal:
Wear of the spherical tile or wear of the thrust bearing: Wear of the spherical tile will cause a small gap between the t-type seal at the lower edge of the moving cone and the u-type seal on the counterweight; wear of the thrust bearing will cause a small gap between the t-type seal at the lower edge of the counterweight and the u-type seal on the frame. The reduction of the tu-type labyrinth gap will cause wear and damage to the tu seal. It should be replaced in accordance with the regulations.
Damage to the dust ring: It will cause a large number of fragments to enter the tu seal space and damage the seal. Therefore, the dust ring on the outside of the counterweight needs to be checked and replaced regularly.
Replacement of spherical tile:
Poor quality lubricating oil: It will accelerate the wear of the spherical tile, resulting in an oil groove depth lower than 3.5mm, resulting in insufficient oil volume of the spherical tile and easy rupture of the oil film. When the oil groove depth is lower than 3.5mm, the spherical tile needs to be replaced.
Loose fit between the spherical tile and the tile frame: During the disassembly and inspection of the crusher, the spherical tile is pulled out, resulting in multiple damages on the surface, resulting in the failure of the interference fit between the spherical tile and the tile frame and loosening. It should be replaced in time.
Replacement of thrust bearing: When the thickness of the thrust bearing is lower than 13.5mm, it will cause a small gap between the tu seal and the top clearance of the large and small gears, and poor meshing. It should be replaced in time.
Jumping of the adjustment ring:
Wear of threads: Generally, the gap between the locking ring and the adjustment ring of a newly installed HP800 crusher is 12.5mm. According to the wear situation of the threads of the adjustment ring and the locking ring, the gap between the two can be appropriately enlarged to increase the locking stroke.
Large feed particle size: The maximum feed particle size for fine crushing production of the HP800 cone crusher is 110mm. If the particle size exceeds this range, it will cause an increase in crushing load, while the locking force is relatively insufficient, resulting in the jumping of the adjustment ring. At the same time, it will have an adverse effect on the product particle size and accelerate the wear of various components. Therefore, the feed particle size needs to be strictly controlled.
Unbalanced feeding: Due to the incorrect or unreasonable position of the crusher feeding funnel, the falling material center is seriously deviated from the crusher center, resulting in unbalanced crushing force of the crusher and large unilateral force on the adjustment ring. The design of the crusher head funnel is very important. The falling material center and the crusher center should be as close as possible.
Fracture of locking bolt: The locking ring and the adjustment ring are connected by four bolts. Due to iron passing or large feed particle size of the crusher, the locking bolt of the crusher is overloaded and fractures, resulting in failure of locking and jumping of the adjustment ring. This problem can be solved by replacing the locking bolt and adjusting the gap between the locking ring and the adjustment ring.
Regarding the specific manufacturing process of the Metso HP800 cone crusher, this involves the manufacturer's technology and trade secrets and is usually not disclosed publicly. Generally speaking, its manufacturing process needs to go through multiple links, including design and research, raw material selection, parts processing, assembly and debugging. During the manufacturing process, strict quality control of each link is required to ensure the performance and reliability of the crusher. The manufacturer will use advanced processing equipment and processes to perform precision processing and treatment on key parts, and at the same time conduct strict quality inspection and testing to meet the design requirements and standards of the equipment.
