Following these tips and techniques can save manufacturers money and downtime.
For as long as rocks have been known, people have been designing and perfecting tools to dismantle them. Fracking technology has evolved rapidly in recent years to optimize crushing efficiency, reduce operating costs for mining and aggregate operations, and help reduce operational downtime.
Be sure to inspect the key wear points of a hydraulic breaker on a daily basis.
Traditionally, crusher performance has been measured by tons of rock processed per hour, but the cost per ton of crushers is fast becoming the industry standard. One of the easiest ways to keep the cost per ton of tools relatively low is to identify technology that helps reduce the impact of continuous crushers under high PSI conditions in mines and quarries.
In addition, there are some best practices that can help extend the life of your accessories and your excavator.
The power and versatility of high-impact crushers enable operators to perform an increasing number of tasks in mines and quarries.
Hydraulic crushers can be used for large-scale excavation or primary crushing. They are very effective for the ‘extra-large breaking’ of secondary or blasted rock, making it easier to break in size. The crusher is also mounted on the base of the rock system and is usually mounted above the crusher for extra safety, preventing rock from getting stuck in the feeder.
A significant technical improvement for crushers in mining and aggregate applications is the blank ignition protection, which is designed to protect the hammer from additional wear in the event of an operator fire. Standard with leading manufacturers of rock breakers, shelter fire protection uses a hydraulic pad at the bottom of the cylinder hole to attenuate piston motion. It also protects hammer to metal to metal contact, reducing premature degradation of the crusher and its bushings, fixing pins and front guides.
Some manufacturers offer an energy recovery valve in the hammer, which can increase performance of hard materials. By using the energy generated by the piston’s rebound to increase the tool’s strike force, the valve recovers the recoil energy and transfers it to the tool’s next strike, thereby increasing the strike force.
Another key advance in crusher technology is speed control. When the hammer stroke is adjustable, the operator can match the crusher frequency according to the hardness of the material. This provides higher productivity and reduces the amount of harmful energy transferred back into the excavator.
The hammer head configuration of crusher is also very important. Owners should consider the use of closed circuit breaker design; The circuit breaker is cradled in a protective housing that protects the battery from damage and reduces noise levels. The suspension also protects the excavator boom, reducing vibration and improving operator comfort.
Absolutely reliable maintenance
As with any piece of equipment, proper maintenance is critical to operating efficiency, productivity and, most importantly, life. While the circuit breakers mounted on excavators are used in some of the most demanding conditions, there are simple steps that can be taken to mitigate premature wear on tools and machines.
Although some manufacturers include wear indicator devices in their tools, it is vital to check critical wear points daily and weekly. To increase uptime, field replaceable wear parts, such as bushings and retaining pins, can provide performance solutions in minutes.
Although the nitrogen level of the crusher needs to be recharged regularly according to the manufacturer’s specifications, grease is a process that must be performed multiple times per day. It is recommended to focus on lubrication as grease stations are essential for quarries.
Usually, a cradle mounted and/or excavator mounted lube station is available for some circuit breaker systems. For quarry operations, the larger capacity of the grease mounted on the excavator is recommended as it requires fewer fill intervals. Cradle mounting is good when you need to install circuit breakers on different machines.
The following additional breaker/excavator tips are recommended:
- Be sure to grease tools/bushing properly at all times. No. 2 lithium base grease containing 3% to 5% molybdenum is ideal for rated temperatures over 500°F.
- Move tools and reposition them frequently. If the drill hammer runs too long, it will drill. This can lead to overheating and premature failure.
- Use the right tools. Contrary to popular belief, blunt instruments are best suited for most extreme crushing because they provide better positioning and better shock wave propagation.
- Avoid blank shots. This is the roughest act against vandals. The smaller the stone, the more likely it is to be dropped. Outsmart the rock by stopping the hammer before it can Pierce it. Variable speed hammers should be considered to reduce the transfer of damage energy to the crusher.
Post time: Aug-27-2022