Ballast production system
By employing a three-stage crushing process, combining compression and impact crushers, the problem of high needle-like and flaky proportions in ballast was solved, thereby improving the service life and production efficiency of ballast and reducing costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- CHINA RAILWAY CONSTR HEAVY IND
- Filing Date
- 2025-05-13
- Publication Date
- 2026-07-07
AI Technical Summary
In the existing ballast production process, the proportion of needle-shaped and flaky stones formed after hard rock is high, resulting in short ballast life and easy wear.
A three-stage crushing process is adopted, including first and second compression crushers and an impact crusher. Through two compression crushing processes and one shaping process, the proportion of needle-like and flaky structures is reduced. Jaw crushers and cone crushers are used to improve crushing efficiency and uniformity.
This reduces the proportion of needle-like and flaky particles in the ballast, extends the service life of the ballast, reduces the wear frequency of vulnerable parts, lowers production costs, and improves the service life of the impact crusher.
Smart Images
Figure CN224462867U_ABST
Abstract
Description
Technical Field
[0001] This application relates to ballast production technology, and more particularly to a ballast production system. Background Technology
[0002] Ballast is the crushed stone used to support track sleepers in a railway transportation system. The stone used to make ballast is natural stone, which is obtained after being crushed by a crusher and screened by a screening machine.
[0003] Currently, most existing ballast production processes use only compression crushers. While compression crushers offer advantages such as a large crushing ratio and high crushing efficiency, to obtain higher quality ballast, hard rock (such as granite or basalt) is typically used as raw material. Due to the high hardness of hard rock, the compression crushing process produces a significant amount of needle-like and flaky stones, resulting in a higher proportion of needle-like and flaky stones in the ballast. Since the edges and corners of these needle-like and flaky stones are prone to wear after prolonged use, this shortens the service life of the ballast. Utility Model Content
[0004] This application provides a ballast production system to solve the problem of short ballast life caused by the high proportion of needle-like and flaky parts in existing ballast.
[0005] On one hand, this application provides a ballast production system, including a stone crushing assembly, which includes a first compression crusher, a second compression crusher, and an impact crusher; the first compression crusher is used to crush stone into first particles; the inlet of the second compression crusher is connected to the outlet of the first compression crusher, and the second compression crusher is used to crush the first particles into second particles; the inlet of the impact crusher is connected to the outlet of the second compression crusher, and the impact crusher is used to shape the second particles into third particles; wherein, the particle size of the first particles is larger than the particle size of the second particles, and the particle size of the second particles is larger than the particle size of the third particles.
[0006] Optionally, the first compression crusher is a jaw crusher, and the second compression crusher is a cone crusher.
[0007] Optionally, the first crusher and the second crusher are connected by a first conveyor, and the first conveyor is equipped with an iron remover.
[0008] Optionally, the system further includes a screening assembly comprising: a first screening machine having a first feed inlet, a first discharge outlet, a second discharge outlet, and a third discharge outlet, the first feed inlet being connected to the outlet of the impact crusher, the first screening machine being configured to screen the third material so that the first discharge outlet discharges large-diameter material, the second discharge outlet discharges ballast material, and the third discharge outlet discharges small-diameter material, wherein the large-diameter material has a larger particle size than the ballast material, and the ballast material has a larger particle size than the small-diameter material.
[0009] Optionally, the ballast production system further includes a reverse conveyor connected between the first discharge port and the inlet of the impact crusher, the reverse conveyor being configured to convey the large-diameter material into the impact crusher.
[0010] Optionally, the ballast production system further includes a conveyor switching device, the inlet of which is connected to the second discharge port, and the outlet of which can be selectively switched between a reverse conveyor and a ballast bin.
[0011] Optionally, the outlet of the second compression crusher is connected to the inlet of the impact crusher via a second conveyor, and the reverse conveyor transports the large-diameter material into the impact crusher via the second conveyor.
