Jaw Crusher

A new Design Concept for a Continuous Double-toggle Jaw Crusher System

14.01.2010 | Autor / Redakteur: A.K. Mukhopadhyay, J. Dey, A. Mohit, and N. Sinha / Marcel Drttboom

Current jaw crusher designs use only half of their working cycle for the actual size reduction. The design concept as presented here, if put into developing a continuous type of crusher, may deliver nearly twice the output of the prevalent systems. The jaw crusher is a reliable and robust piece of equipment, and therefore quite popular in primary crushing plants. There are two basic types of jaw crushers: single toggle Fig. 1: Crusher components in the proposed and double toggle. They are design. intermittent in operation and only half of their working cycle, that is, during the travel of the moving jaw towards the fixed jaw, is actually used for crushing. In the following half cycle, that is, during the return stroke, the opening between the two jaws is widened to discharge the crushed material. This article construes the concept of a continuous Blake type jaw crusher where both forward and return strokes of the moving jaw can be utilised for crushing and discharging of rock simultaneously with an aim to enhance its capacity.
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The Basic Concept In the existing single toggle jaw crusher, the moving jaw is mounted on eccentric shaft and is on top of the crusher assembly. Rotation of the shaft causes, along with the toggle plate, a compressive action. Similarly, in the existing double toggle jaw crusher the moving jaw is pivoted at the top while the pitman shaft is mounted on the eccentric shaft to impart motion to two toggle plates. The moving jaw has a reciprocating motion towards the fixed jaw. In both types of crushers half of the working cycle is used for crushing while the other half of the working cycle makes passage for the discharge of material. In order to modify the existing intermittent type jaw crusher into a continuous one, certain changes are imperative in its basic design. The proposed new design of the continuous type jaw crusher will consist of one more additional fixed jaw. The moving jaw will, therefore, be placed between two fixed jaws on either of its sides. This design will give rise to two crushing chambers in the same crusher instead of one as in prevalent crushers. The swing motion will be imparted on the moving jaw with the help of two double eccentric shafts through toggle plates attached at its lower end. The toggles will exert desired compressive force on the rock to crush them. Key Design Features The model consists of a swing jaw and two fixed jaws at either side of the swing jaw to achieve continuous crushing action. The swing jaw has a triangular cross-section to maintain a constant nip angle in both sides of the crushing zone. This particular type of cross-section of the swing jaw helps in preventing the discharge of over-size uncrushed material. Fixed jaws are inclined at certain angle with the vertical axis of the machine converging towards the bottom. The swing jaw reciprocates forward and backward by the toggle mechanism consisting of two double eccentric shafts and four toggle bars as shown in Fig. 1, showing the crusher components in the proposed design. The toggle bars are placed outside the crushing chamber with a certain amount of side clearance from fixed jaws. One end of the toggle bar is mounted on double
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eccentric shaft and the other end rests in the slot, at the bottom swing jaw. Hydraulic cylinders (not shown in the figure) would be required for the purpose of gap adjustment and tramp release by suitably tilting the fixed jaws. The detail of the views of the model is shown in Fig. 2. The model has been developed using Solids Works 2007 software package. Individual parts of the model are first designed in accordance with the existing data of a crusher in operation and finally assembled to give the shape of the proposed complete crusher. The model is tested for feasibility of its mechanisms using the software. The software generated values such as nip angle, feed opening, discharge opening, close set etc, and have showed close resemblance to the actual values of the prevalent crushers in operation. Drive System Design The drive arrangement for the continuous jaw crusher is shown in Fig. 3. Each double eccentric shaft is given rotational motion through two V-belt drive pulleys mounted on it and these pulleys are driven via a motor shaft. The double eccentric shaft carries a driven pulley at its one end and a fly wheel at the other, to take care of the frequent fluctuating loads. As a result of the rotational motion of the eccentric shaft, the two toggle bars push the swing jaw left and right alternately from its either side. This will cause crushing of rock in one chamber and simultaneous discharge of rock from the other. Conclusion In the last few decades, the design of jaw crushers did not undergo much change. A theoretical design concept of a continuous Blake type jaw crusher has been elucidated in this article, where forward and return strokes of the moving jaw can both be utilised for crushing. It may be presumed that the design concept as presented here if put into developing a continuous type of crusher, may deliver nearly twice the output of the prevalent crushers. However, the real-world performance of the proposed continuous jaw crusher can only be ascertained after manufacturing the unit and putting it into operation.

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A.K. Mukhopadhyay, A. Mohit, N. Sinha, Indian School of Mines, J. Dey, Larsen & Toubro Ltd.

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