Split Mainframe Tramp Release Cylinders Cone Crusher
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Solution Overview
Problem
Large cone crushers experience high cycle fatigue failures in their fasteners due to large vertical forces transmitted during operation, which are not effectively mitigated by existing systems.
Innovation Solution
The implementation of tramp release cylinders that create compressive forces to reduce tensile loads on fasteners joining the upper and lower mainframe sections, using a series of hydraulic cylinders to compress the upper mainframe between the lower mainframe and the adjustment ring, thereby reducing the load on fasteners and preventing fatigue failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the mainframe is split into upper and lower sections to facilitate manufacturing and transportation, then ease of manufacture and transportation is improved, but the fasteners joining the sections are subjected to large cyclic tensile loads that lead to high cycle fatigue failures
Solution Approach 1:
The tramp release cylinders generate compressive forces that act as counterforces to the tensile loads on the fasteners. By applying compression to the upper mainframe section, the system offsets the cyclic tensile stresses that would otherwise cause fatigue failure in the fasteners, thereby extending their service life while maintaining the split mainframe configuration.
Solution Approach 2:
The tramp release cylinders serve as intermediary devices between the upper and lower mainframe sections. These cylinders mediate the force transmission by providing an active compression mechanism that reduces the load on the passive fastener connection, allowing the split mainframe design to be both manufacturable and reliable.
2Productivity
If the head assembly is positioned at a significantly declined angle from vertical to achieve crushing function, then crushing effectiveness is improved, but large vertical forces are transmitted through the mainframe that increase fastener tensile loads
Solution Approach 1:
The tramp release cylinders provide counteracting compressive forces that balance the large vertical forces generated during crushing operations. This allows the head assembly to maintain its declined angle for effective crushing while the cylinders compensate for the resulting tensile loads on the fasteners.
Solution Approach 2:
The tramp release cylinders apply preliminary compressive action to the upper mainframe section before the full crushing cycle begins. This pre-compression helps offset the impending vertical forces that will be generated during crushing, reducing the net tensile load on the fasteners throughout the operation.
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 compressive forces generated by the tramp release cylinders significantly reduce the tensile stress on fasteners, extending their lifespan and preventing fatigue failures, while also allowing for a more stable mounting configuration that reduces overturning moments and improves foundation stability.
Implementation Method 1
a plurality of tramp release cylinders that each extend between the upper flange of the lower mainframe and the attachment flange of the adjustment ring. Each of the tramp release cylinders can be actuated to create a compressive force
Implementation Method 2
The compressive force created by the plurality of tramp release cylinders compresses the upper mainframe between the lower mainframe and the adjustment ring. The compressive force created by the tramp release cylinders reduces the tensile forces seen by the fasteners
Data Source
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AI summary
A cone crusher that includes an upper mainframe (16) and a lower mainframe (14) joined to each other. The upper mainframe is positioned between the lower mainframe and an adjustment ring (20). A series of tramp release cylinders (38) extend between an upper flange formed on the lower mainframe and an attachment flange (40) formed on the adjustment ring. The series of tramp release cylinders compress the upper mainframe between the adjustment ring and die lower mainframe. The series of hydraulic tramp release cylinders create a compression force that prevents cyclic tension during crushing for the fasteners used to secure the lower mainframe to the upper mainframe.