鄂式破碎機(jī)批發(fā)價(jià)格優(yōu)質(zhì)貨源PE60×100

常見故障

故障介紹

顎式破碎機(jī)在運(yùn)行過程中承受力矩或振動(dòng)較大，常會(huì)造成傳動(dòng)系統(tǒng)故障，常見的有：皮帶輪與軸頭部位產(chǎn)生間隙造成的軸頭與輪轂?zāi)p，偏心軸受力造成的軸承位磨損等。

出現(xiàn)上述問題后傳統(tǒng)維修方法是將輪轂擴(kuò)孔，補(bǔ)焊或刷鍍后機(jī)加工修復(fù)為主，但兩者均存在一定弊端：補(bǔ)焊高溫產(chǎn)生的熱應(yīng)力無法完全消除，易造成材質(zhì)損傷，導(dǎo)致部件出現(xiàn)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(fù)金屬，無法改變“硬對(duì)硬”的配合關(guān)系，在各力綜合作用下，仍會(huì)造成再次磨損。

上述維修方法在西方國(guó)家已不常見，當(dāng)代歐美等發(fā)達(dá)國(guó)家針對(duì)以上問題多使用高分子復(fù)合材料的修復(fù)方法，應(yīng)用很成熟的是美國(guó)福世藍(lán)技術(shù)，其具有超強(qiáng)的粘著力，優(yōu)異的抗壓強(qiáng)度等綜合性能，可免拆卸、免機(jī)加工進(jìn)行現(xiàn)場(chǎng)修復(fù)。用高分子材料維修既無補(bǔ)焊熱應(yīng)力影響，修復(fù)厚度也不受限制，同時(shí)產(chǎn)品所具有的金屬材料不具備的退讓性，可吸收設(shè)備的沖擊震動(dòng)，避免再次磨損的可能，并大大延長(zhǎng)設(shè)備部件的使用壽命，為企業(yè)節(jié)省大量的停機(jī)時(shí)間，創(chuàng)造巨大的經(jīng)濟(jì)價(jià)值。

故障排除

常見到經(jīng)檢修和初次安裝的錘片式粉碎機(jī)在試運(yùn)轉(zhuǎn)中機(jī)身發(fā)生強(qiáng)烈振動(dòng)。出現(xiàn)這種情況主要有以下幾個(gè)原因：

（1）檢修裝配中錘片安裝錯(cuò)誤。錘片換面掉頭使用時(shí)，為防止轉(zhuǎn)子重量失去平衡，粉碎機(jī)內(nèi)所有的錘片必須一齊換面掉頭，否則會(huì)在運(yùn)行中發(fā)生強(qiáng)烈振動(dòng)。

（2）對(duì)應(yīng)兩組錘片重量之差超過5克。排除的方法是調(diào)整錘片重量，使相應(yīng)兩組重量之差少于5克。

（3）個(gè)別錘片卡得太緊，運(yùn)行中沒有甩開。可停機(jī)后用手轉(zhuǎn)動(dòng)觀察，想辦法使錘片轉(zhuǎn)動(dòng)靈活。

（4）轉(zhuǎn)子上其他零件重量不平衡，這時(shí)需要分別仔細(xì)檢查調(diào)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(jī)潤(rùn)滑　　

（1）經(jīng)常注意并及時(shí)做好摩擦面得潤(rùn)滑工作，可確保機(jī)器的正常運(yùn)轉(zhuǎn)和延長(zhǎng)其使用壽命。

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

（3）加入軸承座內(nèi)的潤(rùn)滑脂為其空間容積的50%左右、每3~6個(gè)月更換一次。換油時(shí)應(yīng)用潔凈的汽油或油清洗滾柱軸承的滾道。

（4）顎式破碎機(jī)開動(dòng)前，推力板與推力板支座之間應(yīng)注入適量的潤(rùn)滑脂。

2. 顎式破碎機(jī)維修　　

為保證顎式破碎機(jī)的正常工作，除正確操作外，必須進(jìn)行計(jì)劃性維修，其中包括日常維護(hù)檢查，小修、中修和大修。

（1）小修主要內(nèi)容包括檢查并修復(fù)調(diào)整裝置，調(diào)整排料口間隙，對(duì)磨損的襯板調(diào)頭或更換。檢查傳動(dòng)部分、潤(rùn)滑系統(tǒng)及時(shí)跟換潤(rùn)滑油等。小修的周期為1~3個(gè)月左右。

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

（3） 大修處進(jìn)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(fù)個(gè)磨損件。大修的周期一般為5年左右。

注意事項(xiàng)

（1）破碎機(jī)正常運(yùn)轉(zhuǎn)后，方可投料生產(chǎn)。

（2）待碎物料應(yīng)均勻地加入破碎機(jī)腔內(nèi)，應(yīng)避免側(cè)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(shí)，軸承的溫升不應(yīng)該超過30℃，很高溫度不得超過70℃。超過上述溫度時(shí)，應(yīng)立即停車，查明原因并加以排除。

