The weight of the traditional jaw crusher frame accounts for a large proportion of the weight of the whole machine (casting frame is about 50%, welding frame is about 30%), and the cost of processing and manufacturing accounts for 50% of the total cost, so it largely affects the price of equipment.
This paper compares the two kinds of integrated and combined rack in weight, consumables, cost, transportation, installation, maintenance and other aspects of the difference, let’s see!
1.1 Integral frame The whole frame of the traditional integral frame is produced by casting or welding, due to its manufacturing, installation and transportation difficulties, it is not suitable for large jaw crusher, and mostly used by small and medium-sized jaw crusher.
1.2 Combined frame The combined frame adopts a modular, non-welded frame structure. The two side panels are firmly bolted together with the front and back wall panels (cast steel parts) by precision machining fastening bolts, and the crushing force is borne by the inset pins on the side walls of the front and back wall panels. The left and right bearing boxes are integrated bearing boxes, which are also closely connected with the left and right side panels by bolts.
Comparison of manufacturability between the combined frame and the whole frame
2.1 The combined frame is lighter and less consumable than the whole frame. The composite frame is not welded, and the steel plate material can be made of high-strength alloy steel with high carbon content and high tensile strength (such as Q345), so the thickness of the steel plate can be reduced appropriately.
2.2 The investment cost of the combination frame in plant construction and processing equipment is relatively small. The combination frame can be divided into the front wall panel, the rear wall panel and the side panel several large parts are processed separately, the weight of a single part is light, the tonnage required to drive is also small, and the overall frame requires the tonnage of the drive is much larger (close to 4 times).
Taking PE1200X1500 as an example: the combined frame and the whole welding frame require the tonnage of the vehicle to be about 10 tons (single hook) and 50 tons (double hook), and the price is about 240,000 and 480,000, respectively, which can save about 240,000 costs alone.
The integral welding frame must be annealed and sandblasted after welding, which requires the construction of annealing furnaces and sandblasting rooms, which is also a small investment, and the combination frame does not require these investments. Secondly, the combined frame is less expensive to invest in the plant than the whole frame, because the driving tonnage is smaller, and it does not have high requirements for the column, supporting beam, foundation, plant height, etc. of the plant, as long as it can meet the design and use requirements.
2.3 Short production cycle and low manufacturing cost. Each part of the combination frame can be processed separately on different equipment synchronously, not affected by the processing progress of the previous process, each part can be assembled after the processing is completed, and the whole frame can be assembled and welded after the processing of all parts is completed.
For example, the groove of the three combined surfaces of the reinforced plate should be processed, and the inner hole of the bearing seat and the three combined surfaces should also be roughed to be matched. After the whole frame is welded, it is also annealing to finish machining (processing bearing holes), the process is more than the combined frame, and the processing time is also more, and the larger the overall size and the heavier the weight of the frame, the more time is spent.
2.4 Saving transportation costs. Transportation costs are calculated by tonnage, and the weight of the combined rack is about 17% to 24% lighter than the overall rack. The combined frame can save about 17% ~ 24% of the transportation cost compared with the welded frame.
2.5 Easy downhole installation. Each major component of the combination frame can be individually transported to the mine and the final assembly of the crusher can be completed underground, which significantly reduces construction time and costs. Downhole installation requires only ordinary lifting equipment and can be completed in a relatively short time.
2.6 Easy to repair, low repair cost. Because the combination frame is composed of 4 parts, when a part of the crusher frame is damaged, it can be repaired or replaced according to the degree of damage to the part, without replacing the entire frame. For the overall frame, in addition to the rib plate can be repaired, the front and rear wall panels, side panels tear, or bearing seat deformation, usually can not be repaired, because the side plate tear will certainly cause the bearing seat displacement, resulting in different bearing holes, once this situation, through welding is unable to restore the bearing seat to the original position accuracy, the only way is to replace the entire frame.
Summary: Jaw crusher frame in the working state to withstand a large impact load, so the frame must meet the following technical requirements: 1 to have sufficient stiffness and strength; ② Light weight, easy to manufacture; ③ Convenient installation and transportation.
By analyzing and comparing the processability of the above two kinds of racks, it can be seen that the combination rack is lower than the overall rack in terms of material consumption or manufacturing costs, especially the crusher industry itself is very low in profit, if not in the material consumption and manufacturing process, it is difficult to compete with foreign counterparts in this field. The improvement of rack technology is very necessary and an effective way.
Post time: Oct-29-2024