1. Cone Crushers Evolution - D. Kaja

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CONE CRUSHER

DESIGN EVOLUTION

DE

AN KA

JA

Global Technical Support Manager

Metso

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G

yratory

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Invention of the gyratory crusher by

Charles M. Brown in 1878 for Gates

Iron Works in Chicago, Illinois, USA.

Became known as the Gates gyratory

crusher.

17-19 Noviembre 2010, Santa Cruz-Chile

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M

cC

ully

P

rima

ry G

yra

tory

Gyratory was introduced with its

shorter shaft design

(4)

SUPERIOR

_{™ Primary Gyratory}

IIn

n 1

19

95

51 1 tth

he

e S

SU

UP

PE

ER

RIIO

OR

R

design was introduced which

included bottom discharge.

(5)

SUPERIOR

_{™ Primary Gyratory}

The SUPERIOR design

included the option of hydraulic

mai

mainsh

nshaft

aft pos

positi

itioni

oning to

ng to

compensate for mantle and

concave wear

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SUPERIOR

_{™ MK II Primary Gyratory}

IIn

n 1

19

99

94 4,, tth

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e S

SU

UP

PE

ER

RIIO

OR

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Prriim

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G

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orry

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up

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42-65 MK-II

and

50-65 MK-II

In 1998 the SUPER

SPIDER design

was introduced.

Includes:

New arched spider

Extra top shell

section Longer

to provide:

Larger feed

Lower nip angles

Higher capacity

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The next evolution:

-

-2010 introduction of the

2010 introduction of the

SUPERIOR™

_{60-110E MK-II}

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SUPERIOR

™™

60-110E MK-II Gyratory

Recent Upgrades

¾

¾ Spider DesignSpider Design

Using FEA and strain gage data, the Spider was Using FEA and strain gage data, the Spider was redesigned. The Spider now features an

redesigned. The Spider now features an archedarched o

oppeenn nng g o o rree uucce e mmaa eerr a a rr gg nngg. . eew w aarrmm shields and spider cap provide improved protection shields and spider cap provide improved protection to the Spider.

to the Spider.

9

9 Standard Rock Box arm shields and Standard Rock Box arm shields and Spider capSpider cap

9

9 Arm shields wr Arm shields wrap around and intap around and integrate into rim lineregrate into rim linerss

9

9 New rim liner retention system requires no bolts for installationNew rim liner retention system requires no bolts for installation

9

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SUPERIOR

™™

60-110E MK-II Gyratory

Recent Upgrades

6

60 0--1

11

10

0

6

60 0--1

11

10 0E

E

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SUPERIOR

™™

60-110E MK-II Gyratory

Recent Upgrades

¾

¾ Bottomshell DesignBottomshell Design

The redesigned single piece Bottomshell reduces components and The redesigned single piece Bottomshell reduces components and installation time.

installation time. Using strain Using strain gage data gage data from gyratory from gyratory crushers in crushers in use,use, new FEA

new FEA models were created. models were created. Using these Using these newly created FEnewly created FEAA

models, the new Bottomshell was conceived using state of the art and models, the new Bottomshell was conceived using state of the art and modern design tools.

modern design tools.

9

9 Smart design increases strength through smooth sections andSmart design increases strength through smooth sections and transitions

transitions

9

9 Additional bracing on internal pinion arm Additional bracing on internal pinion arm

9

9 Raised mounting flangeRaised mounting flange

9

9 Robust four arm designRobust four arm design

9

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SUPERIOR

™™

60-110E MK-II Gyratory

Recent Upgrades

60-110

T

Two Pie

wo Piece

ce

60-110E

One Piece

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SUPERIOR

™™

60-110E MK-II Gyratory

Recent Upgrades

¾

¾ TTopsopshelhelll DesDesignign

9

9 Redesigned using FEA models generated with strain gage data fromRedesigned using FEA models generated with strain gage data from crushers in use

crushers in use

9

9 High strength banded construction provides trouble-free operation andHigh strength banded construction provides trouble-free operation and long life

long life

9

9 FEA aFEA analyzed to reduce nalyzed to reduce stress concentrationsstress concentrations

9

9 Tapered flanges for simplified constructionTapered flanges for simplified construction

¾

¾ Component InterchangeabilityComponent Interchangeability

9

9 SpiderSpider, Bottomshell, and T, Bottomshell, and Topshellsopshells can be installed onto can be installed onto existing 60-1existing 60-11010 MK-II crushers

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SUPERIOR

™™

60-110E MK-II Gyratory

Recent Upgrades

60-110

60-110E

60-110

60-110E

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SUPERIOR

™™

60-110E MK-II Gyratory

Model Information

¾

¾ Largest of theLargest of the SUPERIOR SUPERIOR ™™ _{Gyratory family}_{Gyratory family}

¾

¾ Maximum of 1600 horsepower (1200 kW)Maximum of 1600 horsepower (1200 kW)

¾

¾ Model Naming Convention:Model Naming Convention:

>

> 1st number = feed opening in inches1st number = feed opening in inches

>

> 2nd number = mantle diameter in inches2nd number = mantle diameter in inches

1

1.. 11..

2. 2.

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Cone Crusher Evolution

Edgar B. Symons designs the pillar Edgar B. Symons designs the pillar shaft gyratory crusher in 1907 while shaft gyratory crusher in 1907 while working for Smith & Post, the

working for Smith & Post, the

predecessor to Smith Engineering predecessor to Smith Engineering

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The Symons Horizontal Disc Crusher

In 1911, Mr. Symons develops another crusher, the horizontal disc In 1911, Mr. Symons develops another crusher, the horizontal disc crusher

crusher. He and his . He and his brothers start a new company brothers start a new company called, the Symonscalled, the Symons rroott eerrs s oo. . tto o eevvee oop p aan n sse e tt s s nneew w nnvveenntt oonn..