（4）停車前，應(yīng)先先停止加料，待破碎腔內(nèi)物料完全排出后，方可關(guān)閉電源。

（5）破碎時(shí)，如因破碎腔內(nèi)物料阻塞而造成停車，應(yīng)立即關(guān)閉電源停止運(yùn)行，將破碎腔內(nèi)物料清理干凈后，方可再行起動(dòng)。

（6）顎板一端磨損后，可調(diào)頭使用。

（7）破碎機(jī)使用一段時(shí)間后，應(yīng)將緊定襯套松動(dòng)而損傷機(jī)器。

選材組裝

設(shè)計(jì)、選材

在設(shè)計(jì)時(shí)，動(dòng)顎和定顎的破碎板應(yīng)該齒峰對(duì)齒谷。這樣，破碎時(shí)對(duì)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(qiáng)破碎板的使用壽命，中小型破碎機(jī)的破碎板設(shè)計(jì)成上下對(duì)稱的形狀，當(dāng)下部磨損后可調(diào)頭使用；大型顎式破碎機(jī)的破碎板設(shè)計(jì)成互相對(duì)稱的幾塊，以便磨損后可將破碎板調(diào)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(jià)格便宜；缺點(diǎn)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210HB），但是，因?yàn)榫哂欣浼庸び不奶攸c(diǎn)，在壓力作用下會(huì)不斷被強(qiáng)化，故在工作中不斷磨損又不斷強(qiáng)化，直到磨損至不能使用才報(bào)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1 000～1100 ℃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(fā)生相變而使性能變差。錳鋼的缺點(diǎn)是價(jià)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(zhǎng)、成本低。

組裝

組裝時(shí)，破碎板必須牢固地貼在鄂板上，兩者之間應(yīng)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(jī)工作時(shí)，破碎板不應(yīng)有松動(dòng)現(xiàn)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(shí)一定要安裝好破碎板，從而延長(zhǎng)破碎板的使用壽命。

使用過程中改進(jìn)以加強(qiáng)破碎板的壽命 在生產(chǎn)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(shí)，導(dǎo)致安裝破碎板的螺栓振動(dòng)，螺母松動(dòng)，使破碎板磨損加劇并產(chǎn)生極大的噪音，嚴(yán)重時(shí)破碎板脫落或折斷使設(shè)備停機(jī)，影響正常生產(chǎn)。遇到這種情況，只是開機(jī)前擰緊螺栓、螺母是不能徹底解決問題的，要根據(jù)現(xiàn)場(chǎng)的實(shí)際情況具體問題具體分析，想辦法采取切實(shí)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(dòng)，從而延長(zhǎng)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(dòng)及自緊裝置，該裝置由內(nèi)彈簧壓蓋、彈簧、外彈簧壓蓋組成，把這個(gè)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(chǎn)生很強(qiáng)的防振效果，由巨大的破碎力產(chǎn)生的螺栓松動(dòng)力被彈簧張緊力自動(dòng)彌補(bǔ)，故螺栓不致于松動(dòng)，從而延長(zhǎng)破碎板的使用壽命，提高生產(chǎn)效率。在使用過程中可以針對(duì)具體情況想辦法解決具體問題，防止破碎板松動(dòng)、磨損加劇、折斷等情況，從而延長(zhǎng)破碎板的使用壽命，降低成本，提高工作效率。

結(jié)論

加強(qiáng)顎式破碎板使用壽命從設(shè)計(jì)選材、組裝、使用過程中的改進(jìn)等方面著手，能很好地加強(qiáng)顎破破碎板使用壽命，從而提高顎式破碎機(jī)的生產(chǎn)效率，降低生產(chǎn)成本。

Jaw Cer - Wholesale Price - High-QualityPE60x100

Common Faults

Fault ntroduction

During operation, jaw cers are subjected tosignificant torque or vibration, which often leads to transmissionsystem failures. Common issues include: wear between the shaft headand hub caused by clear between the pulley and shaft head, and wearon the bearing position caused by forces acting on the eccentricshaft.

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

The above repair methods are no longer commonin Westen countries. Developed countries in Europe and America nowmostly use high-performance polymer composite materials to addressthese issues. The most mature application is the American Fushiluantechnology, which featuresior adhesion and excellent compressivestrength. It allows for on-site repair without disassembly ormachining. Repairing with polymer materials eliminates theinfluence of welding thermal stress and is not limitir thickness.Additionally, the material's resilience, which metal lacks, canabsorb impact vibrations from the e, avoiding thepossibility of re-wear and significantly extending the service lifeofonents. This saves enterprises substantial downtime and createssignificant economic value.

Troubleshooting

It is common to observe severe vibration ofthe machine body during trial operation of hammer cers aftermaintenancinstallation. This situation is mainly caused by thefollowing reasons:

(1) Incorrect installation of hammer bladesduring maintenance assembly. When reversing the hammer blades foruse, all blades insidecer must be reversed together to preventrotor imbalance; otherwise, severe vibration will occur duringoperation.

