In mining, construction materials production and many other industrial fields, jaw crusher as a key crushing equipment, its production efficiency directly affects the cost and efficiency of the entire production process. How to improve the production efficiency of jaw crusher has become a key issue for many enterprises. In this paper, we will discuss the effective methods to improve the production efficiency of jaw crusher from the optimisation of the equipment itself, the improvement of the operation process and the reasonable control of the material characteristics.
一.Optimisation of equipment selection and installation
1.Reasonable selection
Jaw crusher has a variety of models and specifications, its processing capacity, feed size, discharge size and other parameters are different. Enterprises must fully consider their own production needs and the nature of the material when selecting the type. For example, if the material hardness is large, you should choose the model with strong crushing force and good abrasion resistance; if the processing capacity is required to be higher, you need to choose the equipment with matching production capacity. Blindly choosing too small or too large equipment will lead to low productivity. Too small equipment can not meet the output demand, while too large equipment in the processing capacity is not enough, not only will cause energy waste, but also may affect the service life of parts due to equipment idling.
2.Correct installation
The installation quality of the jaw crusher has a crucial impact on its operational stability and productivity. In the installation process, first of all, make sure that the foundation of the equipment is firm and level, so as to avoid excessive vibration or even equipment displacement in the operation process. All parts of the crusher should be installed accurately according to the installation instructions, especially the gap between the moving jaw and the fixed jaw should be adjusted accurately, the gap is too big or too small will affect the crushing effect and productivity. In addition, the installation of transmission components such as pulleys, couplings, etc. should ensure concentricity, reduce the energy loss in the transmission process, to ensure that the equipment can run smoothly and efficiently.
二.The routine maintenance and repair of equipment
1.lubrication system maintenance
Lubrication is an important link to ensure the normal operation of jaw crusher, prolong the service life of the equipment and improve the production efficiency. Each moving part of the crusher, such as eccentric shaft, moving jaw shaft, etc., need good lubrication. Regularly check the lubrication system to ensure that the oil quality and oil quantity of the lubricant meet the requirements. According to the use environment and operation time of the equipment, choose the type of lubricant reasonably and replace it according to the specified time interval. In high temperature, high dust and other harsh environments, it is more important to strengthen the maintenance of the lubrication system to prevent poor lubrication leading to increased wear and tear of components, which in turn affects the productivity of the equipment.
2.Replacement of wearing parts
During the working process of jaw crusher, some parts such as jaw plate and liner plate are easy to be impacted and worn by materials. Timely replacement of these wearing parts is the key to ensure the continuous and efficient operation of the equipment. Enterprises should establish a wear parts inventory management system, according to the use of equipment and wear parts life, reserve enough wear parts in advance. When the wearing parts wear to a certain degree, they should be replaced immediately to avoid the use of badly worn parts which may lead to the deterioration of crushing effect, the reduction of production efficiency, or even the equipment failure. For example, after the wear of jaw plate, the shape and size of its crushing teeth change, which will affect the crushing ability of the material, then timely replacement of jaw plate can restore the normal crushing effect of the equipment and improve the production efficiency.
3.Equipment cleaning and inspection
Regularly clean the jaw crusher, remove the dust and material accumulation on the surface and inside of the equipment, which can help the heat dissipation of the equipment and ensure the normal operating temperature of the equipment. At the same time, the cleaning process can also be a comprehensive inspection of the equipment to see whether the components are loose, wear and tear, cracks and other abnormalities. Problems are found to be handled in a timely manner to avoid small problems from developing into big failures and affecting production efficiency. For example, checking the bolt is loose, timely tightening can prevent the displacement of parts due to loose bolts, which in turn affects the stability of the operation of the equipment and production efficiency.