[0012] Optionally, the screening assembly further includes a second screening machine, the inlet of which is connected to the third discharge port, and the second screening machine is configured to screen the small-diameter material.
[0013] Optionally, the ballast production system further includes a raw material silo and a bar feeder. The bar feeder has a first receiving port, a stone discharge port, and a waste discharge port. The first receiving port is connected to the raw material silo, and the stone discharge port is connected to the inlet of the first extrusion crusher. The bar feeder is configured to screen the raw material into stone and waste with a particle size smaller than the stone. The stone discharge port is used to output the stone, and the waste discharge port is used to output the waste.
[0014] Optionally, the screening assembly further includes a vibrating screen disposed between the waste discharge port and the inlet of the second extrusion crusher, the vibrating screen being configured to screen impurities in the waste before supplying it to the second extrusion crusher.
[0015] The ballast production system provided in this application utilizes the high crushing efficiency of a compression crusher. The stone is crushed twice, through a first and a second compression crusher, rapidly breaking it into smaller particles. These smaller particles are then thrown into an impact crusher and impacted by the crusher's impact plate. The impact plate reshapes the edges of the smaller particles, reducing the number of needle-like and flaky structures in the resulting smaller particles. This results in a lower proportion of needle-like and flaky structures in the smaller particles used as ballast material. Attached Figure Description
[0016] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.
[0017] Figure 1 This is a system diagram of a ballast production system provided in an exemplary embodiment of this application.
[0018] Figure label:
[0019] 10 - Ballast Bin; 20 - First Crushed Stone Bin; 30 - Second Crushed Stone Bin; 40 - Stone Chip Bin; 50 - Waste Soil Bin;
[0020] 100 - Raw Material Warehouse;
[0021] 200-Bar feeder;
[0022] 300 - First extrusion crusher;
[0023] 400 - Second extrusion crusher;
[0024] 500-Impact Crusher;
[0025] 600 - First screening machine; 610 - Second screening machine;
[0026] 700 - Conveyor switching device;
[0027] 800-vibrating screen;
[0028] 900 - Waste soil conveyor; 910 - First conveyor; 911 - Iron separator; 920 - Second conveyor; 930 - Third conveyor; 940 - Reverse conveyor; 950 - Fourth conveyor; 960 - Fifth conveyor; 970 - Sixth conveyor; 980 - Seventh conveyor; 990 - Eighth conveyor.
[0029] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation
[0030] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application.
[0031] The terms “first,” “second,” “third,” “fourth,” etc., as used in this application (if applicable), are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented, for example, in a sequence other than those illustrated or described herein.
[0032] In this application, the terms "exemplarily" or "for example" are used to indicate examples, illustrations, or descriptions. Any embodiment or design described as "exemplarily" or "for example" in this application should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of terms such as "exemplarily" or "for example" is intended to present the relevant concepts in a specific manner.
[0033] In related technologies, the production process of ballast mostly uses only a crusher to crush the stone. The crushed stone contains a lot of needle-shaped and flaky stones. Since the edges and corners of needle-shaped and flaky stones are prone to wear after long-term use, if such needle-shaped and flaky stones are used as ballast to lay on the track, they are prone to wear and breakage after the train passes, which will shorten the service life of the ballast and also easily lead to unevenness of the laid track.
[0034] The ballast production system provided in this application aims to solve the above-mentioned technical problems of the prior art.
[0035] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.
[0036] like Figure 1As shown in the illustration, this application provides a ballast production system, which includes a stone crushing assembly comprising a first compression crusher 300, a second compression crusher 400, and a third compression crusher. The first compression crusher 300 crushes the stone into first granules. The inlet of the second compression crusher 400 is connected to the outlet of the first compression crusher 300, and the second compression crusher 400 crushes the first granules into second granules. The inlet of an impact crusher 500 is connected to the outlet of the second compression crusher 400, and the impact crusher 500 shapes the second granules into third granules. The first particle size is larger than the second particle size, and the second particle size is larger than the third particle size.
