In mineral processing and construction aggregate production, double roll crushers are widely employed in sand-making operations due to their unique structure and working principles. However, equipment durability remains a key concern for users. Huasheng Ming Heavy Industry will systematically analyze the durability performance of double roll crushers in sand-making applications from perspectives of operational principles, critical component performance, and maintenance practices. Structural Principles and Sand-Making Process The double roll crusher consists of two counter-rotating high-strength alloy rollers, with adjustable roller gaps (typically 1-5 mm) via hydraulic or spring systems. Material undergoes compressive and grinding forces within the V-shaped crushing chamber between the rollers, forming medium and fine sand particles with cubic shapes. Key Advantages of Double Roll Crushers Laminated Crushing: Continuous extrusion forces reduce over-crushing and improve product yield. Controlled Particle Size: Precise adjustment of roller spacing ensures over 80% of finished products fall within the target size range (0.5-5 mm). Durability in Medium-Hard Material Applications Double roll crushers demonstrate excellent durability when processing medium-hard materials for sand production. Compared to impact crushers, they exhibit approximately 25% lower lifecycle operating costs, making them ideal for production lines prioritizing long-term stability and maintenance convenience. By adopting gradient-hardened alloy roller skins, configuring…
The discharge particle size in a double-roll crusher is controlled by adjusting the gap between the two rolls. Below are detailed steps and considerations: I. Adjustment Principle Core Mechanism: The minimum gap between the rolls (discharge opening) determines the maximum allowable particle size (e.g., a 10mm gap ensures 95% of output ≤10mm). Compression Crushing: Quartz is crushed by the rotating rolls; particles smaller than the gap fall through, while oversized fragments undergo repeated compression. II. Adjustment Steps 1. Pre-Adjustment Preparation Power off and lock out the machine. Clear residual quartz particles from roll surfaces to prevent interference. Check adjustment mechanisms (screws, hydraulic cylinders) for flexibility and lubrication. 2. Double-Roll Crushers Measure Current Gap Method 1: Use feeler gauges or calipers to measure the narrowest point between rolls. Method 2: Insert calibration blocks (e.g., 10mm steel plate) to test roll pass-through. 3. Gap Adjustment Methods Depending on the crusher design: Screw-Spring System: Loosen locknuts. Rotate adjustment screws (clockwise to reduce gap, counterclockwise to increase). Adjust both sides synchronously to maintain parallel roll axes (verify symmetry with calipers). Tighten locknuts and manually rotate rolls to check for jamming. Hydraulic System: Activate the hydraulic station, monitoring pressure (≤70% of rated value). Control hydraulic…
Vulnerable Parts of Double Roll Crushers The primary vulnerable parts of double roll crushers include roll skins, bearings, gears, and belts, with lifespans directly tied to material hardness and maintenance frequency. Double Roll Crushers Core Vulnerable Components List Roll crushers of roller surface Function: Direct contact with materials, enduring compression and friction. Wear Causes: Continuous impact and abrasion from high-hardness materials (e.g., pebbles). Material Options: High-chromium alloy (lifespan: 800–1,500 hours) Tungsten carbide composite rolls (30–50% longer lifespan) Overlay welding repair technology (extends lifespan by 20–30%). Bearings (Rolling/Slide Bearings) Function: Support roller rotation and withstand radial/axial loads. Failure Modes: Poor lubrication, dust ingress, overheating, or seizing due to overload. Maintenance Interval: Clean and refill high-temperature lithium grease every 500 hours. Transmission Gears Function: Transmit motor power to rollers. Wear Signs: Pitting, tooth breakage (common during material jamming or misalignment). Recommendation: Use carburized and hardened gears (HRC 58–62 hardness). V-Belts Function: Connect the motor to the reducer. Failure Risks: Aging, slippage, fracturing (due to insufficient tension or sudden load changes). Lifespan: ~3–6 months; maintain ≥2 sets of spare belts. Adjustment Shims and Bolts Function: Control roll gap for output size regulation. Issues: Frequent adjustments cause thread wear or shim deformation. Spring Safety…
Double Roll Crusher: Suitable Materials and Key Considerations Double roll crushers utilize two counter-rotating rollers to crush materials through compression and grinding. They are ideal for medium- to low-hardness materials (Mohs hardness ≤ 8) with high brittleness. Double Roll Crusher Applicable Material Types Coal and Coke Reason for Suitability: Medium hardness and high brittleness make coal and coke easy to crush via roller compression, commonly used in coal mines and coking plants. Non-metallic Ores Examples: Limestone, gypsum, dolomite, marl, sandstone. Applications: Raw material processing for construction materials and chemical industries. Metallurgical Waste Materials: Sintered ore, blast furnace slag (moderate hardness), metal silicon slag. Caution: High-hardness metallurgical waste (e.g., some slags) may accelerate roller wear; regular maintenance is required. Construction and Chemical Raw Materials Construction Sector: Cement clinker (secondary crushing), quartz sand, feldspar. Chemicals: Phosphate rock, potash salts, pyrite, where uniform particle sizing is critical. Glass and Ceramic Raw Materials Examples: Quartz, feldspar (primary crushing of brittle materials), provided moisture content is controlled to prevent roller sticking. Key Limitations Avoid Processing: High-hardness materials: Granite, basalt (Mohs hardness >8), which damage roller surfaces. Adhesive or high-moisture materials: Wet clay or viscous substances may cause blockages. Ultrafine grinding requirements: Minimum discharge size typically…
There are countless double roller crusher manufacturers on the market currently. Therefore, we should choose the excellent equipment manufacturers. The machines produce by professional manufacturers features long service life, which can prove the satisfaction of customers and earn a higher income for them. There are a lot of friends who buy crushers do not know why the double roller crusher must run empty when it is first installed? Here is a brief chat for you, I hope to help friends who buy sand making machine. The double roller crusher needs to run for a while to make the machine lubricant sufficiently before it begins to work, which minimizes wear and tear on the machine. In addition, machine-testing in advance can also detect the equipment. If the machine is faulty, shut down the machine in time to repair the abnormality. Furthermore, when the machine is running empty, we can effectively find out if there is any abnormality in the equipment, and check out if the machine is installed correctly. If there is a problem with the installation of the machine, we need to find out the problem and re-install it. If the empty machine runs normally, we can add a small amount of material to test the machine again.
