顎式破碎機PE60x100

鄂式破碎機-批發價格-優質貨源PE60×100

常見故障

故障介紹

顎式破碎機PE60x100顎式破碎機在運行過程中承受力矩或振動較大，常會造成傳動系統故障，常見的有：皮帶輪與軸頭部位產生間隙造成的軸頭與輪轂磨損，偏心軸受力造成的軸承位磨損等。

出現上述問題后傳統維修方法是將輪轂擴孔，補焊或刷鍍后機加工修復為主，但兩者均存在一定弊端：補焊高溫產生的熱應力無法消除，易造成材質損傷，導致部件出現彎曲或斷裂；而電刷鍍受涂層厚度限制，容易剝落，且以上兩種方法都是用金屬修復金屬，無法改變“硬對硬”的配合關系，在各力綜合作用下，仍會造成再次磨損。

上述維修方法在西方國家已不常見，當代歐美等發達國家針對以上問題多使用高分子復合材料的修復方法，應用的是美國福世藍技術，其具有的粘著力，優異的抗壓強度等綜合性能，可免拆卸、免機加工進行現場修復。用高分子材料維修既無補焊熱應力影響，修復厚度也不受限制，同時產品所具有的金屬材料不具備的退讓性，可吸收設備的沖擊震動，避免再次磨損的可能，并大大延長設備部件的使用壽命，為企業節省大量的停機時間，創造巨大的經濟價值。

