Effective strategies to increase the production capacity of impact crushers

As a kind of mechanical equipment that can crush materials by means of impact, impact crusher occupies an important position in industrial production.Its working principle is: the motor drives the rotor to run at high speed, and when the material enters the area of action of the hammer, it is broken by the high-speed impact of the hammer.The broken material is thrown in the tangent direction to the counterattack plate mounted above the rotor, and then undergoes the crushing process again, and then bounces back from the counterattack plate to the area of action of the hammer, repeating the crushing action.This cycle goes back and forth until the material is broken to the desired particle size and finally discharged from the discharge port.

Due to the advantages of simple structure, good particle shape after crushing, and easy maintenance, impact crushers are widely used in the field of stone crushing.The size of its production capacity is directly related to the economic benefits of the entire production line.So, how can we effectively increase the production capacity of impact crushers?

1. Reduce the water content of the material

If the water content of the material is too high, it is easy to adhere in the crushing chamber, and at the same time cause clogging during the unloading process, which seriously affects the production capacity of the impact crusher.For materials with large water content, drying or drying methods can be used in advance to reduce the humidity of the material, thereby increasing the production capacity of the impact crusher.For example, in some sand and gravel production plants, for ore with high water content that has just been mined, a special drying site is set up to lay the material flat and dry for a certain period of time before crushing, which can significantly reduce the production problems caused by the moisture of the material and increase the production capacity of the equipment.

2. Implement material pre-screening

Impact crushers have specific requirements for feed size.If there are a large number of large pieces of ore in the material, it will significantly increase the difficulty of crushing the material, and may even damage the machine, thereby affecting the output.And when the content of fine powder in the material is too high, it is prone to adhesion, which hinders the conveying and cutting process.The material is pre-screened before the crushing operation, which can filter out large pieces of material and fine powder.For example, pre-screening equipment such as vibrating screens is installed to separate materials that do not meet the feeding requirements in advance, so that the particle size of the materials entering the impact crusher is more uniform and more in line with the crushing conditions of the equipment, thereby increasing the production capacity of the impact crusher.

3. Reasonably increase the power of the main motor

Within the allowable range of the rated motor power, the greater the power of the main motor, the higher the production efficiency of the impact crusher, and the higher the corresponding production capacity.Therefore, the power of the main motor can be moderately increased within a reasonable range to achieve increased production capacity.However, it should be noted that when increasing power, the overall performance and energy consumption of the equipment should be considered comprehensively to ensure that while increasing production capacity, excessive production costs will not be increased due to excessive energy consumption.For example, after the monitoring and analysis of the operating data of the equipment by professional and technical personnel, the power is increased by a certain proportion on the basis of the original motor. After the actual operation test, it is found that the production capacity of the equipment has been effectively improved, and the overall operation is stable.

4. Moderately increase the rotor speed

The rotor speed is one of the key working parameters of the impact crusher, which plays a decisive role in the crusher's production capacity, product particle size and crushing.However, if the rotor speed is too high, the power consumption will increase significantly, and the wear of the hammer will also accelerate, resulting in an increase in production costs.Therefore, in actual production, the high speed of the rotor cannot be blindly pursued, and the speed increase should be moderate.For example, through preliminary tests and production practice exploration, it is determined that when the rotor speed is increased to a certain value under the current material characteristics and equipment operating conditions, it can not only ensure a significant increase in production capacity, but also keep the power consumption and hammer wear within an acceptable range, and maximize production efficiency.

5. Ensure that the angle of the counterattack plate is appropriate

At present, there are two common counterattack plates on the market: polyline and arc-shaped.The structure of the polyline counterattack plate is relatively simple, but it cannot ensure that the stone obtains the maximum impact crushing effect.When debugging the angle of the polyline counterattack plate, the material should be perpendicular to the counterattack plate when it collides with the counterattack plate as much as possible, so as to increase the production capacity of the counterattack crusher.In the arc-shaped counterattack plate, the involute shape is more commonly used.This structural form of counterattack plate can make the stone impact in the vertical direction at all points, and the crushing efficiency is higher, thereby increasing production capacity.For example, in some large stone factories, by replacing the original polyline counterattack plate with an involute linear arc-shaped counterattack plate, and after precise commissioning and installation, the equipment production capacity has been significantly improved.