Double roller crusher, also called double roller sand making machine, is mainly used for fine sand-making. There are many sand plants to pick it as a crushing machine for its outstanding advantages in recent years. It is capable of handling both dry and wet materials, and performs well in handling more than two hundred kinds of materials including pebbles, river pebbles, quartzite, steel slag, glass, and so on. Double roller crusher also operates well in sand-making with adjustable discharge size. When the size of feeding material is less than 8cm and the discharge size is less than 5mm, the finished product rate can reach about 90%. The wear parts of the double roller crusher are also very durable with the long service time for more than 1 year. And if the feeding materials is soft, its service time even reaches to three years without replacement. Furthermore, the double roller crusher has also been improved in recent years. Compared with the previous manual spring double roller crusher, the new large-size double roller crusher are equipped with direct-connected drive structure, semi-automatic and fully automatic hydraulic equipment, which greatly optimizes the productivity of the double roller crusher. Different manufacturers produce double roller crushers of different quality with different accessories. When it comes to the price, such as small double roller crusher 2PG400*250, with production capacity of 2-10 tons per hour, its price is generally more…
Double roller crusher makes up for the lack of natural sand. Double roller crusher, as a great tool of sand-making, is highly favored by our customers. Many directors set up sand plants would like to purchase the double roller crusher for its convenient operation, less wearing parts and the adjustable discharge size. Double roller crusher is widely used in all walks of life due to its strengths. However, there exists many people who wonder what materials are suitable for crushing by double roller crusher? Then, let’s talk about this question now! Double roller crusher is suitable for crushing solid and medium or fine materials with compressive strength less than 250Mpa and water less than 35%, such as river pebbles, pebbles, iron ore, quartzite, potassium feldspar, sodium feldspar, limestone, silicon, barite, basalt, granite, steel slag, cement clinker, construction waste concrete), shale, quicklime, coal, coke, clay, bentonite, chemical raw materials and so on. With the adjustable gap between the two rolls of the double roller crusher, the discharge size can be adjusted to meet the customers’ various production needs, which earns more popularity than other crusher equipments. The gap between the two rolls of the double roller crusher can be adjusted flexibly. When the size of feeding material is less than 8cm and the discharge size less than 5mm, 3mm, 1mm, the finished…
The roller sand making machine is guaranteed for one year. We are responsible for guiding the installation. When your equipment meets the startup conditions, we will arrange technical personnel to guide debugging and installation, and train your operators how to use the equipment correctly.
The output of roller sand making machine has full grain size and conforming to China Construction Construction Sand Standards.
A: Choose the roll sand machine first of all to choose a large factory, professional factory, see their market share is not high, because who the higher the market share of the corresponding higher technical content, because the more customers respond to the proposal and improve the quality of the higher the chances, and then see whether the manufacturers supporting accessories are big manufacturers of brand-name products, as long as the supporting manufacturers are big manufacturers, equipment prices are high also worth buying, usually said a price A point of goods! is the law of the millennium! Like our Huashengming used reducer for Jiangsu Guomao, Tyrone’s hardened gear reducer, large shaft 40 chromium calcined parts, roller skin using manganese 18 chromium 2 material centrifugal casting method of casting spare parts, high density of material, wear-resistant and durable! Lifetime warranty for the hydraulic system! Buy with confidence!
1,easy to operation 2,adjustable discharge 3,more durable and patented material of roller skin 4,high capacity,low cost 5,good performance,low over-crushing rate
Hydraulic cylinder heating is a common problem. After years of testing and improvement, our hydraulic roll crusher is equipped with a complete water cooling system to cool the hydraulic cylinder and achieve 24-hour continuous operation of the equipment.
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