故障排除

常見到經檢修和初次安裝的錘片式粉碎機在試運轉中機身發生強烈振動。出現這種情況主要有以下幾個原因：

（1）檢修裝配中錘片安裝錯誤。錘片換面掉頭使用時，為防止轉子重量失去平衡，粉碎機內所有的錘片必須一齊換面掉頭，否則會在運行中發生強烈振動。

（2）對應兩組錘片重量之差超過5克。排除的方法是調整錘片重量，使相應兩組重量之差少于5克。

（3）個別錘片卡得太緊，運行中沒有甩開。可停機后用手轉動觀察，想辦法使錘片轉動靈活。

（4）轉子上其他零件重量不平衡，這時需要分別仔細檢查調整平衡。

（5）主軸彎曲變形。解決的辦法是校直或更換。

（6）軸承間隙超過極限或損壞。一般都采用更換新軸承才能解決問題。

維修方法

1. 顎式破碎機潤滑　　

（1） 經常注意并及時做好摩擦面得潤滑工作，可確保機器的正常運轉和延長其使用壽命。

（2） 顎式破碎機所采用潤滑脂應根據使用的地點、氣溫條件下而定，一般情況下采用鈣基、鈉基和鈣鈉基潤滑脂。

（3） 加入軸承座內的潤滑脂為其空間容積的50%左右、每3~6個月更換一次。換油時應用潔凈的汽油或煤油清洗滾柱軸承的滾道。

（4） 顎式破碎機開動前，推力板與推力板支座之間應注入適量的潤滑脂。

2. 顎式破碎機維修　　

為保證顎式破碎機的正常工作，除正確操作外，必須進行計劃性維修，其中包括日常維護檢查，小修、中修和大修。

（1） 小修主要內容包括檢查并修復調整裝置，調整排料口間隙，對磨損的襯板調頭或更換。檢查傳動部分、潤滑系統及時跟換潤滑油等。小修的周期為1~3個月左右。

（2） 中修處進行小修的工作外，還包括更換推力板、襯板、檢查并修復軸瓦等。中修的周期一般為1~2年左右。

（3） 大修 處進行中修的工作外，還包括和更換車削偏心軸和鄂心軸，澆鑄連桿頭上部的巴氏合金，更換或修復個磨損件。大修的周期一般為5年左右。

注意事項

（1） 破碎機正常運轉后，方可投料生產。

（2） 待碎物料應均勻地加入破碎機腔內，應避免側向加料或堆滿加料，以免單邊過載或承受過載。

（3） 正常工作時，軸承的溫升不應該超過30℃，溫度不得超過70℃。超過上述溫度時，應立即停車，查明原因并加以排除。

（4） 停車前，應首先停止加料，待破碎腔內物料排出后，方可關閉電源。

（5） 破碎時，如因破碎腔內物料阻塞而造成停車，應立即關閉電源停止運行，將破碎腔內物料清理干凈后，方可再行起動。

（6） 顎板一端磨損后，可調頭使用。

（7） 破碎機使用一段時間后，應將緊定襯套松動而損傷機器。

顎式破碎機PE60x100選材組裝

設計、選材

在設計時，動顎和定顎的破碎板應該齒峰對齒谷。這樣，破碎時對物料除了有擠壓作用外，還有彎曲作用，物料比較容易破碎。為了加強破碎板的使用壽命，中小型破碎機的破碎板設計成 上下對稱的形狀，當下部磨損后可調頭使用；大型顎式破碎機的破碎板設計成互相對稱的幾塊，以便磨損后可將破碎板調換使用。破碎板的材料可以選用白口鑄鐵。白口鑄鐵硬度較大、耐 磨性較好、來源容易、價格便宜；缺點是性脆、容易折斷、使用壽命短。為了提高破碎板的使用壽命，材料采用含錳12 %以上的錳鋼更好，常用的是ZGMn13。錳鋼的韌性較好，雖然硬度不高 （大約為210 HB），但是，因為具有冷加工硬化的特點，在壓力作用下會不斷被強化，故在工作中不斷磨損又不斷強化，直到磨損至不能使用才報廢。錳鋼破碎板澆鑄后要通過水韌處理，水韌 處理的操作大體上與淬火相同，即把鑄造出來的錳鋼破碎板加熱到1 000～1 100 ℃后在水中快速冷卻。水韌處理后可以得到均勻的金相組織，并使金相組織固定下來，避免了在使用中自然 發生相變而使性能變差。錳鋼的缺點是價格較貴，但從使用壽命、成本等方面總體考慮，ZGMn13 比白口鑄鐵使用壽命長、成本低。

組裝

組裝時，破碎板必須牢固地貼在鄂板上，兩者之間應該墊平，破碎板與顎板之間要用軟金屬（如鉛、鋅等） 作墊片，并用螺栓緊固。破碎機工作時，破碎板不應有松動現象，否則容易折斷或 磨損破碎板，降低破碎板的使用壽命。所以，組裝時一定要安裝好破碎板，從而延長破碎板的使用壽命。

使用過程中改進以加強破碎板的壽命 在生產過程中，破碎板與物料直接作用,破碎力很大，特別是破碎硬度較大的物料時，導致安裝破碎板的螺栓振動，螺母松動，使破碎板磨損加劇并產 生極大的噪音，嚴重時破碎板脫落或折斷使設備停機，影響正常生產。遇到這種情況，只是開機前擰緊螺栓、螺母是不能解決問題的，要根據現場的實際情況具體問題具體分析，想辦法 采取切實可行的方法解決問題。例如，可以采用彈簧防松減振裝置解決破碎板在工作中的松動，從而延長破碎板的使用壽命，提高工作效率。具體做法是利用彈簧做成螺栓防松動及自緊裝 置，該裝置由內彈簧壓蓋、彈簧、外彈簧壓蓋組成，把這個裝置穿在螺栓上擰緊螺母，由于彈簧被螺母壓緊到一定程度后，產生很強的防振效果，由巨大的破碎力產生的螺栓松動力被彈簧張 緊力自動彌補，故螺栓不致于松動，從而延長破碎板的使用壽命，提高生產效率。總之，在使用過程中可以針對具體情況想辦法解決具體問題，防止破碎板松動、磨損加劇、折斷等情況，從而 延長破碎板的使用壽命，降低成本，提高工作效率。

結論

加強顎式破碎板使用壽命從設計選材、組裝、使用過程中的改進等方面著手，能很好地加強顎破破碎板使用壽命，從而提高顎式破碎機的生產效率，降低生產成本。

Jaw Crusher - Wholesale Price - High-Quality PE60x100

Common Faults

Fault ntroduction

During operation, jaw crushers are subjected to significant torque or vibration, which often leads to transmission system failures. Common issues include: wear between the shaft head and hub caused by clear between the pulley and shaft head, and wear on the bearing position caused by forces acting on the eccentric shaft.