[0037] It is understandable that after the stone is fed into the first compression crusher 300 through the inlet, the first compression crusher 300 crushes the stone, breaking it into particles smaller than the original stone. The first particle then enters the inlet of the second compression crusher 400 through the outlet of the first compression crusher 300. The second compression crusher 400 crushes the first particle, breaking it into particles even smaller than the original material. The second particle then enters the impact crusher 500 through the processing port of the second compression crusher 400. The impact crusher 500 shapes and crushes the second particle, shaping it into particles even smaller than the original material.
[0038] The above scheme utilizes the high crushing efficiency of the compression crusher. The stone is crushed twice, by a first compression crusher 300 and a second compression crusher 400, rapidly breaking it into smaller particles. These smaller particles are then thrown into an impact crusher 500 and impacted by the impact plate, which shapes their edges. This reduces the number of needle-like and flaky structures in the resulting third particle. Consequently, the proportion of needle-like and flaky structures in the third particle is lower when used as ballast material. Furthermore, by employing a first compression crusher 300, a second compression crusher 400, and an impact crusher 500, three-stage crushing of the raw material is achieved. Compared to traditional two-stage crushing, this method offers advantages such as a lower proportion of needle-like and flaky structures and less wear on vulnerable parts, reducing the frequency of replacement and lowering production costs.
[0039] Furthermore, it should be noted that if the stone or the first particle is directly fed into the impact crusher 500 for shaping, the impact plate is easily deformed and damaged upon collision due to its large particle size and high hardness. However, in this embodiment, because the stone undergoes two compression crushing processes, the resulting second particle size is close to that of the third particle. Therefore, the second particle has a smaller particle size, making it less likely to deform the impact plate during collision. The impact crusher primarily functions to shape the stone, thereby extending the service life of the impact crusher 500.
[0040] In some alternative embodiments, the first compression crusher 300 is a jaw crusher, and the second compression crusher 400 is a cone crusher. A jaw crusher has wear-resistant and pressure-resistant moving and stationary jaw plates. During operation, it simulates the biting motion of an animal to crush the stone. It has a large feed opening, making it suitable for processing large pieces of raw material. Therefore, the first compression crusher 300 is a jaw crusher, which can quickly crush the stone. A cone crusher uses the rotation and oscillation of a moving cone to crush the material, resulting in more uniform particle size. Therefore, the second compression crusher 400 is a cone crusher, which can make the particle size of the second material more uniform. Furthermore, because the jaw crusher uses frontal compression, its jaw plates experience greater wear, while the cone crusher uses rotary compression, resulting in less wear on its moving cone. Therefore, using a cone crusher as the second compression crusher 400 can reduce the wear of the material on the second compression crusher 400.
[0041] Of course, in some other alternative embodiments, the second compression crusher 400 may also be a jaw crusher, for example, the second compression crusher 400 may be a fine jaw crusher.
[0042] It should be noted that extrusion crushers include jaw crushers, cone crushers, and roll crushers.
[0043] Optionally, the particle size of the stone is no greater than 600 mm, the particle size range of the first particle is 200-300 mm, the particle size range of the second particle is no greater than 100 mm, and the particle size range of the third particle is no greater than 63 mm.
[0044] In some alternative embodiments, the first crusher 300 and the second crusher 400 are connected by a first conveyor 910, on which an iron remover 911 is provided.
[0045] The first conveyor 910 is used to convey the first granular material. By setting the first conveyor 910, the positions of the first crusher 300 and the second crusher 400 can be adjusted more easily. In addition, since the first granular material may contain steel impurities from collection or crushing, the iron separator 911 can adsorb the steel and reduce the steel content of the first granular material entering the second crusher 400.
[0046] In some alternative embodiments, the second compression crusher 400 is connected to the impact crusher 500 via a second conveyor 920.
[0047] Optionally, depending on the actual layout requirements, the second conveyor 920 can be composed of two conveyor belts (e.g., Figure 1 As shown in the figure, it can also be composed of a single conveyor belt; however, this application does not specifically limit this.
