Four-roller crusher

Abstract

The utility model discloses a four-roller crusher and belongs to the technical field of material crushing. The device comprises a single motor, a bucket-shaped shell, four transmission rollers and a linkage gear set, the motor is meshed with one of the transmission roller gears through a motor gear, and is linked with the other adjacent gears to be meshed in sequence to drive the four rollers to synchronously and reversely rotate; the width of an upper opening of the shell is 1.5-2 times that of a lower opening of the shell, the gap between the two transmission rollers on the upper side is 1.5-3 times that of the lower side, and roller teeth are welded in a crossed mode and arranged in a staggered mode. After materials enter from the upper opening, the two rollers on the upper side rotate inwards to stir the materials and preliminarily crush the materials, and the two rollers on the lower side extrude the materials through a small gap to achieve secondary crushing. According to the scheme, a traditional double-motor structure is replaced with single-motor driving, and energy consumption is reduced by 30% or above; a material flowing path is optimized through the design of a bucket-shaped shell and a step gap, and the crushing uniformity is enhanced through cross distribution of roller teeth; the eight symmetrical bearing seats are used for fixing the transmission rollers, and vibration abrasion is reduced.

Description

Technical Field

[0001] This utility model provides a crusher, and particularly relates to a four-roll crusher. Background Technology

[0002] The four-roll crusher is a material crushing equipment widely used in mining, building materials, and other fields. Its core function is to compress and shear materials through the coordinated rotation of multiple rollers, achieving particle size control from coarse to fine crushing. Traditional four-roll crushers typically employ two independent drive systems: two motors drive two pairs of upper and lower drive rollers respectively, with each pair linked by a chain or gear set. Its basic structure includes: dual motors, a split housing, four symmetrically arranged drive rollers, and welded or detachable roller teeth. The gap between the drive rollers is usually set to a fixed value or is simply adjustable. The upper and lower roller sets operate in the same direction of rotation, crushing materials through the meshing action of the roller teeth.

[0003] However, the dual-motor drive of traditional four-roll crushers leads to redundant energy consumption and an increased number of transmission chains, which not only increases manufacturing costs but also makes them prone to failure due to insufficient synchronization. The fixed gap between the upper and lower rollers and the single rotation direction mean that the material undergoes only one crushing, which can easily lead to uneven particle size, especially for materials with large differences in hardness. Traditional shells are mostly rectangular or cylindrical structures, which can cause material to accumulate at the inlet, and the short crushing path can cause some material to be discharged without being fully crushed. The split shell and complex transmission structure make the equipment difficult to disassemble and assemble, and the replacement cycle after the roller teeth wear is short, which affects the efficiency of continuous operation. Utility Model Content

[0004] To address the aforementioned shortcomings, this application proposes a novel four-roll crusher. Through innovations such as single-motor drive with gear linkage of the four rollers, optimized flow path of the bucket-shaped shell, and stepped gap and rotation direction design, it significantly improves energy consumption, crushing effect, and ease of maintenance.

[0005] To solve the above-mentioned technical problems, this utility model provides the following technical solution: a four-roll crusher, comprising: a motor, a housing, a bearing seat, a motor gear, a transmission roller gear, and a transmission roller;

[0006] The housing is a bucket-shaped housing with a larger upper opening and a smaller lower opening; the motor is connected to the housing, and the motor gear is mounted on the motor's output shaft;

[0007] There are four drive rollers in total, which are symmetrically fixed inside the housing by eight bearing seats; among the four drive rollers, the gap between the two upper drive rollers is greater than the gap between the two lower drive rollers.

[0008] Each of the drive rollers is welded with cylindrical roller teeth, and the roller teeth of the four drive rollers are distributed in a crisscross pattern.

[0009] Each of the drive rollers is equipped with a drive roller gear at its end. The motor gear meshes with one of the drive roller gears, and the remaining adjacent drive roller gears mesh in sequence to form a linkage transmission structure.

[0010] The two upper drive rollers rotate in the direction of the housing and are used for feeding and initial crushing of the material; the two lower drive rollers rotate in the direction of the housing and are used for secondary crushing of the material.

[0011] Preferably, the width of the upper opening of the bucket-shaped structure of the shell is 1.5-2 times the width of the lower opening.

[0012] Preferably, the number of transmission roller gears is four, each corresponding to one of the four transmission rollers.

[0013] Preferably, the gap between the two upper drive rollers is 1.5-3 times the gap between the two lower drive rollers.

[0014] Preferably, the teeth of the drive roller are evenly distributed along the circumferential direction, and the teeth of adjacent drive rollers are arranged alternately.

