Gyratory Crusher Spider Open Channel Design
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Solution Overview
Problem
Existing rock crushing machines, such as gyratory and cone crushers, face challenges in withstanding large crushing forces that can lead to spider damage, requiring frequent shutdowns and repairs, due to the inherent weaknesses in the spider's design, particularly in open sections that are prone to torsional stresses.
Innovation Solution
The spider design features a central hub and bushing with spider arms formed from a pair of vertically oriented flanges and an underlying web, creating an open channel configuration that minimizes torsional stresses by positioning the shear center below the connecting web, thereby enhancing structural strength and durability while simplifying manufacturing and reducing access hole requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the spider arms are constructed with open sections to simplify manufacturing, then ease of manufacture is improved, but torsional stresses increase reducing structural strength
Solution Approach 1:
The spider arm cross-section is designed as an asymmetric open channel shape with the web positioned below the flanges. This asymmetric configuration strategically places material to resist torsional stresses while maintaining manufacturing simplicity. The shear center is positioned within the web area, creating an asymmetric load path that reduces torsional deformation compared to symmetric open sections.
Solution Approach 2:
The channel depth, flange thickness, and web thickness are optimized as specific parameters to balance manufacturing ease with torsional strength. By carefully controlling these dimensional parameters, the open section achieves sufficient torsional resistance without requiring closed section construction, thus maintaining manufacturing simplicity while improving strength.
2Strength
If the spider arms are constructed with larger cross-sections to withstand crushing forces, then strength is improved, but device complexity and cost increase
Solution Approach 1:
The spider arm is segmented into distinct functional components: flanges for lateral support and web for torsional resistance. This segmentation allows each part to be optimized for its specific function, achieving adequate overall strength without requiring a uniformly larger and more complex cross-section throughout the entire arm.
Solution Approach 2:
Material is distributed non-uniformly within the cross-section, with thicker flanges at the top for lateral load resistance and a web positioned below for torsional resistance. This local quality variation optimizes strength where needed while minimizing material usage and complexity in less critical areas.
3Ease of repair
If access holes are added to closed section spider arms to facilitate manufacturing and maintenance, then ease of repair is improved, but structural integrity deteriorates
Solution Approach 1:
The closed section is transformed into an open channel section by removing material to create an open configuration. This extraction of material eliminates the need for access holes while maintaining manufacturing accessibility, as the open structure allows direct access to internal components and lubrication points without compromising structural integrity.
Data Source
AI summary
A spider for use with a gyratory crusher. The spider includes spider arms each formed from two spaced flanges joined by a connecting web to define an open channel having an open top end. The configuration of the spider arms increases manufacturability and provides the required strength and rigidity for the spider. The channel formed in each spider arm is covered by a spider arm shield to reduce abrasive wear to the spider arm.