[0048] In some alternative embodiments, the ballast production system further includes a screening assembly comprising a first screening machine 600. The first screening machine 600 has a first feed inlet, a first discharge outlet, a second discharge outlet, and a third discharge outlet. The first discharge outlet is connected to the outlet of the impact crusher 500. The first screening machine 600 is configured to screen the third particle size so that the first discharge outlet discharges large-diameter material, the second discharge outlet discharges ballast material, and the third discharge outlet discharges small-diameter material. The large-diameter material has a larger particle size than the ballast material, and the ballast material has a larger particle size than the small-diameter material.
[0049] It is understandable that the first screening machine 600 has a multi-layer screening structure. After the third particle enters the first screening machine 600, it will be sequentially screened into large-diameter particles, ballast material, and small-diameter particles with gradually decreasing diameters. By screening the third particle, a finished material with a better particle size range can be obtained as ballast material, resulting in better quality ballast material. The large-diameter and small-diameter particles can be used as materials for other applications, such as construction and road paving.
[0050] Optionally, the screening structure in the first screening machine 600 is a series of screens with progressively smaller apertures, thereby achieving sequential screening of the third particle through the screens.
[0051] Optionally, the particle size range of large-diameter material is greater than 63 mm, the particle size range of ballast material is 25 mm to 63 mm, and the particle size range of small-diameter material is less than 25 mm.
[0052] In some alternative implementations, the outlet of the impact crusher 500 is connected to the inlet of the first screening machine 600 via a third conveyor 930.
[0053] In order to obtain more ballast material, in some alternative embodiments, the ballast production system also includes a reverse conveyor 940 connected between the first discharge port and the inlet of the impact crusher 500, the reverse conveyor 940 being configured to convey large-diameter material into the impact crusher 500.
[0054] By setting up a reverse conveyor 940, large-diameter materials can be re-conveyed to the impact crusher 500 for reshaping. During the reshaping process, the particle size of the large-diameter materials is reduced, and they then enter the first screening machine 600 from the outlet of the impact crusher 500 for further screening. This cycle allows most of the large-diameter materials to become ballast, while a small portion becomes small-diameter materials, thus obtaining more ballast.
[0055] In related technologies, a foundation is laid before the ballast is used to construct the railway tracks. This foundation utilizes a large amount of small-diameter ballast, which cannot be used as the foundation material itself. After production, the ballast is typically stored in ballast bins (10) until the foundation is completed, at which point it is used. This results in low production efficiency of small-diameter ballast in the early stages of track laying, and a large amount of ballast is stockpiled.
[0056] In view of this, in some alternative embodiments, the ballast production system further includes a conveyor switching device 700, the inlet of which is connected to a second discharge port, and the outlet of which can be selectively switched between the reverse conveyor 940 and the ballast bin 10.
[0057] It can be understood that the ballast bin 10 is a warehouse for storing ballast material. When the second discharge port is not connected to the conveyor switching device 700, the ballast material conveyed by the second discharge port will directly enter the ballast bin 10. When the outlet of the conveyor switching device 700 is connected to the ballast bin 10, the ballast material conveyed by the second discharge port will also enter the ballast bin 10, thus obtaining ballast material. When the outlet of the conveyor switching device 700 is connected to the reverse conveyor 940, the ballast material output from the second discharge port will be conveyed to the reverse conveyor 940, and then conveyed by the reverse conveyor 940 to the impact crusher 500 for further shaping, so that the ballast material becomes smaller particle size material, and after being screened by the first screening machine 600, it is discharged from the third discharge port.
[0058] This setup allows for the omission of ballast material production during the early stages of track laying when it is not required. Instead, more stone can be used to produce small-diameter ballast. Ballast material production can then commence when it is needed.
[0059] In some alternative implementations, the second discharge port is connected to the ballast bin 10 via a fourth conveyor 950.
