Crusher Wedge Concave Retention for Fast Liner Replacement
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Solution Overview
Problem
The removal and replacement of concave segments in gyratory and cone crushers is cumbersome and time-consuming, often requiring hot works and specialized training, leading to significant downtime and safety risks.
Innovation Solution
A concave retaining system with a wedge concave design that allows for easy removal and replacement without thermal lancing, using a wedge concave with angled side walls and wedges to create access gaps, secured by connectors, and a removal tool to push the wedge concave inward.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermal lancing is used to remove concave segments, then the concaves can be released from hoop stresses and removed, but the process becomes time-consuming and requires hot works with safety risks
Solution Approach 1:
The concave liner is divided into multiple individual segments that can be removed independently. Each segment has a convex engagement surface that interfaces with corresponding concave surfaces in the frame, allowing segments to be removed one at a time without requiring thermal lancing to release hoop stresses across the entire liner.
Solution Approach 2:
The wedge-shaped removal tool extracts the concave segments from the frame by inserting into the removal space and applying mechanical force to disengage the convex engagement surfaces from the concave surfaces in the frame, eliminating the need for thermal lancing.
2Ease of repair
If thermal lancing and rock breakers are used for concave removal, then concaves can be detached, but specialized training and hot works equipment are required
Solution Approach 1:
The concave segments are designed with self-retaining features where the convex engagement surfaces automatically secure the segments in the frame during operation, but allow for tool-free or simple tool-assisted removal by pulling or prying, eliminating the need for complex thermal lancing equipment and rock breakers.
Solution Approach 2:
A wedge-shaped removal tool acts as an intermediary device that inserts into the removal space between the concave segment and frame, applying mechanical force to disengage the convex engagement surfaces, replacing the need for complex thermal lancing and rock breaker equipment.
3Reliability
If traditional concave retention methods are used, then concaves are securely held in place, but removal requires destructive thermal lancing
Solution Approach 1:
The concave liner is segmented into multiple removable sections, each with convex engagement surfaces that interface with concave surfaces in the frame. This segmentation allows secure retention during operation while enabling non-destructive removal by simply pulling or prying the segments away from the frame.
Solution Approach 2:
The design enables extraction of concave segments from the frame without destructive thermal lancing by utilizing the removal space and convex-concave surface geometry, allowing segments to be pulled or pried away using simple tools or even manual force.
Data Source
AI summary
A removable and replaceable crushing shell for use in a top shell of a gyratory or cone crusher. The crushing shell includes a series of concaves that are arranged in a row with straight side walls of the concaves in contact with each other. A wedge concave is positioned within a receiving gap between two adjacent concaves. The wedge concave includes opposite angled side walls that converge in a radially outward direction. One or more connectors hold the wedge concave in place on the frame of the top shell. A wedge is inserted between the angled side walls of the wedge concave and the straight side walls of the concaves to restrict radially outward movement of the wedge concave. The wedge concave can be removed from the crushing shell though a inward force to release hoop stresses in the row of concaves.