[0015] Preferably, the number of bearing seats is eight, and each end of the transmission roller is fixed to the housing by two bearing seats.

[0016] Preferably, the motor is a single motor that drives four transmission rollers to rotate synchronously through gear meshing.

[0017] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:

[0018] This device uses a single motor to drive a motor gear that meshes with one of the transmission roller gears, which in turn meshes with the remaining adjacent transmission roller gears in sequence, forming a synchronously rotating four-roller transmission structure. This replaces the traditional dual-motor drive mode, significantly reducing energy consumption and transmission chain complexity. The bucket-shaped shell, with its large upper opening and small lower opening, combined with the structure of the two upper transmission rollers having a larger gap and rotating inwards towards the shell, guides the material to fall naturally and initially disperse it. Meanwhile, the two lower transmission rollers have a smaller gap and rotate in a direction suitable for secondary crushing, improving particle size uniformity through two-stage crushing. The cross-distribution of the roller teeth and the meshing of the gears on the four transmission rollers ensure that the material is fully stressed during the two crushing processes. At the same time, eight bearing seats are symmetrically fixed inside the shell, enhancing the operational stability of the transmission rollers and reducing vibration and maintenance requirements. Thus, while simplifying the structure and reducing energy consumption, this device effectively solves the problems of high energy consumption, uneven crushing effect, and low material flow efficiency of traditional four-roller crushers.

[0019] Other advantages, objectives and features of this invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be taught from the practice of this invention. Attached Figure Description

[0020] Figure 1 This is a front view of a four-roll crusher according to the present invention;

[0021] Figure 2 This is a top view of a four-roll crusher according to the present invention;

[0022] Figure 3 This is a schematic diagram of the internal structure of a four-roll crusher according to the present invention;

[0023] Figure 4 This is a schematic diagram of the feeding and crushing path of a four-roll crusher according to the present invention.

[0024] As shown in the figure:

[0025] 1. Motor; 2. Housing; 3. Bearing housing; 4. Motor gear; 5. Drive roller gear; 6. Drive roller; Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0027] It should be noted that the terms "vertical," "horizontal," "up," "down," "left," "right," and similar expressions used in this article are for illustrative purposes only and do not represent the only possible implementation.

[0028] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the terminology used herein in the description of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention; the term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0029] like Figure 1 and Figure 2As shown, a four-roll crusher includes: a motor 1, a housing 2, bearing seats 3, a motor gear 4, a transmission roller gear 5, and transmission rollers 6; the housing 2 is a bucket-shaped housing with a larger upper opening and a smaller lower opening, and the width of the upper opening is 1.5-2 times the width of the lower opening; the motor 1 is a single motor connected to the housing 2, and the motor gear 4 is mounted on the output shaft of the motor 1; there are four transmission rollers 6, which are symmetrically fixed inside the housing 2 by eight bearing seats 3, and each transmission roller 6 is fixed at both ends by two bearing seats 3; among the four transmission rollers 6, the gap between the upper two transmission rollers is the same as the gap between the lower two transmission rollers. The gap is 1.5-3 times larger than the material's diameter. Each transmission roller 6 is welded with cylindrical roller teeth evenly distributed along the circumference, and the roller teeth of adjacent transmission rollers 6 are arranged alternately. Each transmission roller 6 has a transmission roller gear 5 installed at its end. There are four transmission roller gears 5, which correspond one-to-one with each transmission roller 6. The motor gear 4 meshes with one of the transmission roller gears 5, and the remaining adjacent transmission roller gears 5 mesh in sequence to form a linkage transmission structure. The rotation direction of the two upper transmission rollers 6 faces the inside of the housing 2 and is used for feeding and initial crushing of materials. The rotation direction of the two lower transmission rollers 6 is used for secondary extrusion and crushing of materials.

[0030] In this implementation plan, the connection and positional relationships of the components are clearly defined:

[0031] Single-motor linkage transmission: A single motor 1 directly drives one of the transmission roller gears 5 through the motor gear 4, and then through the sequential meshing of adjacent gears, the synchronous rotation of the four transmission rollers 6 is achieved, which simplifies the complex structure of the traditional dual-motor drive and reduces energy consumption.

[0032] Staged crushing layout: The upper two rollers have a larger gap and rotate inward, using the cross-distribution of roller teeth to push the material towards the center and initially disperse it; the lower two rollers have a smaller gap and rotate in the opposite direction, using the staggered arrangement of roller teeth to perform secondary compression on the material, improving the uniformity of crushing.

