Jaw Crusher Frame Front End Ribbed Curved Wall Design
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Solution Overview
Problem
Jaw crushers face issues with fretting fatigue due to bolt joints, which lead to loosening and stress concentration, increasing maintenance needs and costs, and the heavy, cumbersome nature of entirely casted frames complicates handling and assembly. Additionally, existing solutions either require numerous parts and expensive machining or suffer from reduced fatigue strength and increased weight.
Innovation Solution
A front end frame design for jaw crushers featuring a detachable, curved front wall with rib structures that transfer loads as membrane stresses, reducing bending strain and weight, and utilizing flange-screw or fork-pin joints to connect frame parts, minimizing the need for bolt joints and allowing for easier assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a multipart frame is assembled with bolt joints and extending pins, then the frame can be manufactured and assembled, but fretting fatigue occurs at the joints leading to loosening and decreased fatigue strength
Solution Approach 1:
The frame is divided into multiple parts (side plates, ends, intermediate pieces) that can be manufactured separately and then assembled. This allows for easier manufacturing and assembly while using connection methods that minimize fatigue vulnerability.
Solution Approach 2:
Intermediate pieces are introduced between the side plates and ends to serve as mediators in the assembly. These intermediate pieces distribute loads and reduce stress concentration at the joints, thereby reducing fretting fatigue and improving reliability.
2Strength
If the frame is entirely casted as a single piece, then structural integrity is improved, but the weight increases and handling becomes difficult
Solution Approach 1:
The frame is segmented into multiple casted parts that can be manufactured separately and then assembled. This reduces the weight and improves handling compared to a single-piece casted frame, while still maintaining structural integrity through proper connection methods.
Solution Approach 2:
Multiple frame parts are combined through assembly to form the complete frame structure. This merging approach allows for weight reduction compared to a single-piece cast while achieving the necessary structural integrity through the connection of individual components.
3Ease of manufacture
If numerous bolt joints and extending pins are used in the frame assembly, then the frame can be constructed, but the number of parts and machined surfaces increases leading to higher costs and assembly time
Solution Approach 1:
The frame is divided into manageable segments (side plates, ends, intermediate pieces) that can be manufactured separately. This segmentation reduces the overall complexity compared to a monolithic structure while allowing for efficient assembly.
Solution Approach 2:
The connection elements (extending pins, bolt joints) are extracted as separate, standardized components. This allows for simplified manufacturing of individual parts and reduces the complexity of the overall assembly process.
4Stability of the object's composition
If welding is used to construct the frame, then structural continuity is achieved, but fatigue strength of the base substance decreases significantly
Solution Approach 1:
The frame is constructed from segmented parts connected through interfaces that preserve fatigue strength. This segmentation avoids the need for continuous welding while maintaining structural continuity through the assembly of individual components with proper connection methods.
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
The design reduces the number of fatigue-critical joints, decreases the overall weight of the frame, and simplifies assembly by reducing the number of parts and machined surfaces, while maintaining or improving fatigue resistance and handling ease.
Implementation Method 1
loads of a crushing event are transferred to membrane stress in the front wall wherein less bending strain is present in the front end
Implementation Method 2
loads of a crushing event are transferred to membrane stress in the front wall wherein less bending strain is present in the front end
Implementation Method 3
The front wall may be stiffened with a rib structure and loads of a crushing event may be transferred to membrane stress in the front wall
Implementation Method 4
The front end may comprise at least one first flange in both side wall parts for a flange-screw joint to be realized with the frame
Implementation Method 5
A fork-pin joint comprises a fork in the side wall of the front part and/or the rear part, and a tongue as a counter joining part
Data Source
Figure 1~8
Figure 2~4
Figure 5~7
AI summary
A front end (10; 310) of a frame (1; 30) of a jaw crusher (100) comprises a curved front wall (411) for receiving crushing force. The front end (10; 310) comprises an inner rib structure (427, 428, 417, 418) formed to the curved front wall (411). A jaw crusher (100) and a crushing plant (200).