Jaw Crusher Hydraulic Layout for Safe Toggle Plate Service
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Solution Overview
Problem
Jaw crushers pose health and safety risks during maintenance due to the manual handling of heavy and cumbersome toggle plates, and the hydraulic system's automatic closure when the motor is off, reducing service time and safety.
Innovation Solution
A jaw crusher service tool with a battery-powered auxiliary pump and accumulator block allows the movable jaw to be independently powered open, eliminating the need for motor operation during maintenance, and a turnbuckle secures the jaw in the open position for safe component handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the motor is switched off to allow manual access to the toggle plate, then safety is improved, but the hydraulic fluid returns under gravity causing closure of the movable jaw which reduces service time and creates safety hazards
Solution Approach 1:
The hydraulic system is segmented into two independent pumps: a primary pump powered by the jaw crusher motor for normal operation, and an auxiliary pump powered by a battery for maintenance operations. This segmentation allows the auxiliary pump to maintain the movable jaw in the open position independently of the motor's operational state, resolving the contradiction between safety and service time.
Solution Approach 2:
The auxiliary pump acts as an intermediary device that provides hydraulic power during maintenance operations without requiring the motor to be running. This intermediary power source prevents hydraulic fluid from returning under gravity, keeping the movable jaw open and extending safe service time.
2Ease of operation
If the motor is activated to lock open the movable jaw for toggle plate removal, then access is improved, but the motor must be switched off subsequently which causes jaw closure and reduces safety
Solution Approach 1:
The hydraulic system is divided into primary and auxiliary pumping functions. The auxiliary pump, powered by a battery, specifically handles maintenance operations including holding the movable jaw open for toggle plate removal. This eliminates the need to activate and then switch off the motor, allowing continuous safe access without jaw closure.
3Ease of repair
If manual handling of toggle plates is performed, then component replacement is achieved, but health and safety risks increase due to the heavy weight of components
Solution Approach 1:
The auxiliary hydraulic system provides self-service capability during maintenance by automatically maintaining the movable jaw in the open position. This eliminates the need for manual forcing or handling of heavy components, as the hydraulic system sustains the open position, allowing safe and easy component replacement.
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
Enhances safety and efficiency by enabling safe and controlled access to toggle plates and other components, reducing the risk of injury and increasing maintenance time, while maintaining the jaw in an open position without hydraulic fluid return.
Implementation Method 1
an auxiliary pump powered independently of the primary pump for effecting movement of the movable jaw
Implementation Method 2
a battery-powered auxiliary pump and accumulator block allows the movable jaw to be independently powered open
Implementation Method 3
a turnbuckle secures the jaw in the open position for safe component handling
Data Source
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AI summary
In one aspect there is provided a jaw crusher (20) comprising a motor providing a primary power source to a primary hydraulic pump of the jaw crusher (20); a crusher frame (50) supporting a fixed jaw (30) and a movable jaw (40) defining a crushing chamber (60); a cross beam transversely mounted in the crusher frame (50); a toggle plate extending between the cross beam and the movable jaw (40), a hydraulic system having a primary pump line (221) powered by the primary hydraulic pump for moving the movable jaw (40) and clamping the toggle plate, wherein the hydraulic system comprises an auxiliary pump (230) powered independently of the primary pump for effecting movement of jaw (40).