[0033] The bucket-shaped shell optimizes material flow: the upper and lower design of the shell 2, combined with the roller tooth arrangement, guides the material to fall naturally, avoids blockage, and extends the crushing path;

[0034] Symmetrical bearing fixing: Eight bearing seats 3 are symmetrically installed on the housing 2 to ensure the stability of the transmission roller 6 and reduce vibration and wear.

[0035] Based on the above implementation scheme, the innovation and beneficial effects of this device are as follows:

[0036] Energy-saving and efficient: The single motor drives the four rollers to rotate synchronously, which reduces energy consumption by more than 30% compared with the traditional dual-motor solution. At the same time, the staged crushing design improves processing efficiency.

[0037] Enhanced crushing uniformity: The combination of cross-welded and staggered roller teeth with two-stage gap adjustment allows the material to undergo two crushing processes of different intensities, resulting in significantly improved particle size uniformity.

[0038] Compact and reliable structure: The gear linkage transmission and symmetrical bearing fixed design simplify maintenance costs, and the bucket-shaped shell and roller tooth layout are adaptable to various material characteristics, expanding application scenarios.

[0039] This solution achieves energy conservation and operational stability while ensuring crushing effectiveness through the synergistic effect of its components, thus meeting the needs of industrial production.

[0040] like Figure 3 and Figure 4 As shown, the four-roll crusher is driven by a single motor 1 and a motor gear 4, which in turn drives four transmission rollers 6 to rotate synchronously. The upper two transmission rollers 6 have a larger gap to facilitate material entry and initial dispersion, while the lower two transmission rollers 6 have a smaller gap to achieve secondary crushing. The bucket-shaped structure of the shell 2 and the cross-distribution design of the roller teeth optimize the material flow path, and the staggered arrangement of the roller teeth enhances the uniformity of crushing. Eight bearing seats 3 symmetrically fix the transmission rollers 6 to ensure operational stability. This scheme, which drives four rollers to work together through a single motor, combines energy saving and high efficiency with improved crushing effect.

[0041] In this implementation plan, the basic composition and quantitative parameter classification of each structure are detailed as follows:

[0042] 1. Key Component Composition and Selection

[0043] Motor: A Y-series three-phase asynchronous motor with a power range of 15-30kW and a rated speed of 1450rpm is adopted. It is directly connected to the motor gear through a coupling to meet the torque requirements of four-roller synchronous drive.

[0044] Gear set:

[0045] Motor gear: Module 8, number of teeth 24, material is 42CrMo alloy steel, surface carburizing and quenching treatment;

[0046] Transmission roller gears: module 8, number of teeth 36, material and heat treatment process are the same as motor gears, four sets of gear meshing transmission ratio is designed to be 1:1.5, to ensure that the speed of transmission rollers decreases step by step, which is suitable for the needs of staged crushing.

[0047] Drive roller:

[0048] The roller body has a diameter of Φ400-600mm, a length of 800-1200mm, and a tooth height of 50-80mm, which are welded to the surface of the roller body.

[0049] The roller teeth are made of ZGMn13 high manganese steel, which has been water-cooled, improving wear resistance by more than 30%.

[0050] The gap between the two upper rollers is 30-50mm, and the gap between the two lower rollers is 10-20mm. The gap ratio between the two stages is controlled within the range of 1.5-3 times.

[0051] Bearing housing: adopts double-row self-aligning roller bearings with a rated dynamic load of 320kN. They are symmetrically installed on both sides of the housing, with one bearing at each end of each roller, for a total of eight bearings, to support the high-speed rotation of the drive roller and absorb vibration.

[0052] case:

[0053] The bucket-shaped structure has an upper opening width of 1200-1600mm, a lower opening width of 600-800mm, and a side plate thickness of 20-30mm. It is made of Q345B steel plate welded together.

[0054] The inner wall is lined with replaceable wear-resistant plates to extend the service life of the housing.

[0055] 2. Implementation Key Points and Parameter Adaptation Logic

[0056] Single-motor linkage design: Through module matching and transmission ratio optimization, a single motor can drive four rollers to rotate synchronously, reducing power loss by more than 35% compared to the traditional dual-motor solution, while also reducing the complexity of the transmission chain.

[0057] Staged crushing parameter settings:

[0058] The upper two rollers have a larger gap and a higher rotation speed, using the cross-distribution of roller teeth to break up large pieces of material.

[0059] The gap between the two lower rollers is smaller, and the rotation speed is reduced to 12-15 rpm. The material is subjected to extrusion and shearing force through the staggered arrangement of roller teeth to ensure that the final crushed particle size is ≤5mm.

[0060] Optimized bucket-shaped shell and material flow: The combination of a wide top and narrow bottom structure with an inclined design guides the material to fall naturally, avoiding accumulation and blockage, and extending the crushing path to 1.5-2m, thereby improving crushing efficiency.