[0060] In some alternative embodiments, the outlet of the second compression crusher 400 is connected to the inlet of the impact crusher 500 via a second conveyor 920, and a reverse conveyor 940 conveys large-diameter materials into the impact crusher 500 via the second conveyor 920.
[0061] The second conveyor 920 allows for convenient placement of the second compression crusher 400 and the impact crusher 500. Furthermore, the reverse conveyor 940 can directly feed large-diameter materials onto the second conveyor 920, which then transports them to the impact crusher 500. This also makes it easier to connect the outlets of the reverse conveyor 940 and the impact crusher 500.
[0062] Since the particle size range of small-diameter materials is less than 25mm, further screening of these materials is necessary to allow for the use of different particle sizes in various applications.
[0063] In some alternative embodiments, the screening assembly further includes a second screening machine 610, the inlet of which is connected to a third outlet, the second screening machine 610 being configured to screen small-diameter materials.
[0064] The second screening machine 610 screens small-diameter materials, so that stones of different sizes can be used in different places, making the use of stones more reasonable.
[0065] Optionally, the third discharge port of the first screening machine 600 and the inlet of the second screening machine 610 are connected by a fifth conveyor 960.
[0066] Optionally, the second screening machine 610 has a first crushed stone inlet, a second crushed stone inlet, and a stone chip inlet. The particle size of the stone output from the first crushed stone inlet is larger than that of the stone output from the second crushed stone inlet, and the particle size of the stone output from the second crushed stone inlet is larger than that of the stone output from the waste soil inlet.
[0067] Optionally, the first crushed stone outlet outputs first crushed stone with a particle size range of 16mm to 25mm. The second crushed stone outlet outputs second crushed stone with a particle size range of 5mm to 16mm. The stone chip outlet outputs stone chips with a particle size range of less than 5mm.
[0068] It is understandable that the first crushed stone can be placed in the first crushed stone bin 20, the second crushed stone can be placed in the second crushed stone bin 30, and the stone chips can be placed in the stone chip bin 40.
[0069] For ease of transportation, in some optional embodiments, the first crushed stone inlet and the first crushed stone bin 20 are connected by a sixth conveyor 970, the second crushed stone inlet and the second crushed stone bin 30 are connected by a seventh conveyor 980, and the stone chip inlet and the stone chip bin are connected by an eighth conveyor 990.
[0070] In some optional embodiments, the ballast production system further includes a raw material silo 100 and a bar feeder 200. The bar feeder 200 has a stone discharge port and a waste discharge port. A first receiving port is connected to the raw material silo 100, and the stone discharge port is connected to the inlet of a first compression crusher 300. The bar feeder 200 is configured to screen the raw materials in the raw material silo 100 into stone and waste with a particle size smaller than stone. The stone discharge port is used to output stone, and the waste discharge port is used to transport waste.
[0071] It is understandable that the raw materials in the raw material bin 100 are usually directly mined from the mine and typically contain impurities such as soil. By installing a bar feeder 200, after the raw materials enter the bar feeder 200, the raw materials with a particle size larger than the gap between the bars are conveyed to the stone discharge port through the bars, while the raw materials with a particle size smaller than the gap between the bars (including soil) fall through the gap between the bars and are discharged from the waste port. This reduces the total soil content of the stone.
[0072] Since the waste still contains stones, it can be used as small-diameter stone material. Discarding it directly may result in some waste.
[0073] In view of this, in some alternative embodiments, the ballast production system further includes a vibrating screen 800, which is disposed between the waste discharge port and the inlet of the second extrusion crusher 400. The vibrating screen 800 is configured to screen impurities in the waste before supplying it to the second extrusion crusher 400.
[0074] By setting up a vibrating screen 800, impurities such as mud in the waste can be screened out, and the waste after removing impurities is then conveyed to the second compression crusher 400.
[0075] It is understandable that, since the raw material has a small particle size, the waste material is directly fed to the second extrusion crusher 400, which can reduce the amount of waste material crushed once.
