Jaw Crushers are used to reduce the size of many different types of particles into smaller ones of the desired size in many applications. This mechanical pressure is achieved by the two jaws of the crusher of which one is fixed while the other reciprocates. They are designed to exceed the primary needs of customers in the mineral processing, aggregates, and recycling industries. It consists of many parts such as an eccentric shaft, bearings, flywheels, swing jaw (pitman), fixed jaw, toggle plate, jaw dies (jaw plates), etc.
How a Jaw Crusher Works
A jaw crusher uses compressive force for breaking materials. This mechanical pressure is achieved by the two jaws die of the crusher, one of which is stationary and the other is movable. These two vertical manganese jaw dies to create a V-shape crushing chamber. The electrical motor drives transmission mechanism driven swing hanging around the shaft relative to the fixed jaw do periodic reciprocating motion, The swing jaw undergoes two types of motion: one is a swing motion toward the opposite chamber side called a stationary jaw die due to the action of a toggle plate, and the second is a vertical movement due to the rotation of the eccentric. These combined motions compress and push the material through the crushing chamber at a predetermined size.
Types of Jaw Crushers
There are several other jaw crushers like bulldog jaw crushers and force feed jaw crushers. But for reference, we’ll focus on the two most widely-used jaw crushers in the mining industry. Down below we’ll discuss how these pieces of equipment operate and what makes them different from each other.
Single-toggle jaw crushers
Single-toggle jaw crusher (also known as overhead eccentric crushers) is a modern design which is lighter, has greater throughput and is less expensive than a double toggle jaw crusher. The eccentric shaft in this design acts as the pivot as well as the actuator for the reciprocation. The toggle plate directly connects the back of the crusher to the swinging jaw. The single toggle jaw crusher has fewer bearings and shafts as compared to a double toggle jaw crusher. It operates with its eccentric shaft above it. In here, the eccentric is built into the the swing jaw plate that moves in an up and down motion as the flywheel is rotated. A single-toggle jaw crusher pivots at the bottom of the swing plate, causing the jaw to move in an arc-like direction. The material is crushed when the moving crusher compresses it against the fixed plate. It has more planes of movement of the swinging jaw (Hinge door movement plus vertical up and down movement) which leads to higher throughput. On the downside, it produces more fines, and has a higher jaw plate consumption.
These types of equipment come with heavy-duty and light versions that are built with stainless steel housings. The eccentric shaft is made of high-grade forged steel and the moving jaw comes in either cast steel or welded version. The toggle on these crushers are kept in place by a compression spring. Shims allow for small gap adjustments since they are inserted firmly into the toggle block and mainframe.
Double-toggle jaw crushers
In a double-toggle Jaw Crusher the eccentric shaft is located behind the swinging jaw. This protects the eccentric shaft and bearings from the shock loading. The moving crusher jaw is driven by the eccentric shaft that moves the front and rear toggles up and down. Each shaft revolution causes the moving crusher jaw to close at the downstroke and open up during the upstroke. Two toggle plates from either side of the pitman are respectively connected to the back of the crusher and the swing jaw. The eccentric is found right behind the swinging jaw which prevents the eccentric from getting damaged since there is no shock loading transferred to the bearings and the shaft when the material is being crushed.
As the eccentric shaft rotates, reciprocation of the pitman causes to and fro swinging door motion of the moving jaw. This creates a powerful compression in the crushing chamber. Thus a double toggle jaw crusher is more effective for crushing very strong abrasive rocks. Since there is no other plane of motion, there is lesser wear and tear of the jaw plate but also lesser throughput.
In essence, a double-toggle jaw crusher works by crushing hard materials between two huge jaw plates without the use of rotary motion like in a single-toggle jaw crusher. Another distinguishing factor between the two is that the position of the eccentric is different. The eccentric in a double-toggle jaw crusher is found behind the swinging jaw, while the eccentric on the single-toggle is
Powerups Jaw Crusher
Powerups engineers have been researching how to improve the capacity, decrease the energy consumption and jaw crusher wear parts for year, as a result, our PE compound pendulum jaw crusher is the most reliable jaw crusher as primary crushing, and it has the benefits of simple structure, easy operation and maintenance, low parts replacement cost and long lifetime. Naturally, it has been used widely in many different kinds of industries worldwide.
Powerups PE Jaw Crusher
Powerups engineers have been researching how to improve the capacity, decrease the energy consumption and jaw crusher wear parts for year, as a result, our PE compound pendulum jaw crusher is the most reliable jaw crusher as primary crushing, and it has the benefits of simple structure, easy operation and maintenance, low parts replacement cost and long lifetime. Naturally, it has been used widely in many different kinds of industries worldwide. PE series jaw crusher is with large crusher ratio and capacity, which is capable of crushing the ores up to 300MPa, such as limestone, ironstone, basalt, granite, cobble, gold mine, etc. In addition to the good quality of the jaw crusher, we strive to keep the price of our PE jaw crusher equal to the OEM used jaw crusher for sale in global market.
