Double roll crusher, also known as roll crusher, is a kind of crushing equipment widely used in mining, metallurgy, chemical industry, building materials and other industries. Below is a summary of some common problems about the double roll crusher solutions and routine maintenance of the notes.
Common Problems
1.Poor crushing effect
Reason: roller surface wear, feed size is not appropriate, improper adjustment of roll spacing.
Performance: the size of the crushed material is not uniform, can not achieve the expected crushing effect.
Solution
Regularly check the wear of roll surface and replace the worn roll surface in time.
Adjust the feed size according to the requirements of the equipment to ensure that the material meets the crushing requirements.
Reasonable adjustment of roll spacing, according to the nature of the material and crushing requirements, in order to achieve the best crushing effect.
2.Noisy equipment
Reason: bearing wear, poor gear meshing, loose fasteners.
Performance: The equipment makes abnormal noise when running, affecting the working environment.
Solution
Check the bearing wear and replace the worn bearing in time.
Adjust the gear mesh clearance to ensure that the gear mesh is good.
Check whether the fasteners are loose, and tighten the loose parts in time.
3.Reduced output
Reason: feeding speed is too fast or too slow, roller surface wear, motor failure.
Performance: the crushing output per unit time is obviously reduced.
Solution
Control the feeding speed and keep even and stable feeding.
Regularly check the wear of roll surface and replace the worn roll surface in time.
Check whether the motor is running normally, and repair or replace it in time if there is any fault.
4.Equipment clogging
Reason: too much feed, high humidity of material, foreign matter inside the crushing chamber.
Manifestation: the equipment can not operate normally, and the material accumulates in the crushing chamber.
Solution
Control the amount of feed material to avoid excessive feeding.
Pre-treat the material to reduce the humidity.
Regularly clean the foreign matter inside the crushing chamber to ensure the normal operation of the equipment.
5.Failure of transmission parts
Cause: Belt slipping, broken chain, damaged coupling.
Manifestation: the equipment cannot transmit power and stops running.
Solution
Adjust the belt tension to avoid belt slippage.
Check whether the chain is broken, if so, replace it in time.
Check whether the coupling is damaged, if damaged, timely replacement.
In short, when using double roller crusher, you should regularly maintain and repair the equipment, and find and solve problems in time to ensure the normal operation and crushing effect of the equipment.
How to correctly install and debug double roll crusher？
Correct installation and commissioning of the double roller crusher is also an important part of the subsequent use to avoid problems.
一. Installation method
Foundation preparation:
Choose a suitable installation site and make sure the ground is level, solid and has sufficient bearing capacity.
According to the size and weight of the equipment, make a suitable concrete foundation and reserve holes for ground bolts.
Equipment in place:
Use crane and other lifting equipment to place the double roller crusher smoothly on the foundation, make sure the centre line of the equipment coincides with the centre line of the foundation.
Adjust the level of the equipment, which can be measured by using a levelling device, by adjusting the height of the foot bolt to achieve the level of the equipment.
Connecting components:
Install the transmission device, including motor, reducer, coupling, etc., to ensure that the connection of each component is firm and accurate.
Connect the feeding device and discharging device to ensure the smooth conveying of materials.
Installation of accessories:
Install the safety accessories such as guards and rails of the equipment to ensure the safety of the operators.
Install the electrical control system and wire it according to the electrical schematic diagram to ensure the normal operation of the equipment.
二. Debugging method
No-load commissioning:
Check whether the connection of each part of the equipment is firm, especially the ground bolts, transmission parts and so on.
Start the motor, observe the operation of the equipment, check whether the steering of the motor is correct, whether the transmission parts are running smoothly, and whether there is any abnormal noise and vibration.
Adjust the gap of the rollers to make them meet the technical requirements of the equipment. Adjustment of the roller gap can be achieved by adjusting the shim or screw mechanism.
Run no-load for a period of time, check the temperature, lubrication and other conditions of the equipment to ensure normal operation.
Load debugging:
Gradually add a small amount of material and observe the crushing effect and operation of the equipment. Check whether the crushing size of the material meets the requirement and whether the equipment is blocked or overloaded, etc. Adjust the feeding speed and lubrication according to the actual situation.
Adjust the feeding speed and roller gap according to the actual situation to achieve the best crushing effect.
Run the load for a period of time, check the various performance indexes of the equipment, such as output, energy consumption, crushing ratio, etc., to ensure that the equipment meets the production requirements.
