Toothed roller wear has the following effects on the normal operation of the sizer crusher.
First, the crushing effect.
1. Changes in the size of the discharged material
With the wear of the toothed roller, its crushing capacity to the material gradually decreases, and the discharge particle size will become larger and uneven. Materials that could have been crushed precisely to a specific size range may have large quantities of particles that exceed the expected particle size. For example, in the mine crushing operation, the ore needs to be crushed to a certain size to meet the subsequent processing requirements, and after the toothed roller is worn, it may lead to the appearance of large ore blocks in the discharge, which affects the subsequent process flow.
The uneven discharge particle size may also lead to increased difficulty in subsequent screening, classification and other operations, reducing the efficiency of the entire production system.
2. Crushing efficiency is reduced
Worn toothed rollers require longer time and more energy to complete the same crushing task when crushing material. This reduces the processing capacity of the sizer crusher and reduces the amount of material crushed per unit time. For example, a certain number of tons of material that could be crushed per hour may only be processed by half or less due to the wear of the toothed rollers, and the crushing efficiency is reduced, which seriously affects the production schedule.
Second, the performance of the equipment
1. The stability of the device deteriorates
After the toothed rollers are worn, the crusher will be unbalanced during operation. This imbalance can lead to increased vibration of the equipment, which can not only cause damage to the structure of the equipment itself, but also affect the normal operation of peripheral equipment. For example, strong vibrations may loosen the conveying equipment connected to the crusher, or even cause the belt to deviate from the conveyed material, affecting the stable operation of the entire production line.
Unbalance can also cause uneven stress on key components such as bearings and gears, accelerating the wear of these components and further reducing the reliability and service life of the equipment.
2. Increased energy consumption
In order to overcome the increased crushing resistance caused by the wear of the toothed rollers, the motor of the crusher needs to output more power. This leads to a significant increase in the energy consumption of the equipment and an increase in production costs. For example, when the toothed roller is not worn, the motor power of the crusher is a certain value, and with the wear of the toothed roller, the motor power may gradually rise, or even exceed the rated power, which not only increases the electricity bill, but also may cause the risk of overload damage to the motor.
3. Increased noise
When the worn toothed roller crushes the material, it will produce more noise due to the uneven crushing force and the increased vibration of the equipment. This not only has an impact on the health of the operator, but can also violate the noise limits required by environmental regulations. For example, in some mines or factories close to residential areas, excessive noise may cause complaints from surrounding residents, exposing enterprises to environmental pressure and legal risks.
Third, the maintenance cost
1. Frequent repairs and replacement of parts
Toothed roller wear accelerates the damage of other related components, such as bearings, seals, etc. This requires frequent equipment repairs and replacement of parts, increasing maintenance costs and downtime. For example, worn toothed rollers may subject bearings to greater stress and vibration, resulting in shorter bearing life and more frequent bearing replacements, increasing human, material and time costs.
Frequent repairs can also affect the execution of production schedules, leading to order delays and financial losses for businesses.
2. The overall equipment life is shortened
If the serious wear of the toothed roller is not treated in time, it will cause damage to the overall structure of the crusher and shorten the service life of the equipment. For example, a crusher that has been running in a state of wear for a long time may have problems such as frame deformation and weld cracking, which are difficult to repair and costly, and may even lead to the early scrapping of equipment, which requires the purchase of new equipment, which brings a huge economic burden to the enterprise.
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