Full Analysis of Wearing Parts of Jaw Crusher: Types, Replacement Cycles and Tips for Extending Service Life

 As the core equipment in mining, building materials and other industries, the jaw crusher's operating status is directly related to production efficiency and economic benefits. However, due to the harsh environment of crushing operations and long-term use, the jaw crusher is subject to high-intensity impact and friction, and its wearing parts are prone to wear, breakage and other problems. This will not only affect the performance and efficiency of the equipment but also may cause production line shutdown. Therefore, timely and regular inspection and replacement are required to ensure the normal operation and production efficiency of the equipment.

1. Types and replacement cycles of wearing parts for jaw crushers

The wearing parts of the jaw crusher include a movable jaw plate, fixed jaw plate, side guard plate, toggle plate, bearings, spring tension rods and spring components, etc.

(1). Fixed and movable jaw plate:

The jaw plate is the main working component of the jaw crusher and bears huge impact loads. During the crushing process, serious wear will occur on the edge of the fixed and movable jaw plate, and the wear is mostly concentrated in the middle and lower parts. This is due to the repeated impact and friction of the materials during the crushing process. The shape of the fixed and movable jaw plate is designed to be symmetrical up and down, so when one end of the fixed jaw plate is worn, it can be turned around and used. To extend its service life, the fixed and movable jaw plate is generally made of high manganese steel and other materials with good hardness and wear resistance, such as ZGMn13 material. The replacement cycle of the fixed and movable jaw plate is generally about a few months to half a year, depending on factors such as usage conditions, stone hardness, and equipment load.

(2). Side guard plate:

The side guard plates are located on the left and right inner sides of the jaw crusher rack and are used to protect the jaw crusher body. The side guard plate will wear away from material impact. When the wear of the side guard plate reaches a certain level, it needs to be replaced with a new one. The replacement cycle of the side guard plate is generally longer, usually about half a year, depending on the usage conditions and the working intensity of the crusher.

(3). Toggle plate:

The toggle plate is an important component of connecting the movable and fixed and movable jaw plates. It is also an insurance part of the crusher. When unbreakable materials fall into the crusher and the machine exceeds the normal load, the toggle plate will break immediately and the crusher will stop working, thereby avoiding damage to the entire machine. Toggle plates need to be inspected and replaced regularly, and the replacement cycle is usually about half a year. The toggle plate and toggle plate pad adopt a sliding contact method. There is little friction under normal use. It is enough to apply a layer of grease on the contact surface.

(4). Spring tension rods and spring components:

As an important component of the jaw crusher, the spring pull rod mainly plays the role of connecting the adjustment seat and the back support plate. It can also adjust the size of the ore discharge port and maintain the stability of the jaw plate. The spring component and the spring tension rod are matched and have the main function. It is a fixed toggle plate to prevent the toggle plate from falling off and absorbs and buffers the vibration and impact during the crushing process. It has a good buffering and vibration-damping effect and can effectively reduce the impact damage to the machine during the crushing process. In actual operation, if the spring tension rod and the spring components are found to be damaged or failed, they need to be replaced in time to ensure the normal operation of the equipment. The replacement cycle of spring rods and the spring components is generally about half a year. The specific replacement cycle depends on factors such as usage conditions, work intensity, and maintenance.

(5). Bearings:

The jaw crusher's bearings use 4 sets of spherical roller bearings, which have good load-bearing and self-aligning properties. The bearings of the jaw crusher mainly bear the radial load when the equipment is working. Under long-term high-load operation, the bearings will wear and need to be inspected and replaced regularly. The turning eccentric shaft and jaw mandrel are replaced, the Babbitt alloy on the upper part of the connecting rod head is cast, and the worn parts are replaced or repaired. To increase the service life of the bearing, bearing materials with higher durability and load-bearing capacity can be used. The replacement cycle of bearings is generally more than one year, depending on bearing quality, usage conditions and maintenance.

