Inertial Cone Crusher Disc Coupler Transmission
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Solution Overview
Problem
The existing design of inertial cone crushers faces challenges in combining high operating abilities with reliability, economy, and ease of operation and maintenance, particularly due to the inefficiencies in the transmission subassembly and counterbalance weight arrangement, which result in increased height, cost, and maintenance complexity.
Innovation Solution
The integration of a disc coupler transmission subassembly, based on the Oldham coupler design, which allows for dynamic balancing and torque transmission with angular displacement, and the placement of a counterbalance weight within the crusher body to reduce overall dimensions and simplify maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a traditional transmission assembly is used to transmit torque from the engine to the unbalance weight, then the required rotation speed can be achieved, but the device complexity and maintenance cost increase
Solution Approach 1:
The patent extracts the essential function of torque transmission and rotation speed achievement from the complex traditional transmission assembly. By using a simplified direct drive configuration where the engine crankshaft directly connects to the unbalance weight shaft, the patent removes unnecessary intermediate transmission components while maintaining the required rotational motion and speed characteristics.
Solution Approach 2:
Instead of using a conventional transmission assembly to achieve the required rotation speed, the patent inverts the approach by directly coupling the engine output to the unbalance weight shaft. The speed control is achieved not through complex transmission mechanisms but through the engine's inherent rotational characteristics and direct mechanical connection.
2Stability of the object's composition
If counterbalance weights are installed outside and below the crusher body, then dynamic balance can be achieved, but the overall height and device dimensions increase
Solution Approach 1:
The patent applies the nesting principle by placing the counterbalance weight inside the crusher body structure rather than outside. The counterbalance weight is positioned within the available internal space of the crusher body, nested within the existing structural envelope, thereby achieving dynamic balance without increasing the external dimensions or overall height of the equipment.
Solution Approach 2:
The patent transitions from a vertical arrangement (outside and below the crusher body) to a horizontal or internal arrangement (inside the crusher body). By utilizing the internal three-dimensional space of the crusher body, the counterbalance weight achieves the required dynamic balance effect without extending the equipment's external height or footprint.
3Reliability
If a complex transmission assembly is used, then torque transmission reliability can be maintained, but the manufacturing and installation costs increase
Solution Approach 1:
The patent extracts the core reliability function from the complex transmission assembly and implements it through a simplified direct drive system. By removing intermediate transmission components that are prone to failure, the patent maintains torque transmission reliability through a more robust and simpler mechanical connection between the engine and unbalance weight shaft.
Solution Approach 2:
The patent merges the functions of the engine output shaft and the unbalance weight drive shaft into a single direct connection. This consolidation eliminates multiple separate transmission components and their associated failure points, achieving reliable torque transmission through a unified, simpler mechanical system that reduces both manufacturing and installation costs.
4Power
If the transmission assembly and counterbalance weight are arranged in the traditional configuration, then torque transmission can be achieved, but the overall cost and maintenance complexity increase
Solution Approach 1:
The patent extracts the essential torque transmission function from the complex traditional transmission assembly and implements it through a simplified direct drive configuration. This reduction in mechanical components directly lowers maintenance complexity by eliminating multiple moving parts, bearings, and lubrication points that require regular maintenance attention.
Solution Approach 2:
The patent combines the transmission function and counterbalance mechanism into a more integrated and simplified arrangement. By merging these functions into a compact configuration with fewer discrete components, the patent reduces the overall maintenance complexity while maintaining effective torque transmission to the unbalance weight.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the reliability and cost-effectiveness of the crusher by reducing the height by 20% and total cost by 5-10%, while improving maintenance efficiency and extending the service life of components through a more compact and simpler design.
Implementation Method 1
When the unbalance weight rotates, a centrifugal force is generated, making the inner cone roll without a gap between it and the outer cone
Implementation Method 2
a counterbalance, in other words an additional unbalance weight, which is installed in phase opposition to the unbalance weight and generates its own centrifugal force directed opposite to the centrifugal forces of the inner cone and its unbalance weight. The forces compensate each other, which results in lower vibration loads on the crusher's components
Data Source
AI summary
A cone crusher includes body installed on foundation with resilient dampers and having an outer cone and an inner cone. Unbalance weight is on the drive shaft of inner cone using a slide bushing, with center of gravity adjustable relative to rotation axis, slide damper of unbalance weight connected to transmission coupler, through which torque is transmitted. Transmission coupler is a disc coupler comprising a drive half-coupler, a driven half-coupler, and a floating disc between them. The driven half-coupler is rigidly connected to slide bushing, and the drive half-coupler, to gear rigidly connected to counterbalance weight. The drive half-coupler, gear and counterbalance weight are mounted on the slide bushing, and driving half-coupler, gear, counterbalance weight, and the slide bushing form one movable dynamic assembly, installed using a mounting disc, on fixed rotation axis, which rests upon flange rigidly fixed in the bottom part of body of the crusher.