Crusher Concave Liner Geometry for Top-Edge Wear Resistance
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Solution Overview
Problem
Gyratory and conical crushers experience rapid wear of mantel and concave liners, leading to high maintenance costs and downtime due to frequent replacements, particularly at the top edges of concaves where wear is preferential.
Innovation Solution
Designing concaves with a front face angle greater than 90 degrees at the top edge and a bottom face angle less than 90 degrees, along with parallel top and bottom faces to minimize gaps, enhances wear resistance and improves the concaves' service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If concaves are designed with traditional 90-degree angles at top edges, then manufacturing is simpler, but wear resistance at critical edges deteriorates
Solution Approach 1:
The patent applies local quality by giving different angle configurations to different parts of the concave. Specifically, the top edges have angles greater than 90 degrees (e.g., 95-110 degrees) to enhance wear resistance at these critical locations, while other portions of the concave maintain conventional geometries. This localized modification addresses the specific wear problem at top edges without unnecessarily complicating the entire concave design and manufacturing process.
2Reliability
If concaves are replaced frequently to maintain crushing efficiency, then crushing performance is maintained, but maintenance costs and downtime increase
Solution Approach 1:
The patent implements preliminary action by designing concaves with enhanced wear resistance features (angles >90 degrees at top edges) before they are installed and begin to wear. This preventive design approach ensures that the concaves can operate for longer periods before requiring replacement, thereby reducing both maintenance frequency and downtime while maintaining crushing efficiency throughout the extended service life.
3Duration of action of stationary object
If concave angles are modified to enhance wear resistance, then service life extends, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by modifying the angular parameters of the concave from the conventional 90 degrees to greater than 90 degrees (e.g., 95-110 degrees) at specific locations. This parameter modification enhances wear resistance and extends service life. The patent specifies acceptable ranges for these angles rather than requiring exact precise values, which balances the need for improved performance with practical manufacturing capabilities and tolerance requirements.
Data Source
AI summary
A concave for gyratory or conical crushers including a front face for providing a crushing surface and a top face proximate to the front face or adjacent to the front face. A first internal angle measured around a top front edge of the concave, and between the front face and the top face, is greater than 90 degrees. A liner is formed including a first concave and a second concave. The first concave is axially above and adjacent the second concave such that a top face of the second concave is substantially parallel to a bottom face of the first concave. The substantially parallel faces define a joining surface at an angle Y with respect to vertical. A front face of the first concave and a front face of the second concave are substantially parallel and define a surface having an angle M with respect to vertical, wherein M+Y>90 degrees.