2. How to extend the service life of the wearing parts of the jaw crusher?

(1). Optimize the crushed materials: Different materials crushed by the jaw crusher will have different wear conditions of wearing parts. The crushed materials should be optimized as much as possible to reduce the use of materials with high hardness and many impurities.

(2). Use the correct operating method: The correct operating method can reduce the wear of the liner. For example, the feeding should be kept uniform to avoid too much or too little feeding; Overloading should be avoided during operation to prevent excessive damage to the equipment with a big load.

(3). Regular inspection and maintenance: Regularly check the wearing parts of the crusher. If any serious wear or damage is found, they should be replaced in time. In addition, the inside of the equipment should be cleaned regularly to prevent the accumulation of impurities and cause additional wear and tear.

(4). Reasonable installation and adjustment: When installing and adjusting the jaw crusher, ensure the correct installation position and reasonable adjustment of each component to avoid additional wear caused by deviations and instability.

(5). Proper maintenance and lubrication: Keep the lubricating oil clean, and replace and replenish the lubricating oil in time to ensure that the equipment operates under normal lubrication conditions.

(6). Pay attention to safe operation: When using the jaw crusher, you must strictly follow the operating procedures, pay attention to safety matters, and avoid equipment damage caused by human factors.

(7). Choose high-quality wearing parts: Choose high-quality wearing parts suppliers and purchase original or high-quality certified wearing parts to ensure the quality and service life of wearing parts and reduce equipment failure rates.

In summary, the types and replacement cycles of wearing parts will vary depending on factors such as equipment model, manufacturing process, usage environment, and operating methods. Therefore, in actual production, the jaw crusher should be inspected and maintained regularly, and problems should be discovered and dealt with in a timely manner to ensure normal operation of the equipment and improve production efficiency. At the same time, users also need to standardize the use of crushing equipment, perform maintenance and repair of wearing parts, strengthen the inspection process, and replace them in time if wear and tear is found, to ensure the normal operation of the entire gravel production line.

Gratitude and Forge Ahead | Vanguard Machinery Year-end Shipment Guarantee Delivery

If you plow the fields early in winter, the work will be done in the coming year. Although winter is the end of the year, it is also the foundation and prelude to the new year's work. Since the beginning of winter, many sets of equipment in the production plant of Vanguard Machinery need to be delivered centrally. The severe cold in winter cannot withstand the enthusiasm of Vanguard Machinery's people. They show their enthusiasm in their respective positions, work overtime to catch up with the schedule, ensure production, and keep busy. We are rushing to produce equipment and deliver goods to customers in Saudi Arabia, Malaysia, Mongolia, and Thailand in a timely manner. Every process is in an orderly manner, and every link is taken seriously and responsibly, striving to achieve high efficiency and high quality! Come with me to experience the busy scene of delivery in the workshop!

▲We braved the low temperature, wind and snow to pack the 6CX106 crawler-type mobile crushing plant

▲Equipment waiting to be shipped in the dispatching area

▲The 100 T/H cone crusher fixed production line is loaded and shipped.

▲ 150 T/H steel structure crushing production line for container delivery.

▲The goods arrive at the port and head towards the destination!

Vanguard Machinery maintains a long-term and stable cooperative relationship with the port customs brokers of major fleets and port areas and has efficient coordination capabilities, which can enable the goods to safely arrive at the port and port in a short time and be smoothly cleared and released for shipment and loading.

Hot sales bear witness to strength, and quality wins favor. Vanguard Machinery will continue to fulfill its solemn commitment to be responsible for the brand, reputation and customers, maintain strong fighting spirit and pragmatic innovative style, and work with customers to make greater contributions to the development of mining machinery in my country!

The Original Intention is as Strong as Rock, and They Work Hard and Diligently | "Terminators of Difficult and Complicated Diseases", They are the Cutest People

In the increasingly fierce market competition, service quality has increasingly become an important manifestation of the core competitiveness of a corporate brand. Service is not just a promise, but a manifestation of immediate action. Vanguard Machinery listens to customer needs with a considerate attitude and provides high-quality services with professional skills.

