Gyratory Crusher Shell With Radial Wedges
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Solution Overview
Problem
Gyratory crushers often choke due to insufficient crushing force, leading to premature opening of the crushing zone and disruption in material processing, as they struggle to handle material beyond their capacity in the lower crushing zones.
Innovation Solution
The introduction of radially projecting wedges on the crushing shells, which create channels to control material flow and increase the choke zone's axial position, reducing the volume of material processed and allowing operation at a smaller close side setting without increasing crushing force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the crusher processes more material in the lower crushing zones, then the productivity increases, but the crushing force becomes insufficient leading to choking
Solution Approach 1:
The crushing shell is segmented into multiple zones with different wedge configurations. Upper zones have wedges that create channels to control material flow, while lower zones have different configurations. This segmentation allows material to be progressively controlled and crushed through different stages, preventing choking in any single zone while maintaining overall productivity.
Solution Approach 2:
Different regions of the crushing shell have locally optimized properties. The upper crushing zones feature wedges with specific profiles designed to control material flow and create appropriate choke points, while lower zones have different geometries. This local quality optimization ensures that each zone performs its specific function effectively, maintaining crushing force where needed while managing material flow.
2Manufacturing precision
If the close side setting is reduced to increase reduction capacity, then the reduction potential increases, but the crushing force requirement increases beyond available capacity
Solution Approach 1:
The wedge configurations create dynamic material flow patterns that adapt to the crushing process. As material moves through the crushing zones, the wedges guide and control its progression, creating optimal crushing conditions at each stage. This dynamic control allows the system to achieve high reduction ratios without requiring excessive crushing force, as the material is progressively reduced through controlled flow paths.
Solution Approach 2:
The solution moves beyond simply adjusting the close side setting in one dimension. Instead, it introduces a third dimension through axial wedge profiles that create channels and control material flow in the axial direction. This multi-dimensional approach to material control allows high reduction capacity to be achieved by managing material flow paths rather than just reducing gap size, avoiding the need for excessive crushing force.
3Productivity
If the crusher operates at high material flow rates, then the productivity increases, but the material flow becomes uncontrolled causing choking
Solution Approach 1:
The wedges act as intermediary elements between the material flow and the crushing zones. They create channels that guide material flow and establish controlled choke points where material is temporarily restrained before being crushed. These intermediary wedge structures mediate between high material flow rates and the need for controlled processing, preventing uncontrolled choking while maintaining high productivity through efficient material guidance.
Solution Approach 2:
The wedge geometry parameters are specifically designed to control material flow characteristics. The wedge height, angle, and spacing are optimized to create appropriate flow resistance and channel dimensions. By carefully adjusting these geometric parameters, the system can handle high material flow rates while maintaining stable, controlled flow patterns that prevent choking and ensure consistent crushing performance.
Data Source
AI summary
A gyratory crusher crushing shell having a mount face for contacting a support region of the crusher and a crushing face to contact material to be crushed and passing through the crushing zone. The crushing shell includes a plurality of wedges project radially from the crushing surface, the wedges being spaced apart in a circumferential direction around the axis to define channels extending axially between the wedges.