What is double roll crusher？
Double roll crusher, as the name suggests, is a crushing equipment composed of two relatively rotating rolls. When the material enters the gap between the two rolls from the feed opening, it begins a journey full of challenges and changes. With the slow rotation of the rollers, the material is subjected to powerful squeezing, shearing and grinding. Under the action of this force, the original hard material is gradually crushed into smaller particles, and finally discharged from the discharge port, completing the magical transformation from large to small pieces.
一. Structural composition
It mainly consists of rollers, transmission device, frame, adjustment device and other parts.
1.Roller: usually made of wear-resistant material, such as high manganese steel. The surface of rollers can be smooth or with tooth structure to adapt to the crushing needs of different materials.
2.Transmission device: including motor, reducer, etc., to provide power for the rotation of the roll.
3.Frame: used to support the whole equipment to ensure its stability.
4.Adjusting device: it can adjust the gap between two rolls, so as to control the granularity of the crushed products.
二. Working Principle
Double Roll Crusher mainly relies on two relatively rotating rollers to squeeze and crush materials. The material enters into the gap between the two rolls from the inlet, and is crushed by extrusion, shearing and grinding with the rotation of the rolls. The crushed material is discharged from the discharge port.
三.The characteristics
1.Large crushing ratio: able to crush larger size materials into smaller size products.
2.Simple structure: the structure of the equipment is relatively simple, easy to operate and maintain.
3.low energy consumption: adopting extrusion crushing method, lower energy consumption compared with other crushing equipment.
4.Uniform product size: the size of crushed material is uniform, which is favourable for subsequent processing.
Features of Double Roll Crusher
It has a very large crushing ratio and is able to crush larger size materials into smaller size products. This feature makes the double roll crusher widely used in mining, building materials, chemical industry and other industries. Secondly, the structure of double roll crusher is simple, easy to operate and easy to maintain. Compared with other complex crushing equipment, double roll crusher has lower maintenance cost and longer service life. In addition, the energy consumption of double roll crusher is low, which is of great significance to reduce the production cost and improve the economic efficiency of enterprises. Meanwhile, due to the extrusion crushing method, the particle size of the crushed material of the double roll crusher is uniform, which is favourable to the subsequent processing.
Application fields of double roll crusher
It is widely used in mining, building materials, chemical industry and other industries. For example, it can be used to crush various ores such as iron ore, copper ore, limestone, etc. in the mining industry; in the construction material industry, it can crush cement raw materials, sand and gravel, etc.; in the chemical industry, it can crush chemical raw materials, etc.
In the mining industry, double roll crusher is one of the indispensable equipment. It can be used to crush various ores, such as iron ore, copper ore, limestone and so on. During the crushing process, the double roll crusher can effectively crush the ore into suitable particle size, providing good conditions for the subsequent ore dressing, smelting and other processes. In the construction material industry, double roll crusher also plays an important role. It can crush cement raw materials, sand and gravel, etc., providing high-quality raw materials for the production of building materials. In the chemical industry, double roll crusher can crush chemical raw materials to meet the required particle size requirements for subsequent processing and reaction.
The following are the common problems and solutions of the double roll crusher:
一.Poor crushing effect
1.Problem manifestations:
The product particle size is uneven and fails to meet the expected crushing particle size requirements.
The crushing ratio is small and the material cannot be fully crushed.
2.Cause analysis:
The gap between the rollers is inappropriate. If the gap is too large, the material cannot be fully crushed by extrusion; if the gap is too small, it may cause excessive load on the equipment and affect the crushing effect.
The rollers are severely worn. The surface shape of the worn rollers changes, reducing the crushing capacity.
The feeding speed is uneven or the feeding particle size is inappropriate. Too fast feeding speed may cause the material to accumulate between the rollers and affect the crushing effect; too large feeding particle size may exceed the crushing capacity range of the equipment.
3.Solutions:
Adjust the gap between the rollers. According to the particle size requirements of the crushed product, reasonably adjust the gap between the two rollers. Precise adjustment can be made through the adjustment device, and a test run should be conducted after adjustment to ensure that the crushing effect meets the requirements.
Replace the rollers. When the rollers are severely worn, new rollers should be replaced in time. Select rollers with reliable quality and good wear resistance to extend the service life of the equipment.
Control the feeding speed and particle size. Ensure uniform feeding and avoid too fast or too slow feeding speed. For materials with larger feeding particle size, pre-crushing treatment can be carried out to make it meet the feeding requirements of the double roll crusher.
二.Abnormal equipment operation
1.Problem manifestations:
Excessive equipment vibration and abnormal noise.
Transmission device failure, such as overheating of the motor, abnormal noise of the reducer, etc.
2.Cause analysis:
The equipment installation is not firm. Unstable foundation or loose anchor bolts will cause vibration and noise during the operation of the equipment.
