Crusher Mantle Locking Bolt Assembly with Reusable Thrust Plate
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Solution Overview
Problem
The existing locking bolt assemblies for cone crushers require significant manual effort and safety hazards for mantle installation and replacement, leading to increased maintenance costs and risks due to the use of heavy tools and consumable torch rings.
Innovation Solution
A locking bolt assembly featuring a re-useable thrust plate and permanent jacking screws that secure the mantle to the head assembly, allowing for safer and more efficient installation and removal without the need for heavy tools or consumable torch rings, utilizing a torque wrench for controlled force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy tools (pendulum rams or sledge hammers) and large wrenches are used to tighten the locking bolt, then the locking bolt can be secured, but the threads of the locking bolt are subjected to undetermined force which can mechanically weaken the locking bolt or strip the threads
Solution Approach 1:
A thrust plate is introduced as an intermediary component between the locking bolt and the mantle. The thrust plate distributes the clamping force over a larger area, preventing direct concentration of force on the locking bolt threads. This mediator allows the locking bolt to secure the mantle without subjecting its threads to damaging point loads from heavy impact tools.
2Ease of manufacture
If a consumable torch ring is used to secure the mantle, then the mantle can be attached to the head assembly, but the torch ring requires an oxygen/acetylene torch to cut it off which is unsafe and unnecessary, and the consumable product increases customer costs
Solution Approach 1:
The harmful consumable torch ring is completely removed from the system. Instead, a reusable thrust plate with a hardened bearing surface is installed on the mantle, which can withstand repeated tightening and loosening cycles without requiring cutting or replacement. This extracts the dangerous element while maintaining the functional requirement of securing the mantle.
Solution Approach 2:
The consumable torch ring is replaced with a reusable thrust plate that can be recovered and reused across multiple mantle installations. The thrust plate is designed to withstand wear from repeated use, eliminating the need to discard and replace a consumable component for each maintenance cycle.
3Strength
If large wrenches and heavy tools are used to tighten the locking bolt, then the locking bolt can be secured, but several maintenance personnel are required which increase maintenance costs and time
Solution Approach 1:
The thrust plate acts as a force-distributing intermediary that allows standard-sized wrenches to be used effectively. By distributing the clamping force across the thrust plate's surface area, the system achieves adequate securing force without requiring oversized tools or multiple personnel applying coordinated force.
4Ease of manufacture
If a torch ring is used to secure the mantle, then the mantle can be attached, but the torch ring is a consumable product which increases customer costs
Solution Approach 1:
The consumable torch ring is replaced with a reusable thrust plate that remains on the mantle and can be recovered and reused for subsequent mantle installations. This eliminates the recurring cost of replacing consumable torch rings while maintaining the attachment function.
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 reduces maintenance time and costs by enabling single-person operation with reduced risk, preventing thread stripping, and eliminating the need for consumable torch rings, while ensuring a secure mechanical connection.
Implementation Method 1
one or more permanent jacking screws disposed in and at least partially through the axial bores for forcing the locking bolt up and the thrust plate down onto the top surface portion of the mantle
Implementation Method 2
one or more fasteners disposed in and at least partially through the axial bores for connecting the locking bolt to the re-useable thrust plate
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A locking bolt assembly (1) for securing a mantle (40) to a head assembly (60) of a crushing device comprising: a locking bolt (10) having a head portion (10a) and a thread portion (10b); a re-useable thrust plate (30) disposed between the head portion (10a) and a top surface portion (42) of the mantle (40); one or more fasteners (20) for connecting the locking bolt (10) to the re-useable thrust plate (30); and one or more permanent jacking screws (34) for forcing the locking bolt (10) up and the thrust plate (30) down onto the top surface portion (42) of the mantle (40) so that the mantle (40) is secured on the head assembly (60). Also provided is a method for securing a mantle (40) to a head assembly (60) of a crushing device using the locking bolt assembly (1).