[0061] Roller tooth layout and wear resistance: The roller teeth are evenly distributed around the circumference with a spacing of 80-100mm, and the staggered angle between adjacent roller teeth is 15°-30°, which enhances the material biting effect; the high manganese steel material and surface hardening process enable the roller teeth to have a service life of 8000-10000 hours.

[0062] 3. Innovative parameter integration

[0063] Energy consumption and efficiency balance: The single motor power is adapted to four-roller load, with no-load current ≤15A and full-load current ≤45A, and the overall energy consumption is reduced by 30% compared with traditional models.

[0064] Crushing particle size control: By adjusting the gap between the two lower rollers, different material hardness can be quickly adapted, and the finished product qualification rate is ≥95%;

[0065] Convenience of maintenance: The bearing housing adopts a split structure, which supports quick disassembly and assembly; the wear-resistant liner is fixed by bolts, and the replacement time is ≤2 hours, reducing downtime losses.

[0066] This implementation plan achieves multiple goals—energy saving, consumption reduction, improved crushing efficiency, and optimized maintenance costs—while ensuring mechanical reliability through precise matching of quantitative parameters and structural design. It is suitable for industrial crushing scenarios involving medium to high hardness materials.

[0067] The operating steps of this device are as follows: Start a single motor 1 to drive the motor gear 4 to rotate. Through gear meshing, the four transmission rollers 5 synchronously drive the transmission rollers 6 to rotate in different directions. After the material is fed into the upper opening of the bucket-shaped shell 2, the two transmission rollers 6 with larger gaps on the upper side rotate inward to push the material towards the center and use the cross-distributed roller teeth for initial dispersal and coarse crushing. The crushed material falls naturally to the two transmission rollers 6 with smaller gaps on the lower side under the action of gravity. The secondary fine crushing is completed by the squeezing and shearing action of the roller teeth. Finally, the crushed material is discharged from the lower opening of the shell 2. During the process, eight symmetrically fixed bearing seats 3 ensure the stable operation of the transmission rollers. The gear meshing transmission structure maintains the synchronous speed of the four rollers. The single motor drive mode simplifies the operation process and reduces energy consumption. After shutdown, maintenance can be quickly completed by checking the wear of the gears and the condition of the bearing seats, realizing efficient, uniform and continuous crushing operation.

[0068] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention should be determined by the claims.

Claims

1. A four-roll crusher, characterized in that, include: Motor (1), housing (2), bearing seat (3), motor gear (4), transmission roller gear (5) and transmission roller (6); The shell (2) is a bucket-shaped shell with a large upper opening and a small lower opening; the motor (1) is connected to the shell (2), and the motor gear (4) is mounted on the output shaft of the motor (1); There are four transmission rollers (6), which are symmetrically fixed inside the housing (2) by eight bearing seats (3); among the four transmission rollers (6), the gap between the two upper transmission rollers is greater than the gap between the two lower transmission rollers. Each of the drive rollers (6) is welded with cylindrical roller teeth, and the roller teeth of the four drive rollers (6) are distributed in a cross pattern; Each of the transmission rollers (6) is equipped with a transmission roller gear (5) at its end. The motor gear (4) meshes with one of the transmission roller gears (5), and the remaining adjacent transmission roller gears (5) mesh in sequence to form a linkage transmission structure. The two upper drive rollers (6) rotate in the direction of the housing (2) and are used for feeding and initial crushing of materials; the two lower drive rollers (6) rotate in the direction of the material for secondary crushing.

2. A four-roll crusher according to claim 1, characterized in that: The upper opening width of the bucket-shaped structure of the shell (2) is 1.5-2 times the lower opening width.

3. A four-roll crusher according to claim 1, characterized in that: The number of transmission roller gears (5) is four, which are installed one-to-one with the four transmission rollers (6).

4. A four-roll crusher according to claim 1, characterized in that: The gap between the two upper drive rollers (6) is 1.5-3 times the gap between the two lower drive rollers.

5. A four-roll crusher according to claim 1, characterized in that: The teeth of the transmission roller (6) are evenly distributed along the circumferential direction, and the teeth of adjacent transmission rollers (6) are arranged alternately.

6. A four-roll crusher according to claim 1, characterized in that: The number of bearing seats (3) is eight, and each drive roller (6) is fixed to the housing (2) at both ends by two bearing seats (3).

7. A four-roll crusher according to claim 1, characterized in that: The motor (1) is a single motor that drives four transmission rollers (6) to rotate synchronously through gear meshing.

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