Integrated Jaw Crusher Screen Magnet for On-Site Rubble Processing
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Solution Overview
Problem
Existing devices for crushing and screening stony material are inefficient in producing a 0 - X fraction, particularly 0 - 40 fraction, as they require separate crushing and screening units, leading to high transportation costs due to the need for on-site rubble to be transported to fixed location crushers and screens.
Innovation Solution
A device integrating a jaw crusher, screen with adjustable openings (5 - 100 mm), and a magnet for demagnetization, allowing for on-site crushing and screening of stony material to produce a 0 - X fraction, with the screen placed downstream of the jaw crusher and driven by a hydraulic vibration motor, mounted on a tilting suspension system for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate crushing and screening units are used, then crushing and screening functions are performed, but transportation costs increase due to needing to transport rubble to fixed location crushers
Solution Approach 1:
The patent combines the jaw crusher and screening device into a single integrated unit that can be positioned at the demolition site. The jaw crusher crushes rubble while the screen simultaneously separates crushed material by size, eliminating the need to transport rubble to separate fixed-location crushing and screening facilities.
Solution Approach 2:
The integrated device performs multiple functions at one location: crushing rubble of various sizes, screening crushed material through adjustable mesh sizes, and separating oversize grain for recirculation. This multi-functional capability replaces what previously required separate specialized equipment at fixed locations.
2Manufacturing precision
If a screen is placed upstream of the jaw crusher, then dust and sand are removed first, but the device cannot produce a 0 - X fraction with lower limit of 0
Solution Approach 1:
Instead of placing the screen upstream before crushing (as in prior art), the patent places the screen downstream after the jaw crusher. This inversion allows the crushing mechanism to reduce all material to smaller pieces first, then the screen separates material by size, enabling production of a 0 - X fraction where the lower limit approaches 0.
3Ease of manufacture
If rubble is transported to fixed location crushers, then crushing can be performed, but high transportation costs are incurred
Solution Approach 1:
The integrated crushing and screening device is brought to the demolition site before rubble needs to be disposed of or further processed. By performing crushing and screening on-site, the system eliminates the preliminary action of transporting rubble to fixed facilities, saving both time and transportation costs.
4Reliability
If separate crushing and screening devices are used, then each function is optimized, but device complexity and space requirements increase
Solution Approach 1:
The patent merges the jaw crusher mechanism with a screening device featuring adjustable mesh screens into a single integrated unit. This combination maintains the reliability of separate specialized functions while reducing the number of discrete devices from two or more to one unified system.
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
Enables on-site production of a 0 - X fraction of stony material, reducing transportation costs and requiring only one operator, while allowing for efficient separation and demagnetization of crushed material, thus enhancing operational efficiency and reducing labor costs.
Implementation Method 1
This crushing takes place between two jaws in a jaw crusher
Implementation Method 2
the bucket comprises a screen with openings such that the fraction of dimension X by X mm, wherein X is about 5 - 100, is allowed through
Implementation Method 3
The bucket preferably further comprises a magnet in order to finally obtain a demagnetized crushed product during operation
Implementation Method 4
The screen is preferably further driven by a hydraulic vibration motor
Data Source
Figure 1
Figure 2
AI summary
Described is a device suitable for crushing and screening stony material, comprising a bucket with an inlet for receiving the stony material for crushing and screening and an outlet for discharging the crushed and screened material, and a jaw crusher (01), wherein the bucket comprises a screen (02) with substantially square openings of about X by X mm, wherein X is about 5 - 100, the screen being placed such that during operation the crushed material is guided over the screen. In a preferred embodiment the bucket comprises a magnet (04) for demagnetizing the crushed material. Further described is a method for obtaining a 0 - X fraction of crushed stony material, wherein stony material is guided over the device as described above. A method is also described for obtaining a demagnetized 0 - X fraction of crushed stony material, wherein stony material is guided over the preferred embodiment of the device with magnet.