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
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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%).
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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.
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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).
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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.
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Adjustment Shims and Bolts
- Function: Control roll gap for output size regulation.
- Issues: Frequent adjustments cause thread wear or shim deformation.
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Spring Safety Device
- Function: Overload protection by pressure release.
- Fatigue Failure: Replace when elasticity declines (test compression deformation ≥10%).
2. Wear Data Comparison (Pebble Example)
| Part | Common Material | Average Lifespan (hours) | Replacement Cost Proportion |
|---|---|---|---|
| Roll Skins | High-chromium cast iron | 800–1,500 | 40–60% |
| Bearings | Spherical roller bearings | 2,000–3,000 | 10–15% |
| Gears | 20CrMnTi alloy steel | 3,500–5,000 | 15–20% |
| V-Belts | Rubber-polyester core | 2,000–4,000 | 5–8% |
3. Key Measures to Extend Component Lifespan
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Material Pre-Treatment:
- Pre-crush pebbles to ≤30mm using a jaw crusher to reduce roll load.
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Wear Resistance Enhancement:
- Apply tungsten carbide overlay to roll surfaces (2–3x wear resistance).
- Periodically flip roll skins (double-sided use extends lifespan by 30%).
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Maintenance Management:
- Daily inspections of bearing temperature (<65°C) and vibration (<4.5 mm/s).
- Use centralized lubrication systems (ensure ≥95% grease coverage).
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Real-Time Monitoring:
- Install online wear sensors (detect roll thickness, trigger replacement alerts).
4. Typical Fault Diagnosis & Solutions
- Uneven wear on roll skins: Output size variation ≥±2mm → Solution: Repair by welding or replacement.
- Abnormal bearing noise: Noise increase ≥10 dB → Action: Clean and relubricate or replace.
- Gear tooth breakage: Current fluctuation >15% → Emergency fix: Install spare gear sets.