This time, the Vanguard Machinery's service team crossed mountains and seas and entered Astana, Kazakhstan to provide technical support for customers' on-site transformation. It is reported that this customer originally had a granite crushing production line with a capacity of 100-150 t/h. However, due to the unreasonable design of the original plan and some old equipment with many faults, the efficiency of the entire production line was reduced, and production had to be stopped from time to time for maintenance. The customer is anxious about this.

On the one hand, the customer was eager to put it into production, and on the other hand, because remote troubleshooting could not completely solve the problem, with the support of the company leaders, our service team decided to go to the customer's construction site to provide on-site services. Whether traveling over mountains or sleeping in the open air, the Vanguard Machinery's service team will always arrive as scheduled. After arriving at the site, despite the fatigue of traveling, to provide customers with a comprehensive understanding of the site, our sales staff will understand and communicate with customers in detail about the site situation. Service Engineer Guo is not afraid of getting dirty or tired. He climbs up and down to inspect the machine. Customers see this work spirit and service attitude and appreciate it very much.

Service engineers always encounter various "difficult problems", but these lovely people always have various ways to deal with them. In the following days, based on the on-site conditions and on the premise of saving costs for customers as much as possible, Engineer Guo proposed an overall reasonable rectification plan for the production line and decided to replace the original low-voltage impact crusher with a powerful hydraulic impact crusher independently developed by us. The old and efficient sand making machine was used, and the existing jaw crusher, vibrating screen, belt conveyor and other equipment were completely repaired and renovated. After the replacement of our new equipment and the overall transformation and upgrade, the entire production line was revitalized on-site. Customer feedback said the equipment is operating normally and the production capacity is up to standard. We are very satisfied with our equipment and the service concept that we think about our customers.Choosing something is precious and lasting. The service and sales engineers of Vanguard Machinery rush from one country to another, from one project to another. They go wherever the customers are. Our service engineers have spanned mountains, rivers and time. Bringing our most sincere service and heartfelt blessings to our customers! In the new year, I hope our customers will achieve whatever they want in 2024! In the future, we will accompany you all the way, with customer-oriented and sincere service!

Hard Power and High Efficiency | Vanguard's Oil-electric Dual-drive Crawler-type Mobile Jaw Crushing Plant was Successfully Tested!

 Recently, in the assembly workshop of the Vanguard Machinery production plant, on-site staff are conducting test acceptance of the LA106 crawler-type mobile jaw crushing plant independently developed and produced by our company.

The crawler-type mobile crushing plant, also known as the crawler-type mobile integrated crusher, is a new product that comprehensively replaces traditional crushing equipment. It integrates material receiving, crushing, transmission and other process equipment, and is mainly composed of a vibrating feeder, jaw crusher and conveying equipment. It is mobile and autonomous and can meet the operating needs of different sites. It is widely used in rock crushing, aggregate production, open-pit mining and other crushing operations. It is suitable for granite, basalt, rock, limestone, quartz stone, coal gangue, construction waste and other materials.

New design: bringing forth the new from the old

The LA106 crawler-type mobile jaw crushing plant has a compact overall structure with a strong operating capacity and excellent performance. The maximum feeding particle size is 620 mm, and the maximum working height is 4.1m. It is equipped with mains power and diesel dual power. The overall power is 186.6KW, and the whole machine is powerful.

Adopting Siemens PLC intelligent control system, it has functions such as remote monitoring, fault diagnosis, maintenance and upgrades, remote start and stop, fault alarm and fault record query. It has a visual workflow and simple operation. It can effectively monitor the operating status of the equipment and provide more precise control and adjustment, thereby improving production efficiency and equipment stability.

New quality: brand new

The new design concept of the LA crawler-type mobile jaw crushing plant achieves a standardized, lightweight and modular design. Whether it is in ore crushing, sand and gravel aggregate processing, or other application scenarios, it has demonstrated excellent performance and wide market acceptance, and will surely become a cost-effective product.

