Sharp tools make good work。 If you want to know the cause of the trouble, you have to know the working principle of the machine. First of all, we will understand the working principle of HP200 cone crusher:

工作原理

1. working principle

The HP200 cone crusher is used for ore crushing and processing, and its main structure is shown in figure 1. The machine starts, the main motor, the horizontal axis and small gear (pinion) clockwise, gear (gear) in small gear driven counterclockwise. When there is no load ore, idling, moving cone liner with movable cone with counterclockwise rotation; when the load ore production, the moving cone rotation direction change immediately for clockwise rotation, clockwise rotation with the moving cone cone liner.

2. fault phenomenon

1 HP200 cone crusher, its standard configuration is 132kW motor (rated current is 260A), the actual configuration is 160kW motor. The machine starts in July 10, 2014, found that knock a cyclical impact sound from within, the rule is the moving cone every 1 turn, sent 1 crash occurred 1 times, the current cyclical fluctuations. The machine was broken and examined, and the big gear was broken by 1 teeth, as shown in figure 2. The broken tooth has fallen into the oil pool under the big and small gear.

3. troubleshooting and cause analysis

(1) overload phenomenon exists

The equipment management engineers carefully check the machine operation record and motor current records, found in the normal production process, there have been large peak current of 1 344A, is 1.32 times the motor rated current is 260A, this is a time of big gear tooth. This shows that the machine had serious overload phenomenon.

(2) frequent alternating load

Once again carefully look at the machine running records and motor current records, found that the machine has repeatedly started, repeated stop phenomenon. Within each class of 8h, most of them were started and closed 6 times, and there were 10 times of no ore inversion and no load idling. The machine ore supply is not stable, i.e. the machine running ore from time to time, less time, the motor is transferred, while not a cone, a reversal, causing the machine under alternating load frequent.

(3) improper adjustment of ore discharge port

When the machine is in normal production, the movable cone liner and the fixed cone liner will cause severe wear and tear, and the ore discharge port will increase with the wear. In order to ensure the crushing size, operators need to regularly adjust the ore discharge port. If the outlet size of the ore is adjusted too small, it will cause the cone liner and the fixed cone liner to collide directly, causing the load of the machine to soar, and cause the big and small gear to impact violently.

The wear cycle of the motor cone lining plate and the fixed cone lining plate is 25 to 30 days. When the fault occurs, the movable cone liner and the fixed cone lining plate have been used for 22 days, and the operator has repeatedly adjusted the ore discharge port more than 5 times. We can deduce that there are adjustments for ore discharge caused by improper moving cone liner and fixed cone liner may lead to unexpected collision, accident and overload load surge.

(4) the big gear is approaching the fatigue limit

The HP200 cone crusher was put into production in 2007 and has been running continuously for 7 years. The big gear has not been replaced, so it is concluded that the big and small gears are approaching the mechanical fatigue limit.

4. preventive measures

In order to prevent the machine from affecting the production of gear broken teeth, we take the following 4 preventive measures:

The first is to improve the ore supply conditions, to ensure uniform, continuous, stable supply of ore.;

The two is to adjust the size of the ore outlet correctly, to prevent the adjustment of too small, causing dynamic cone liner and fixed cone lining plate directly collided with overload;

Three is to install metal detectors and electromagnets on the ore belt conveyor, to ensure clean and thorough iron removal;

Four is to replace the big gear, but also need to reserve 1 small gear, to prevent the small gear to the fatigue limit and fault again. After the above preventive measures were taken and repaired, the operation of the machine returned to normal.

Fig. large gear of 2:HP200 crusher

From this incident, we can see that the cause of the failure, one is because of improper operation, another reason is usually not take on the machine, no maintenance measures, so that the parts reach life limit is still not knowing. Therefore, in the construction machinery industry, maintenance is commonplace, do not be afraid of trouble, do not be afraid of waste of money.