[0076] Optionally, the vibrating screen 800 has a second receiving port, a recycling port and a waste soil port. The waste discharge port of the second receiving port is connected to the recycling port, the inlet of the second crusher 400 is connected to the waste soil port, and the waste soil port is connected to the waste soil bin 50. The waste soil bin 50 is used to store the impurities screened by the vibrating screen 800.
[0077] It should be noted that the particle size of the material output from the waste soil outlet is smaller than the diameter of the material output from the recycling outlet. The material output from the waste soil outlet is mainly soil.
[0078] In some alternative embodiments, a waste conveyor 900 is provided between the waste bin 50 and the waste material outlet to convey the material output from the waste material outlet.
[0079] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the utility model disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein.
[0080] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope.
Claims
1. A ballast production system, characterized in that, Includes a stone crushing assembly, the stone crushing assembly comprising: The first compression crusher (300) is used to crush stone into first particles; The second extrusion crusher (400) has its inlet connected to the outlet of the first extrusion crusher (300) and is used to crush the first granules into second granules. An impact crusher (500) is provided, the inlet of which is connected to the outlet of the second compression crusher (400), and the impact crusher (500) is used to shape the second granules into a third granule. Wherein, the particle size of the first granule is larger than that of the second granule, and the particle size of the second granule is larger than that of the third granule.
2. The ballast production system according to claim 1, characterized in that, The first compression crusher (300) is a jaw crusher, and the second compression crusher (400) is a cone crusher.
3. The ballast production system according to claim 1 or 2, characterized in that, The first crusher (300) and the second crusher (400) are connected by a first conveyor (910), and the first conveyor (910) is equipped with an iron remover (911).
4. The ballast production system according to claim 1, characterized in that, It also includes a screening component, which comprises: A first screening machine (600) has a first feed inlet, a first discharge outlet, a second discharge outlet, and a third discharge outlet. The first feed inlet is connected to the outlet of the impact crusher (500). The first screening machine (600) is configured to screen the third material so that the first discharge outlet discharges large-diameter material, the second discharge outlet discharges ballast material, and the third discharge outlet discharges small-diameter material. The large-diameter material has a larger particle size than the ballast material, and the ballast material has a larger particle size than the small-diameter material.
5. The ballast production system according to claim 4, characterized in that, The ballast production system also includes a reverse conveyor (900) connected between the first discharge port and the inlet of the impact crusher (500), the reverse conveyor (900) being configured to convey the large-diameter material into the impact crusher (500).
6. The ballast production system according to claim 4, characterized in that, The ballast production system also includes a conveyor switching device (700), the inlet of which is connected to the second discharge port, and the outlet of which can selectively switch between the reverse conveyor (900) and the ballast bin (10).
7. The ballast production system according to claim 6, characterized in that, The outlet of the second compression crusher (400) is connected to the inlet of the impact crusher (500) by a second conveyor (920), and the reverse conveyor (900) conveys the large-diameter material into the impact crusher (500) through the second conveyor (920).
8. The ballast production system according to claim 4, characterized in that, The screening assembly further includes a second screening machine (610), the inlet of which is connected to the third outlet, and the second screening machine (610) is configured to screen the small-diameter material.
9. The ballast production system according to claim 1, characterized in that, The ballast production system also includes a raw material silo (100) and a bar feeder (200). The bar feeder (200) has a first receiving port, a stone discharge port and a waste discharge port. The first receiving port is connected to the raw material silo (100), and the stone discharge port is connected to the inlet of the first extrusion crusher (300). The bar feeder (200) is configured to screen the raw material into the stone and waste with a particle size smaller than the stone. The stone discharge port is used to output the stone, and the waste discharge port is used to output the waste.
10. The ballast production system according to claim 9, characterized in that, The ballast production system also includes a vibrating screen (800), which is located between the waste discharge port and the inlet of the second extrusion crusher (400). The vibrating screen (800) is configured to screen impurities in the waste and then supply it to the second extrusion crusher (400).