Heavy-duty special crawler chassis adapts to more terrains; transitions are faster and more efficient. The maximum allowable inclination angle can reach 30°. It is operated by a wireless remote control with a remote control distance of 30 m. It is easy to drive the equipment to the trailer and transport it to the operation location, improving operator safety and work efficiency.

New experience: refreshing

Vanguard Machinery's crawler-type mobile crushing plant has adjustable and controllable grading; it has outstanding advantages such as large capacity and stable equipment production. It can be said that a crawler mobile crushing plant is a small factory. It is not afraid of terrain restrictions, avoids power outages and power shortages, and saves the cost of preliminary infrastructure. Once the mobile plant arrives at the construction site, it can be put into operation immediately after simple debugging, truly allowing customers everywhere to achieve rapid and stable profit growth.

Good products always speak for themselves based on their strength. Accompanied by our company's leaders and project managers, the customer inspects the ordered equipment, focusing on detailed on-site inspection of the product's appearance, structure, product performance and other aspects. The entire process is rigorous and meticulous. The customer was very satisfied with the equipment acceptance results and achieved the expected ideal results. This fully demonstrates the company's strength and technical level in production equipment, and also lays a solid foundation for the company's further market promotion and development.

The Silk Road shines | Vanguard Machinery Leads Chinese Manufacturing Across Mountains and Seas

As an old Chinese saying goes, “Nothing, not even mountains and oceans, can separate people with shared goals and vision”. Over the years, Vanguard Machinery, guided by the value concept of "innovative and intelligent manufacturing, interconnecting the world", has left many solid footprints in the Belt and Road countries in Central Asia. As the country with the largest population and economic volume in Central Asia, the Republic of Uzbekistan has a deep historical relationship with Vanguard Machinery. Over the years, we have deeply cultivated the market in this country, improved the product sales and supply chain, and established a sales network centered in Uzbekistan and radiating throughout Central Asia.

From December 12 to December 15, 2023, Vanguard Machinery makes a surprise appearance at the "Republic Cross-Industry Industrial Cooperation Expo" held in Tashkent, Uzbekistan. As an overall solution provider for crushing and grinding equipment serving the world, Vanguard Machinery was invited to attend this exhibition, explaining the product technology and showing project cases in detail to the attendees at the booth.

To develop new customers and connect with regular ones, Vanguard Machinery takes advantage of the opportunity of the exhibition to warmly welcome every guest who visits the booth. By patiently introducing the company's series of products and providing detailed answers to professional technical questions, we strives to promote Chinese products to the world. At the same time, we actively listens to the needs and feedback from local customers for Chinese made products in order to launch products and services that better meet market demand in the future, create more high-quality mining machinery, and lay a solid foundation for developing overseas markets and increasing market share.

What are the Commonly Used Dust Control Solutions in the Sand and Gravel Crushing Production Lines?-Vanguard Machinery Tech

 The sand and gravel crushing production line typically refers to the specific crushing equipment used to grind and crush ore, reducing its particle size to the required range for subsequent resource recycling operations. However, whether it is during the production of the sand and gravel production line or in the ore field where the original ore is stacked with high processing intensity and a wide footprint. In the past, our crushing production sites were always filled with dust, creating a harsh environment. The dust generated during the crushing process spread into the air with the airflow, causing serious environmental pollution and posing a hazard to the health of the operators.

Therefore, in recent years, the country has increased environmental management and advocated the establishment of environmentally friendly stone crushing plants. Dust suppression treatment has become a necessary condition for the smooth operation of stone plants. So what are the dust control solutions commonly used in establishing sand and gravel crushing production lines? Let's find out now!

1. Suppress dust when transporting materials: The jaw crusher to the pre-screening workshop and the semi-finished material belt outlet are surrounded by fully enclosed light-colored steel, which reduces dust pollution and noise by more than 50% compared to traditional open-air production.