After such problems occur, traditional repair methods primarily involve enlarging he hub hole, followed by machining restoration after welding or brush plating. However, both methods have inherent drawbacks: the thermal stress generated by welding at high temperatures cannot be completely eliminated, easily causerial damage and leading to component bending or fracture; while brush plating is limited by coating thickness and is prone to peeling. Furthermore, both methods involve repairing metal with me, failing to change the "hard-on-hard" mating relationship. Under the combined action of various forces, re-wear will still occur.

The above repair methods are no longer common in Westen countries. Developed countries in Europe and America now mostly use high-performance polymer composite materials to address these issues. The most mature application is the American Fushiluan technology, which featuresior adhesion and excellent compressive strength. It allows for on-site repair without disassembly or machining. Repairing with polymer materials eliminates the influence of welding thermal stress and is not limitir thickness. Additionally, the material's resilience, which metal lacks, can absorb impact vibrations from the equipment, avoiding the possibility of re-wear and significantly extending the service life ofonents. This saves enterprises substantial downtime and creates significant economic value.

Troubleshooting

It is common to observe severe vibration of the machine body during trial operation of hammer crushers after maintenancinstallation. This situation is mainly caused by the following reasons:

(1) Incorrect installation of hammer blades during maintenance assembly. When reversing the hammer blades for use, all blades insidecrusher must be reversed together to prevent rotor imbalance; otherwise, severe vibration will occur during operation.

(2) The weight difference between corresponding pairs of hammer blades exceeds 5 grams.  solution is to adjust the weights of the hammer blades so that the difference between corresponding pairs is less than 5 grams.

(3) Individual hammer blades are jammed too tightly and swing freely during operation. The machine can be stopped and manually rotated to observe the issue, and measures should be taken to ensure the hammer blades move freely.

(4) Weight imbala other parts on the rotor. In this case, the balance needs to be checked and adjusted separately.

(5) Bending or deformation of the main shaft. The solution iso straighten or replace the shaft.

(6) Bearing clearance exceeds limits or the bearing is damaged. Generally, replacing the bearing with a new one is required to solve

Maintenance Methods

1. Jaw Crusher Lubrication

(1) Pay constant attention to and ensure timely lu of friction surfaces to guarantee the normal operation of the machine and extend its service life.

(2) The grease used for the jaw crusher should be selected based on the location and temperatures; generally, calcium-based, sodium-based, and calcium-sodium-based greases are used.

(3) The grease added to the bearing housing should occupy abouof the space volume, and it should be replaced every 3 to 6 months. When changing the oil, clean the raceways of the roller bearings with clean gasoline o kerosene.

(4) Before starting the jaw crusher, an appropriate amount of grease should be injected between the thrust plate and the thrust plate support.

2. Jaw Crusher Maintenance

To ensural operation of the jaw crusher, in addition to correct operation, planned maintenance must be carried out, which includes daily maintenance checks, minor repairs, medium repairs, and majo repairs.

(1) The main content of minor repairs includes checking and repairing the adjusting device, adjusting the discharge opening clearance, turning or replacing worn liners. It also includes checking the transmission part lubrication system, and timely replacing lubricating oil. The cycle for minor repairs is approximately 1 to 3 months.

(2) In addition to the work of minor repdium repairs also include replacing thrust plates and liners, and checking and repairing bearing shells. The cycle for medium repairs is generally about 1 to 2 years.

(3) Ma repairs, in addition to the work of medium repairs, also include turning eccentric shafts and toggle shafts, casting Babbitt metal on the upper part of the connecting rod head, areplacing or repairing worn parts. The cycle for major repairs is generally about 5 years.

Precautions

(1) Feeding for production should only commence after the crusher is runng normally.

(2) Material to be crushed should be added uniformly into the crushing chamber; avoid lateral feeding or overfilling to prevent unilateral overload or excessive load.