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

(3) Individual hammer blades are jammed tootightly and swing freely during operation. The machine can bestopped and manually rotated to observe the issue, and measuresshould be taken to ensure the hammer blades movefreely.

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

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

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

Maintenance Methods

1. Jaw Cer Lubrication

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

(2) The grease used for the jaw cer should beselected based on the location and temperatures; generally,calcium-based, sodium-based, and calcium-sodium-based greases areused.

(3) The grease added to the bearing housingshould occupy abouof the space volume, and it should be replacedevery 3 to 6 months. When changing the oil, clean the raceways ofthe roller bearings with clean gasoline okerosene.

(4) Before starting the jaw cer, anappropriate amount of grease should be injected between the thrustplate and the thrust plate support.

2. Jaw Cer Maintenance

To ensural operation of the jaw cer, inaddition to correct operation, planned maintenance must be carriedout, which includes daily maintenance checks, minor repairs, mediumrepairs, and majo repairs.

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

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

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

Precautions

(1) Feeding for production should onlycommence after the cer is runng normally.

(2) Material to be ced should be addeduniformly into the cing chamber; avoid lateral feeding oroverfilling to prevent unilateral overload or excessiveload.

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

(4) Before stopping, stop feeding first; waituntil all material in the cing chamber is completely dischargedbefore turff the power.

(5) During cing, if the machine stops due tomaterial blockage in the cing chamber, immediately turn off thepower to stop operation, clear the materthe cing chamber, and thenrestart.

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

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

Material Selection andAssembly

Design and MaterialSelection

In the design, the cing plates of the movablejaw and fixed jaw should arranged so that the peaks of the teethalign with the valleys of the teeth. This way, during cing, thematerial is subjected not only to compressive forces but also tobenrces, making it easier to break. To extend the service life ofthe cing plates, those in medium and small cers are designed in anup-down symmetrical shape so that they canreversed for use afterthe lower part wears out; the cing plates in large jaw cers aredesigned as several mutually symmetrical pieces so that they can beinterchanged after wear. The rial for the cing plates can beselected 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 tobreakage, and a short service life. To improve the service life ofthe cing plates, materials with manganese steel containing morethan 12% me are better, with ZGMn13 being the most commonly used.Manganese steel has good toughness; although its hardness is nothigh (approximately 210 HB), ossesses the characteristic of workhardening, meaning it is continuously strengthened under pressure.Therefore, during operation, it undergoes continuous wear andcontinuous strengthening until it is worn to the pof beingunusable. After casting, manganese steel cing plates must undergowater toughness treatment. The operation of water toughnesstreatment is largely similar to , which involves heatingthe cast maneel cing plates to 1000–1100 °C andthen rapidly cooling them in water. Water toughness treatmentresults in a uniform microstructure and fixes the mirostructure,preventing natural phase transformations during use that woulddegrade performance. The disadvantage of manganese steel is itshigher cost, but considering service life and costcomprehensivelyZGMn13 has a longer service life and lower cost thanwhite cast iron.

Assembly

During assembly, the cing plate must befirmly attached to the jaw plate, with a flat surface betwee two. Asoft metal (such as lead or zinc) should be used as a gasketbetween the cing plate and the jaw plate, and they should besecured with bolts. When ther is in operation, the cing plate mustnot be loose; otherwise, it is prone to breakage or excessive wear,shortening its service life. Therefore, it is essential tothe cingplate properly during assembly to extend its servicelife.

Improvements during use to enhance theservice life of the cing plate

During the production process, the cing plateinteracts dtly with the material under high cing forces. Especiallywhen cing hard materials, this causes vibration of the boltssecuring the cing plate and loosening of the nuts, leading toaccelerated wear and signiicant noise. In severe cases, the cingplate may fall off or break, causing e downtime andaffecting normal production. In such situations, simply tighteningthe bolts and nuts before starting the mat completely solve theproblem. Instead, specific problems must be analyzed based on theactual site conditions, and feasible methods must be adopted toresolve them. For example, a spriti-loosening and vibration-dampingdevice can be used to prevent the cing plate from loosening duringoperation, thereby extending its service life and improving workefficiency. Specifically, a spring-bed anti-loosening andself-tightening device can be utilized, consisting of an innerspring cover, a spring, and an outer spring cover. This device ismounted on the bolt and the nut is tightened. Once the spring iscompressed to a certain degree by the nut, it produces a strongvibration-damping effect. The loosening force generated by the hugecring force is automatically compensated by the spring tension,preventing the bolt from loosening. This extends the service lifeof the cing plate and improves production efficiency. Inconclusion, during use, spec methods can be devised to addressspecific problems, preventing issues such as loosening, acceleratedwear, and breakage of the cing plate, thereby extending its servicelife, reducing costs, aproving work efficiency.

Conclusion

By focusing on design and material selection,assembly, and improvements during use, the service life of the jawcer cing plate can be significantly enhanced. This e productionefficiency of the jaw cer and reduces productioncosts.