2. Capture and collect released dust: Select appropriate dust collector equipment according to the crusher model and process characteristics, such as bag dust collector, wet dust collector, etc. Placing dust removal equipment near the source of dust generation can capture dust to the greatest extent.

3. Spray system: Choose to install two water spray devices at the inlet, outlet and crushing cavity of the crusher. The two water spray heads at the feed port point toward the inlet; The two water spray heads at the discharge port form a certain angle relative to each other, so that the sprayed water is in a cross state to achieve the ideal effect.

4. Dust suction device: Install dust suction devices at the discharge port and the inspection port of the crusher equipment. The dust hood of the discharge port should be installed about 1000mm away from the discharge port. The plane of the dust hood should be perpendicular to the direction of dust flow; The connection between the dust hood and the blower of the crusher equipment maintenance port can be designed to be a flexible telescopic pipe making it easy to refuel the crusher and perform routine maintenance.

5. Optimize the structure: The structure can be modified and optimized in places with relatively large slopes such as equipment feed hoppers, protective covers, chutes, etc. The first is to reduce the inclination angle of the chute to reduce the height difference of the materials; The second is to improve the structure of the crusher. While the overall size of the equipment remains unchanged, the number of teeth on the tooth plate is increased and the tooth shape becomes relatively smaller.

6. Design improvement: Use reasonable process plans and equipment for production, and try to use closed transportation methods during material transportation. In addition, the screen must be cleaned in time to prevent clogging, so that some small particles and dust can be screened out before the material enters the crusher.

In summary, the solution of the sand and gravel crushing production line should implement the principle of prevention first, minimize the dust link in the overall plan, and strictly control dust pollution during raw material processing and transfer; Select equipment with less dust, and use spraying dust reduction and dust removal methods in the early stages. The implementation of the above measures can effectively improve the operating environment of the sand and gravel production line and improve the level of environmental protection.

Analyze What are the Reasons for the Low capacity of Sand Making Machines? How to Improve the Sand Production Rate of Sand Making Machine?

 As key equipment for producing artificial sand, the sand making machine has been widely used in construction, roads, railways, water conservancy and other engineering fields. The quality of sand making machine products has a significant impact on the safety and durability of engineering construction, while the sand production rate of the sand making machine is one of the important indicators directly related to its production efficiency and product quality. However, many times we find that the capacity of the sand making machine does not achieve the expected results, and even encounters the problem of low output. This article will delve into the reasons for the low production of sand making machine and propose corresponding solutions to help you improve the sand output rate of the sand making machine.

1. Analysis of the reasons for the low capacity of sand making machine

(1) . Equipment aging:

Long-term use or improper maintenance may cause the sand making machine to age, thus affecting its capacity. Aging of equipment will cause parts to wear, loosen, or even malfunction, thereby reducing the crushing efficiency of the sand making machine.

(2) . Raw material issues:

If the raw material used for sand making is too hard or viscous, it may have a negative impact on the capacity of the sand making machine. Raw materials with high hardness are difficult to crush, while raw materials with high viscosity tend to adhere to the crushing wall, affecting the sand production rate. Uncertainty in the supply of raw materials can also lead to production disruptions, which in turn reduces output and increases production costs.

(3) . Unreasonable design:

The design of the sand making machine has an important impact on its capacity. If there are flaws in the design, it will directly lead to a decrease in production. For example, unreasonable crushing cavity structure, rotor design, feeding method, etc. will affect the crushing effect of the sand making machine.

(4) . Improper operation:

Incorrect operating methods or parameter settings may affect the capacity of the sand making machine. The operator's insufficient understanding of the performance and operating requirements of the equipment, or failure to adjust parameters according to the actual situation, may lead to a reduction in the working efficiency of the sand making machine.

(5) . Lack of motivation:

The sand making machine needs enough power to drive the crushing action. If the power is insufficient, it will also lead to a decrease in capacity. For example, insufficient motor power or low efficiency of the transmission system will affect the power source of the sand making machine.