(3) Dal operation, the temperature rise of the bearings should not exceed 30°C, and the maximum temperature should not exceed 70°C. If the temperature exceeds these limi the machine immediately, identify the cause, and eliminate the problem.

(4) Before stopping, stop feeding first; wait until all material in the crushing chamber is completely discharged before turff the power.

(5) During crushing, if the machine stops due to material blockage in the crushing chamber, immediately turn off the power to stop operation, clear the materthe crushing chamber, and then restart.

(6) After one end of the jaw plate wears out, it can be turned around for continued use.

(7) After using therusher for a period of time, loosen the locking sleeve to prevent damage to the machine.

Material Selection and Assembly

Design and Material Selection

In the design, the crushing plates of the movable jaw and fixed jaw should arranged so that the peaks of the teeth align with the valleys of the teeth. This way, during crushing, the material is subjected not only to compressive forces but also to benrces, making it easier to break. To extend the service life of the crushing plates, those in medium and small crushers are designed in an up-down symmetrical shape so that they canreversed for use after the lower part wears out; the crushing plates in large jaw crushers are designed as several mutually symmetrical pieces so that they can be interchanged after wear. The rial for the crushing plates can be selected as white cast iron. White cast iron has high hardness, good wear resistance, is readily available, and is inexpensive; however, its disadvantages are brittleness, susceptibility to breakage, and a short service life. To improve the service life of the crushing plates, materials with manganese steel containing more than 12% me are better, with ZGMn13 being the most commonly used. Manganese steel has good toughness; although its hardness is not high (approximately 210 HB), ossesses the characteristic of work hardening, meaning it is continuously strengthened under pressure. Therefore, during operation, it undergoes continuous wear and continuous strengthening until it is worn to the pof being unusable. After casting, manganese steel crushing plates must undergo water toughness treatment. The operation of water toughness treatment is largely similar to quenching, which involves heating the cast maneel crushing plates to 1000–1100 °C and then rapidly cooling them in water. Water toughness treatment results in a uniform microstructure and fixes the mirostructure, preventing natural phase transformations during use that would degrade performance. The disadvantage of manganese steel is its higher cost, but considering service life and cost comprehensivelyZGMn13 has a longer service life and lower cost than white cast iron.

Assembly

During assembly, the crushing plate must be firmly attached to the jaw plate, with a flat surface betwee two. A soft metal (such as lead or zinc) should be used as a gasket between the crushing plate and the jaw plate, and they should be secured with bolts. When thrusher is in operation, the crushing plate must not be loose; otherwise, it is prone to breakage or excessive wear, shortening its service life. Therefore, it is essential tothe crushing plate properly during assembly to extend its service life.

Improvements during use to enhance the service life of the crushing plate

During the production process, the crushing plate interacts dtly with the material under high crushing forces. Especially when crushing hard materials, this causes vibration of the bolts securing the crushing plate and loosening of the nuts, leading to accelerated wear and signiicant noise. In severe cases, the crushing plate may fall off or break, causing equipment downtime and affecting normal production. In such situations, simply tightening the bolts and nuts before starting the mat completely solve the problem. Instead, specific problems must be analyzed based on the actual site conditions, and feasible methods must be adopted to resolve them. For example, a spriti-loosening and vibration-damping device can be used to prevent the crushing plate from loosening during operation, thereby extending its service life and improving work efficiency. Specifically, a spring-bed anti-loosening and self-tightening device can be utilized, consisting of an inner spring cover, a spring, and an outer spring cover. This device is mounted on the bolt and the nut is tightened. Once the spring is compressed to a certain degree by the nut, it produces a strong vibration-damping effect. The loosening force generated by the huge cring force is automatically compensated by the spring tension, preventing the bolt from loosening. This extends the service life of the crushing plate and improves production efficiency. In conclusion, during use, spec methods can be devised to address specific problems, preventing issues such as loosening, accelerated wear, and breakage of the crushing plate, thereby extending its service life, reducing costs, aproving work efficiency.

Conclusion

By focusing on design and material selection, assembly, and improvements during use, the service life of the jaw crusher crushing plate can be significantly enhanced. This e production efficiency of the jaw crusher and reduces production costs.