The core components of a mobile crusher are the key basis for its crushing function and mobile operation. The core components of different types (such as jaw crushing mobile stations, cone crushing mobile stations, etc.) may vary slightly, but they can be divided into four modules: "crushing system", "power system", "mobile system", and "auxiliary system", which also affect the overall price of the equipment.
Crushing system: core functional execution unit
Type and function: Select different hosts according to crushing requirements to determine crushing efficiency and material particle size.
Jaw crusher: suitable for coarse crushing, crushing hard rocks (such as granite and basalt) through the squeezing of moving and fixed jaws, with a crushing ratio of 3-6 times.
Cone crusher: for medium and fine hard rocks, utilizing the principle of laminated crushing of dynamic and static cones, the product has uniform particle shape and is suitable for stone shaping.
Counterattack crusher: for medium to fine soft rock (such as limestone and shale), it is crushed by impact plate, and the output is cubic with low needle like content.
Impact crusher (sand making machine): used for sand making and stone shaping, it crushes the material by ejecting it to the lining plate through a high-speed impeller, and the finished product has a sand particle size of 0-5mm.
Key parameters: host processing capacity (50-500t/h), motor power (55-315kW), crushing chamber type (such as deep chamber design for jaw breakage, which can increase production by 20%)
Function: Feed the crushing host uniformly and continuously to avoid material accumulation and overload of the host.
Vibration feeder: driven by a vibration motor, suitable for materials with particle size ≤ 500mm, with a feeding capacity of up to 800t/h.
Plate feeder: impact resistant, suitable for large stone materials (such as ores with particle size ≥ 1000mm), commonly used in the coarse crushing process.
Function: Classify the crushed materials, return the unqualified particles to the main machine for further crushing, and achieve the integration of "crushing screening".
Circular vibrating screen: High screening efficiency (85% -95%), can be configured with 3-4 layers of screen mesh, screening particle size 5-100mm.
Linear vibrating screen: suitable for fine-grained materials (≤ 50mm), commonly used in the fine screening process of sand production lines.
Power System: Energy Supply and Drive Core
Diesel engine: suitable for off grid or remote areas (such as mines and field engineering), with a power coverage of 100-500kW and strong endurance (can operate for 8-10 hours on full fuel).
Electric motor: relying on external power supply, suitable for urban areas or scenarios with stable power supply, with higher efficiency (energy conversion rate over 90%) and lower operating costs (electricity cost about 0.5-1 yuan/ton).
Energy saving design: Some models are equipped with frequency conversion systems that can automatically adjust power according to load, saving 15% -30% energy.
Function: Drive the hydraulic auxiliary functions of the crushing host (such as hydraulic clearance adjustment for jaw breakage and hydraulic overload protection for cone breakage), as well as the lifting and steering of the moving chassis.
Hydraulic pump: plunger pump is commonly used, with a pressure of 20-35MPa, to ensure the stable operation of the crushing host.
Hydraulic cylinder: used to adjust the crushing gap (such as the jaw hydraulic cylinder can adjust the discharge port within 5 minutes), or to support the chassis to achieve climbing (slope ≤ 25 °).
Mobile systems: the foundation for achieving flexible transitions
Type and Characteristics:
Tire type chassis: suitable for road transportation, fast transition speed (20-30km/h), low cost, suitable for flat sites (such as urban construction waste disposal).
Tracked chassis: Strong off-road capability, capable of operating in mountainous and muddy areas (ground pressure ≤ 0.15MPa), with a climbing angle of up to 30 °, but slow transition speed (5-8km/h), suitable for mining.
Suspension system: using springs or hydraulic shock absorbers to reduce damage to equipment caused by bumps during driving.
Traction type: The transition is dragged by a tractor, suitable for short distance movement (such as different work points within the project), with a simple structure and low cost.
Self propelled: equipped with a drive motor or engine, it can travel autonomously and is suitable for long-distance transitions (such as cross project transportation), but the cost is high (self-propelled is 30% -50% more expensive than towed).
Auxiliary system: Ensure stable operation of equipment
Dust removal system:
Bag filter: With a filtration efficiency of 99% and a dust emission of ≤ 20mg/m ³, it is suitable for scenarios with high environmental requirements (such as urban areas).
Spray dust suppression: By using high-pressure water mist to suppress dust, the cost is low and it is suitable for open-pit mines (with a water consumption of about 0.5-1m ³/h).
Noise reduction device: The host is equipped with a soundproof cover (reducing noise by 15-20 decibels), and the engine is equipped with a muffler to meet the noise standards of the industrial field (≤ 85 decibels during the day).
PLC control cabinet: integrates equipment operation data monitoring (such as current, temperature, feeding amount), supports fault warning (such as automatic shutdown in case of overload), and improves operation and maintenance efficiency.
Remote control: Some high-end models are equipped with IoT modules, which can remotely monitor device status and adjust crushing parameters (such as feeding speed and crushing gap) through a mobile app.
Automatic lubrication pump: It supplies oil to the bearings, gears, and other parts of the crushing machine in a timed and quantitative manner to reduce wear (for example, the lubrication cycle of the jaw crushing bearing can be set to once every 2 hours) and extend equipment life (the bearing life can be increased by 50%). When purchasing a mobile crusher, enterprises need to pay special attention to the brand and quality of the core components, and choose the appropriate configuration according to the operating scenario. For mountainous operations, priority should be given to the track chassis+diesel engine, and for urban projects, priority should be given to the tire chassis+electric motor+high-efficiency dust removal system.