PE Jaw Crushers have been playing a very important role in mineral processing, aggregate processing, construction and recycling industries. The models, PE400x600 (1524) jaw crusher, PE600x900 (2436) jaw crusher, PE250x400 (10×15) small jaw crusher, PE250x1000 (1048) jaw crusher are more popular. So far, our equipments haven’t disappointed any of our global customers, and they are all working well.
Features & Benefits
√ Big granularity of feeding material
√ High capacity and large crushing ratio
√ Most effective angle of engagement
√ Big adjusting range of discharge setting
√ Simple structure, high reliability
√ Stable running with less noise
Technical Specification
Note: Technical parameters are subject to change without further notice
Powerups P-C Jaw Crusher
Powerups has been spending great efforts to decrease energy consumed in crushing leading to consideration of decreasing the weight of the pitman assembly of jaw crusher for easily crushed material. Its high performance C jaw crusher, shortened as P-C, is a modern type with optimized and developed design on structure, material selection, manufacture process and assembly, which is based on absorbing the cutting edge technology of jaw crusher worldwide and improved by our engineers. With the features of pinned and bolted, non-welded frame construction, and high-quality components. This design provides excellent fatigue strength even in toughest quarrying or mining applications.
P-C series jaw crusher is new sort of rock crusher with higher efficiency. They are the most productive and cost-efficient jaw crushers for any primary crushing application. They are able to crush all kinds of hard and abrasive rock and mineral ore. In past few years, Powerups engineers have been working to improve the wear life of jaw dies. Through material analysis and performance analysis, we have made jaw die have a longer service life. In addition, P-C series jaw crusher can be selectively equipped with automatic hydraulic control system, and it is extremely safer and easier to adjust the chamber in actual applications.
Features & Benefits
√ Modular bolted structure
√ Steep cavity design for effective crushing
√ Excellent fatigue strength
√ Outstanding performance & excellent capacity
√ Easy to transport and install
√ Safe to operate and maintain
Technical Specification
Note: Technical parameters are subject to change without further notice
Applications
Powerups Jaw Crushers are mostly used as the first stage of material reduction in systems that may use several crushers to complete the circuit, the Jaw Crusher has also been used as a second-stage crushing unit. Depending on the application requirements, Jaw Crushers can be used in stationary, wheeled portable and track-mounted locations. Powerups Jaw Crusher is well suited for a variety of applications, including rock quarries, sand and gravel, mining, construction and demolition recycling, construction aggregates, road and railway construction, metallurgy, water conservancy and chemical industry.
Mineral Processing
This crusher is used in almost all minerals and mining industries. Whether dealing with metal ore or non-metallic ore, we can offer you a solution that reduces the size, for a series of our products are available for crushing, downsizing, and beneficiation with reliable design and versatility for your application.
Aggregate Processing
Many infrastructure industries have a solid foundation, which is a variety of rock aggregates. Recognizing that the widespread use of these aggregates has prompted us to continuously create and improve our rock crushing equipment to help boost your production, reduce maintenance times and increase overall operational efficiency. Aggregates that are crushed from large stones are essential raw materials in construction, transportation, and other infrastructure construction. Therefore, the role of crushing equipment in the aggregate crushing production line is critical.
Powerups jaw crusher is commonly used throughout the industry to reduce the pieces into the required sizes and to impart fineness to the broken material with high quality and efficiency. It can make rocks, sandstones, river pebbles, and other materials into various granularity that meet the requirements of construction sand with high compressive strength, being more in line with building requirements, and characteristic of improving building quality.
Coal Processing
Our jaw crusher is widely used in coal mine operations and attractive to customers because of its uniform end granularity, lower noise, less dust, and less pollution. Under strict environmental regulations, a good deal of coal mine projects has been suspended due to large pollution, which has seriously hindered the development of mining plants, resulting in low efficiency in major mining areas.
However, we have actively responded to the call for environmental protection by using advanced technologies and new materials to manufacture this crusher to meet national environmental standards.
Recycling
The rapid development of society has led to the production of many construction wastes. The original construction waste is not treated, not only occupies the land, but also causes pollution of rivers. The application of the crusher not only solves environmental pollution but also brings a high economic benefit for investors by recycling the construction waste into valuable materials.
Operation & Maintenance
– Installation
The jaw crusher is a large crusher installed and receives no-load testing in the manufacturer’s workshop. However it is disassembled into components for transport. When receiving the product, the user shall check carefully the components with the packing list to identify and remove problems that could be caused during transport.