Acceptance and delivery:
After completing the debugging, conduct a comprehensive inspection of the equipment to ensure that the various performance indicators of the equipment meet the requirements.
Organise the debugging records and related information, and submit the acceptance report to the user.
Train the operators to make them familiar with the operation methods and maintenance requirements of the equipment.
When installing and debugging the double roller crusher, it should be operated in strict accordance with the installation instructions and debugging requirements of the equipment to ensure the safe and stable operation of the equipment. If you encounter problems during installation and commissioning, you should contact the equipment manufacturer or professional technicians for help.
Daily maintenance of double roll crusher needs to pay attention to the following matters:
Equipment operation
1.Check before starting: before starting the double roller crusher, you should carefully check whether the connection of all parts of the equipment is firm, especially the bolts, nuts and other fasteners. At the same time, check whether the transmission device is normal, whether the belt is properly tensioned, whether the gear meshing is good.
2.Uniform feeding: In the process of operation, make sure that the material is fed uniformly, avoiding too much and too little. Too large a feed may lead to equipment clogging, while too small a feed will affect the efficiency and capacity of the equipment. 3.
3.Strictly prohibit overload operation: understand the rated processing capacity of the equipment, do not exceed its maximum load, so as not to cause serious damage to the equipment.
二. Maintenance of parts
1.Roll surface maintenance: check the wear of roll surface regularly. If the roll surface is seriously worn, it will affect the crushing effect. The roll surface can be repaired by surfacing welding and other methods to prolong its service life.
2.Bearing maintenance: Check the temperature and lubrication of the bearings frequently. If the bearing temperature is too high, it may be poor lubrication or serious wear. Add or replace the lubricant in time to ensure the normal operation of the bearings.
3.Gear Maintenance: Check the meshing of gears to ensure smooth gear transmission. Add gear oil regularly to prevent gear wear and damage.
三. Equipment cleaning
1.Timely cleaning: after each use, you have to timely clean up the debris and dust inside and outside the equipment. Especially the material residue in the crushing chamber, so as not to affect the next use.
2.Prevent corrosion: If the equipment is used in a humid or corrosive environment, you should take anti-corrosion measures, such as applying anti-rust paint.
四. Safety inspection
1.Electrical safety: Regularly check the insulation of the electrical system to ensure that there are no broken wires, leakage and other phenomena. At the same time, check whether the grounding of electrical equipment is good to prevent electric shock accidents.
2.Protective devices: Ensure that the protective devices of the equipment are in good condition, such as guards and guardrails. These devices can effectively prevent people from accidentally touching the dangerous parts of the equipment.
Understand the double roll crusher wearing parts to do daily maintenance
一. Crushing roll
1.Roll skin: directly contacting with materials, bearing huge friction and impact, it is the most easy to wear parts. The degree of wear of roll skin depends on the hardness, size and crushing volume of the material, etc. When the roll skin is worn to a certain degree, it will be worn out. When the roll skin is worn to a certain degree, it will affect the crushing effect and product size, and needs to be replaced in time.
2.Roller shaft: Although the strength of the roller shaft is high, it may be bent or broken during long-term operation. Especially when dealing with materials with high hardness, the roller shaft is subjected to a higher load and is easily damaged.
二. Bearing
Bearing is an important transmission part in double roller crusher, which bears all the load of the equipment. During operation, the bearing will be affected by high-speed rotation, friction, vibration and other factors, and is prone to wear, heat and damage. Regular inspection and replacement of bearings is an important measure to ensure the normal operation of the equipment.
三. Gears
1.Transmission Gear: It is responsible for transmitting the power from the motor to make the crushing roller rotate. As the gears are subjected to large torque and impact during high-speed operation, they are prone to wear and tear, broken teeth and so on. Especially when the equipment starts and stops, the gears are subjected to greater force and are more likely to be damaged.
2.Engaging gears: Engage with the transmission gears to ensure the synchronous operation of the crushing rolls. The wear of the engaging gear will affect the transmission precision and stability of the equipment, and needs to be replaced in time.
四. Seals
Seals are mainly used to prevent dust and materials from entering into the equipment and to protect bearings, gears and other key components. In the process of long-term operation, seals will be subject to friction, wear, aging and other factors, prone to sealing the situation. Once the seals are damaged, it will lead to dust and materials entering the inside of the equipment, accelerating the wear and tear of the equipment, and even affecting the normal operation of the equipment.
Understanding the wearing parts of double roller crusher, timely inspection and replacement can effectively extend the service life of the equipment and improve the productivity of the equipment.