三.The optimisation of the operating process
1.Feeding control
Feeding uniformity is one of the important factors affecting the production efficiency of jaw crusher. In the process of feeding, it should be ensured that the material enters the crusher continuously and evenly to avoid the situation of over or under feeding. Too much feeding will lead to overloading of the equipment, causing equipment shutdown or damage; too little feeding will make the equipment idle and reduce the production efficiency. You can install an automatic feeding device to automatically adjust the feeding amount according to the operating status of the crusher to ensure the stability of feeding. In addition, the particle size distribution of the material should be in line with the feeding requirements of the equipment, so as to avoid too large size of the material into the crusher, resulting in equipment blockage or damage. For materials with large particle size, pre-screening or coarse crushing equipment can be set up before the crusher to carry out preliminary processing of materials and improve the feed quality of the crusher.
2.Discharge adjustment
The size of discharge size directly affects the production efficiency and product quality of jaw crusher. According to the production demand, adjust the size of discharge opening reasonably. If the discharge opening is too big, although the production efficiency will be improved, the product size will be coarser and may not be able to meet the requirements of the subsequent process; if the discharge opening is too small, the product size will be finer, but it will lead to a decrease in the processing capacity of the equipment and a decrease in the production efficiency. When adjusting the discharge opening, we should consider the nature of the material, product size requirements and the operating conditions of the equipment and other factors, through the test and actual production experience, to find the best size of the discharge opening. At the same time, we should pay attention to the smoothness of the discharging system, and clean the blocked materials at the discharge opening in time to ensure the smooth discharge of materials.
3.Adjustment of equipment operating parameters
Jaw crusher eccentric shaft speed, moving jaw stroke and other operating parameters also have an important impact on production efficiency. Within the permissible range of the equipment, appropriately increasing the eccentric shaft speed can increase the number of crushing times per unit of time, thus improving the production efficiency. However, too high rotational speed will also lead to increased wear and tear of the equipment, increased energy consumption, and may even cause equipment failure. Therefore, it is necessary to determine the best eccentric shaft rotational speed through test and theoretical calculation. Similarly, reasonable adjustment of the moving jaw stroke can also improve the production efficiency of the equipment under the premise of ensuring the crushing effect. For example, for the materials with large hardness, the moving jaw stroke can be increased appropriately to improve the crushing force, enhance the crushing effect, and then improve the production efficiency.
四.The rational use of material characteristics
1.Material hardness and humidity
Materials with different hardness and humidity have different effects on the production efficiency of jaw crusher. For materials with higher hardness, the crusher needs to consume more energy for crushing, and the production efficiency is relatively low. In this case, multi-stage crushing can be used, first through the coarse crushing equipment for preliminary crushing of materials to reduce the hardness and particle size of materials, and then into the jaw crusher for further crushing, which can improve the production efficiency of the jaw crusher. For materials with large humidity, it is easy to form bonding in the crusher, which affects the conveying and crushing effect of materials. At this time, you can take the way of pre-drying or adding screening equipment to remove the moisture in the material or separate the part with too much humidity to avoid the material clogging in the crusher and ensure the normal operation and production efficiency of the equipment.
2.Material size composition
The particle size composition of the material also plays an important role in the production efficiency of the jaw crusher. If the content of fine grain level in the material is too high, it will form a buffer layer in the crusher and reduce the crushing effect and production efficiency. Therefore, before feeding, the material should be screened to remove excessive fine-grained material. On the contrary, if the coarse-grained content of the material is too high, which is beyond the range of feed size of the crusher, it will lead to clogging and damage of the equipment, and also affect the production efficiency. Therefore, according to the feeding requirements of the crusher, the particle size composition of the material should be reasonably adjusted, so that the particle size distribution of the material entering the crusher is more reasonable and the production efficiency of the equipment is improved.
To sum up, improving the production efficiency of jaw crusher is a comprehensive work, which needs to start from equipment selection and installation, daily maintenance, operation process optimisation, reasonable use of material characteristics and other aspects. By taking effective measures, constantly improving and perfecting all aspects of the production process, we can give full play to the performance advantages of the jaw crusher and improve the production efficiency.