1. To avoid violent vibration caused in operation, this crusher shall be installed on reinforced concrete foundation. The weight of the foundation shall be roughly 8 to 10 times that of this crusher. The depth of the foundation shall be greater than that of the frozen land at local. The positions of anchor bolts for the crusher and motor as well as other dimensions can be found from the foundation drawing. Nonetheless, the foundation drawing may not be used as construction drawing. For these anchor bolts, holes shall be made in the foundation. Grouting in these holes shall be performed after anchor bolt placement. The elevation and size of the discharge chute shall be determined on site according to the discharge process.
2. After the grout hardens, tightening the nuts to anchor bolts. While doing so, measure the levelness of this crusher with a leveling gauge. Along the width of front wall of the framework, the levelness deviation shall be controlled to be less than 2mm. Framework levelness inspection is particularly important to prevent possible skewness of charge port which could cause charge from only one side and bring damage to the crusher because of uneven load.
3. When installing the motor, check the distance between it and the crusher, and whether its pulley corresponds to the crusher pulley so that all the V-belts run effectively in coordination.
4. The size of discharge port shall be adjusted according to granularity of materials and capacity of the crusher. Release the tension spring, adjust the discharge port size, and then tighten the tension spring to prevent the elbow plate detachment. For details, refer to the Component Adjustment Section.
– Lubrication
(1) To ensure normal operation and extend service life of the crusher, regular lubrication shall be performed.
(2) Grease in the bearing block shall be replaced every 3 to 6 months. Before adding grease, clean carefully raceways of roller bearing by using clean gasoline or kerosene, with the drain hole at the bottom of bearing clock open. Add grease to 50% to 70% of the bearing block capacity.
(3) Grease used for this crusher shall be selected according to altitude and climate. Generally, calcium base, sodium base, or calcium- sodium base grease may be used. And thick grease may be diluted with light oil.
(4) Between the toggle plate and toggle plate pad, it is enough to apply proper amount of grease during assembly and inspection.
(5) For reliable and quick application of grease to lubrication points, the lubrication mechanism is utilized (there are four lubrication points in this crusher, i.e. the four bearings). For lubrication time, refer to the drawing.
– Operation
Preparation before starting
Check the lubrication of main bearings in right amount, toggle plate and pitman in right position
Check and confirm all the bolts are fastened
Check the counterweight in good condition and right position
The belts are well installed, and they are in good condition.
Correct the protecting devices if there are not in good condition.
Check whether there are any materials in the crushing groove and clear it.
Check whether the gasket is installed correctly or pressed tightly.
Start the crusher
2.1. Start the machine only after making sure that the machine and transmission part can work in good condition.
2.2. This machine should start with No-Loading.
2.3. Stop the machine immediately if any uncommon fact occurs. Start the machine only after checking and correcting.
Operation
3.1. Start feeding after checking that the machine works well.
3.2. Feed the material uniformly into the machine, and avoid feeding material from one side only or feeding to overload.
3.3. Stop feeding before shutdown the machine. Shut the motor down after the crusher cavity is clear.
3.4. Stop the motor immediately if the crusher is blocked due to material clogging in the cavity
3.5. Jaw dies can be installed upside down once the lower half of jaw dies is not in good condition
3.6. Check all fixed parts before starting to use and tighten all the bolts and screws if they are loose.
– Discharge Setting
The jaw crusher discharge opening is the distance from the valley between corrugations on one jaw to the top of the mating corrugation on the other jaw. The crusher discharge opening governs the size of finished material produced by the crusher.
Measuring Discharge Opening:
Measure distance at bottom of jaws at the point of the crushing cycle when bottom of jaws are closet together.
Turn flywheel so that counter weights are parallel with movable jaw
Using a piece of lumber as a ‘’feeler gage’’ check the distance between the valley of the corrugations on one jaw to the crown of the corrugations on the other
Adjusting the discharge side opening:
Loosen nuts before making the adjustment
Loose tension if the crusher is to be adjusted for finer crusher.
Crusher must be adjusted when it’s stopped and the chamber is empty. Never close crusher discharge opening to less than minimum opening. Close crusher opening to less than recommended will reduce capacity of the crusher and cause premature failure of shaft and bearing assembly.
To compensate for wear on toggle plate, toggle seat, pitman toggle seat and jaws additional shims must be inserted to maintain the same crusher opening. The setting adjustment system is designed to compensate for jaw plate wear and to change the closed side setting of the jaw crusher. The setting adjustment system is built into the back frame end.
– Troubleshooting
1. Movable jaw does not rotate while flywheel is rotating
2. Crushing plate shakes and makes collision noise
3. Thrust plate support makes collision noise or other abnormal noise
4. Flywheel comes loose
5. Increased granularity of crushed products
6. Crushing cavity blockage, resulting in current of main motor exceeds normal operation current
7. Excessively high bearing temperature