2. Measures to improve sand production rate of sand making machine

In terms of materials: The hardness, toughness, humidity, viscosity and other properties of the materials will affect the capacity of the sand making machine. Different materials have different physical properties, so it is necessary to select the appropriate sand making machine model and parameter settings according to the characteristics of the materials. At the same time, try to choose materials with moderate hardness for sand making to avoid affecting the normal operation of the sand making machine due to too high or too low hardness of the material.

Equipment: The internal structure, parts materials, lubrication system, etc. of the sand making machine will all affect its capacity. In order to improve the sand production rate of the sand making machine, the following measures can be taken:

(1) . Regularly check the wear and tear of internal parts: After the internal parts of the sand making machine are worn, they must be replaced in time, otherwise, it will delay production and affect the sand production efficiency of the sand making machine. At the same time, it is necessary to strengthen the maintenance and upkeep of the equipment and check the equipment regularly. The operating status and wear and tear of parts can be used to detect and solve problems in a timely manner.

(2) . Regularly check the tightness of the motor V-belt: On the one hand, the sand production efficiency of the sand making machine is also affected by power transmission, and the main factor that affects power transmission is the tightness of the V-belt. Therefore, we should pay attention to the tightness of the power transmission belt and make daily adjustments to ensure that production efficiency is not affected.

(3) . Check the impeller speed: When the impeller speed of the sand making machine is too low, it will lead to insufficient throwing speed, insufficient collision or impact force between the material and the guard plate, and the sand production rate will be greatly reduced, so it is particularly important to ensure that the speed is within the normal range.

(4) . The sealing operation must be done well: The sealing parts of the sand making machine will gradually wear out when the sand making machine is operated for a long time. If the dust is not adjusted for a long time, it is easy to enter the bearings or oil passages, causing the lubrication of the sand making machine to lose its effect. As a result, the bearings will wear out. It will accelerate and the service life will be reduced, so the sealing condition must be maintained regularly.

(5) . Pay attention to strengthening the shock absorption work: Excessive vibration will not only directly affect the operating status of the sand making machine and its components, but will even reduce the service life of the sand making machine, so the shock absorption work must also be done well.

(6) . Operate according to the oil temperature warning: Because the too high oil temperature of the sand making machine means serious bearing heating, it is necessary to stop the machine for inspection in time, and then continue production after troubleshooting.

Operation: Improper operation and lack of standardized operation will also affect the capacity of the sand making machine. In order to improve the sand production rate of the sand making machine, it is necessary to strictly follow the equipment instructions to avoid illegal operations and misoperations. At the same time, professional training for operators to improve their skills and operating levels will help improve the sand production rate of the sand making machine. Through training, operators can better understand the performance of the equipment, operating requirements and how to deal with common problems, etc., so as to better operate and maintain the sand making machine, improve the sand production rate and ensure the normal operation of the equipment.

Design aspect: The design of the sand making machine also has an important impact on its capacity. In order to improve the sand production rate of the sand making machine, the structural design of the sand making machine can be optimized to improve its crushing efficiency and passing capacity. At the same time, it is necessary to consider the applicable scope and market demand of the sand making machine, and select the appropriate model and parameter settings according to the characteristics and needs of different materials.

To sum up, the low capacity of the sand making machine may be caused by many reasons. In order to improve the sand production rate of the sand making machine, it is necessary to start from many aspects, including material selection, equipment maintenance, operating specifications, design optimization, etc. At the same time, it is also necessary to strengthen personnel training and other measures to improve the efficiency of the sand making machine.

Vanguard Machinery Tech has a professional R&D team with strong technical strength. The company continuously invests in research and development, focuses on technological innovation, and has obtained a number of patents and core technologies in product design and manufacturing processes. The company has rich manufacturing experience and a complete management system. From raw material procurement to production and processing to final product inspection, we strive for excellence in every aspect and strive to provide customers with high-quality products.