The rollers are unbalanced. Unbalanced phenomena may occur during the manufacturing or installation of the rollers, leading to unstable equipment operation.
Components of the transmission device are damaged. Motor failures, gear wear of the reducer, etc. may all cause transmission device failures.
Hard foreign matter is mixed in the material. Hard foreign matter entering the equipment may damage the rollers or block the equipment, resulting in abnormal operation.
3.Solutions:
Check the equipment installation. Ensure that the equipment is firmly installed and the anchor bolts are tightened. If necessary, the equipment foundation can be reinforced.
Conduct roller balance debugging. If the rollers are unbalanced, the balance state of the rollers can be adjusted by adding balance weights or conducting dynamic balance tests.
Check the transmission device. Check the transmission devices such as the motor and reducer, and repair or replace damaged parts in time. Ensure good lubrication of the transmission device to avoid failures caused by poor lubrication.
Clean the material. Before feeding, screen the material to remove hard foreign matter in it to prevent it from entering the equipment and damaging the equipment.
三.Excessive wear of rollers
1.Problem manifestations:
The surface of the rollers is severely worn and the service life is short.
2.Cause analysis:
The material is of high hardness. If the hardness of the crushed material is relatively high, it will accelerate the wear of the rollers.
The roller material is inappropriate. The selected roller material has insufficient wear resistance and cannot meet the requirements for crushing materials.
Improper operation. Such as too fast feeding speed, unreasonable gap adjustment, etc., may all lead to accelerated wear of the rollers.
3.Solutions:
Select an appropriate roller material. According to the hardness and characteristics of the crushed material, select a roller material with good wear resistance, such as high manganese steel, alloy steel, etc.
Optimize operation parameters. Reasonably control the feeding speed to avoid impact on the rollers caused by too fast feeding speed. Adjust the gap between the rollers to make it within an appropriate range to reduce the wear of the rollers.
Regularly maintain and repair the rollers. Conduct regular inspections on the rollers, detect wear conditions in time and repair or replace them. Worn rollers can be repaired by methods such as surfacing to extend their service life.
Precautions for the use of double roll crusher:
一. Equipment installation and commissioning
1.The installation foundation should be firm to ensure that the equipment will not be shaken or displaced during operation. The level and strength of the foundation should be checked before installation, and reinforcement treatment should be carried out if necessary.
2.Install the transmission device correctly to ensure that the connection of the motor, reducer and other components is firm and reliable, and the tension of the transmission belt or chain is moderate.
3.When installing the rollers, make sure the parallelism and gap between the two rollers are even. Professional tools can be used to measure and adjust to ensure the crushing effect.
4.After the installation of the equipment is completed, carry out no-load debugging. Check whether the operation of the equipment is smooth, with or without abnormal noise and vibration. At the same time, check whether the connection of each component is loose and whether the lubrication system works normally.
二. Operation specification
1.Before switching on the machine, check whether there are people or obstacles around the machine to ensure safety. At the same time, check whether the feeding and discharging ports are smooth to prevent blockage.
2.Feed the material according to the rated power and processing capacity of the equipment to avoid overload operation. Feeding should be even and continuous to prevent large materials from concentrating into the equipment to avoid damaging the rollers and transmission devices.
3.pay close attention to the running status of the equipment, pay attention to observe the readings of the ammeter and voltmeter, as well as the temperature, noise and vibration of the equipment. If any abnormality is found, stop the machine immediately for inspection.
4.When adjusting the roll gap, stop the machine first, and then use the adjusting device to adjust. Pay attention to the uniformity of the gap during the adjustment process to avoid the situation that one side is big and one side is small.
5.Regularly check the wearing parts of the equipment, such as rollers, bearings, belts, etc., and replace the parts with serious wear and tear in time. At the same time, pay attention to keep the equipment clean and prevent dust and debris from entering the inside of the equipment.
三.Maintenance
1.Carry out regular lubrication and maintenance of the equipment, select suitable lubricant or grease according to the lubrication requirements of the equipment, and replace it regularly.
2.Carry out regular inspection and maintenance of the rollers, check the wear and tear of the rollers and repair or replace them in time. At the same time, pay attention to keep the surface of the rollers clean to prevent the material from sticking to the rollers.
3.Check whether the fasteners of the equipment are loose, and tighten them in time if they are loose. At the same time, pay attention to check whether the seals of the equipment are intact to prevent dust leakage.
4.After the equipment has been out of use for a long time, it should be fully checked and debugged before it is used again to ensure the performance and safety of the equipment.
As an efficient crushing equipment, double roll crusher plays an important role in industrial production. It provides strong support for the development of various industries with its unique structure, powerful performance and wide range of applications. In the future development, with the continuous progress of science and technology, double roll crusher will continue to innovate and improve, and make greater contributions to the industrial civilisation of mankind.
