Cone Crusher Eccentric Contact Pad for Bearing Stability
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Solution Overview
Problem
Cone crushers experience uneven bearing alignment and loss of oil film during no-load or reduced-load conditions, leading to overheating and component damage due to increased centrifugal forces and impact loading, resulting in costly maintenance and production downtime.
Innovation Solution
A bearing arrangement with a contact pad on the eccentric's outer surface, which engages the lower head bushing during no-load conditions, increasing the contact area and maintaining lubrication, while not affecting the crushing mode operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the cone crusher operates under no-load or reduced-load conditions, then the centrifugal forces increase causing uneven bearing alignment, but the crushing forces decrease resulting in loss of oil film and overheating
Solution Approach 1:
The bearing arrangement provides different contact configurations for different operational conditions: during no-load conditions, the bushing contacts the eccentric at a location optimized for centrifugal force distribution, while during crushing operations, the contact location changes to optimize for load-bearing capacity. This local adaptation of contact geometry resolves the contradiction between maintaining bearing alignment stability and accommodating varying force conditions.
2Quantity of substance
If the bearing system operates with small quantity of feed rock, then the crushing forces are reduced, but the centrifugal forces remain high causing impact loading and bushing misalignment
Solution Approach 1:
The bearing arrangement is designed with pre-configured contact surfaces and geometry that anticipate no-load and reduced-load conditions. The bushing and eccentric are shaped to provide stable contact and distribute centrifugal forces evenly before impact loading occurs, preventing misalignment and reducing harmful impact effects during transitions between load conditions.
3Temperature
If the oil film is lost during no-load operation, then the bushing overheats and burns, but adding more lubrication does not prevent the loss of oil film under high centrifugal forces
Solution Approach 1:
The bearing arrangement modifies the physical parameters of the lubrication system by changing the contact geometry between the bushing and eccentric. This geometric modification creates a lubrication regime that maintains oil film stability under high centrifugal forces, preventing oil film loss and subsequent overheating without requiring increased lubrication quantity.
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 the risk of overheating and component damage by maintaining a stable oil film and proper alignment during no-load or reduced-load operations, extending component lifespan and minimizing downtime.
Implementation Method 1
The contact pad includes a contact surface that is recessed from the outer surface of the eccentric such that the lower head bushing engages the contact pad during operation of the cone crusher without material
Implementation Method 2
During these no-load and reduced-load conditions, a loss of oil film between the bushing and the eccentric can be created. This loss of oil film can result in overheating or burning of the bushing during operation
Implementation Method 3
When the cone crusher is operated without rock or other material, referred to as no-load operation, the centrifugal forces created by the moving head assembly results in a completely different area of contact within the bearing system
Data Source
AI summary
A cone crusher includes a stationary main shaft and an eccentric that rotates about the main shaft to cause gyrational movement of a head assembly to crush rock within a crushing gap. The cone crusher includes a lower head bushing in contact with an outer surface of the eccentric. The eccentric is formed with a contact pad to enhance the contact between the eccentric and the lower head bushing during a no-load condition. The contact pad includes a contact surface that is recessed from the outer surface of the eccentric to enhance contact during no-load conditions while maintaining full contact between the lower head bushing and the eccentric outer surface during full load, crushing conditions.