The horizontal disc crusher used centrifugal force and a gyrating The horizontal disc crusher used centrifugal force and a gyrating ac

actition on to to rere eaeatetedl dl crcrusush h ththe e orore e as as it it asassesed d ououtwtwarard d ththrorouu h h ththee chamber.

(18)

The Symons Vertical Disc Crusher

A

A later designlater design patented in 1915 patented in 1915 became the Symons became the Symons V

Vertical Disc ertical Disc Crusher Crusher

crushing surface and crushing surface and the centrifugal force the centrifugal force to spin the ore

to spin the ore

outward through the outward through the crushing

crushing chamberchamber..

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The Symons™ Cone Crusher

.

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“Symons” Crushing Action

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Symons™ Cone Crusher

““ ”” ““ ””

configurations configurations

Requires different bowl and Requires different bowl and head assemblies

head assemblies

The Short Head version was The Short Head version was

’’ Improvements were made Improvements were made over the years to increase over the years to increase

e p

e poowweer rr raa nngg..

Standard

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7 Ft. Super Heavy Duty

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Nor

dbe

rg™

Gyra

disc

cru

she

r

Gyra

Gyradisdiscc crucrushesher develor developed inped in early 1950’s to operate with early 1950’s to operate with multi-layer crushing on a multi-layer crushing on a n

naarrrroow w zzoonne e o o e e cc aamm eer r Mainly used for producing Mainly used for producing a

ass hhaallt t cchhii s s aanndd manufactured sand manufactured sand

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The Omnicone™ Crusher

The Omnicone was developed in The Omnicone was developed in

’’

modern crusher with the same modern crusher with the same

crushing action as the Symons cone crushing action as the Symons cone which would be better suited to the which would be better suited to the m

moo e e ccrruuss nng g mmaarr eett..

The crusher was more compact, The crusher was more compact, bette

better balr balanced anced and hand had moad moderndern hydraulics to provide setting

hydraulics to provide setting adjustment, tramp release and adjustment, tramp release and cavity clearing

cavity clearing

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The Omnicone™ Crusher

,,

crusher became popular because it crusher became popular because it used one bowl and head for all

used one bowl and head for all crushing cavities and provided the crushing cavities and provided the crushing capacity in a more compact crushing capacity in a more compact machine

machine than than the the Symons Symons conecone

adjustment, tramp release and adjustment, tramp release and

clearing meant that the crusher was clearing meant that the crusher was able to have higher availability and to able to have higher availability and to o

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HP™ and MP™ Cone

a

en

The use of higher speed and The use of higher speed and throw allowed the increase in throw allowed the increase in capacity and power without capacity and power without

,, crusher

crusher

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Prototype MP1000

w

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MP Series Cone Crusher

The MP1000 was designed as a The MP1000 was designed as a combination of the Omnicone combination of the Omnicone s

stt llee iinntteerrnnaall ccoomm oonneennttss aanndd aa Symons 7 Ft. Super HD Cone Symons 7 Ft. Super HD Cone Crusher

Crusher e

erry y g g ccrruuss nng g oorrccee

capability with the advantages of capability with the advantages of modern hydraulics

modern hydraulics

First unit tested starting in 1985 First unit tested starting in 1985 The MP800 was introduced in The MP800 was introduced in of the MP1000

of the MP1000

Over 200 MP cones produced Over 200 MP cones produced

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The HP™ Series Cone Crusher

The HP cone crusher was The HP cone crusher was

It now includes the It now includes the

HP100, HP200, HP300, HP100, HP200, HP300, HP400, HP500 and HP400, HP500 and HP800 size crushers HP800 size crushers

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HP700 and HP200

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The HPX Series Cone Crusher

The HPX Series crushers The HPX Series crushers have larger throw and higher have larger throw and higher it ideal for fine crushing

it ideal for fine crushing applications

applications

The power rating for a given The power rating for a given machine size is increased by machine size is increased by 30% over the same size HP 30% over the same size HP

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The next evolution:

o

r

e

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g

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MP1000 and MP800 MP1000 and MP800

¾

¾ Using the proven Symons principle of crushing,Using the proven Symons principle of crushing, FtFt the new MP1250 builds on the high pivot point

the new MP1250 builds on the high pivot point and increased throw concepts to further

and increased throw concepts to further enhance crusher performance

enhance crusher performance

α α Fc Fc Fcx Fcx ¾

¾ The benefits of the MP1250 can be obtained inThe benefits of the MP1250 can be obtained in either a new crusher or retrofit kit to existing either a new crusher or retrofit kit to existing MP1000 crushers

MP1000 crushers

cy cy

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N

or

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rg MP

™™

1250

cone crusher

New Features

n

nccrreeaasse e oowweer r aappaacc yy

¾

¾ Redesigned MainframeRedesigned Mainframe

¾

¾ Reduced No-Load Head SpinReduced No-Load Head Spin e

eaavvy y uutty y oouunntteerrwwee gg tt

¾

¾ Sleeved EccentricSleeved Eccentric

¾

¾ Gradation Auto-Setting (Optional)Gradation Auto-Setting (Optional) m

mpprroovve e rraammp ep e e e yysstteemm

¾

¾ Higher Speed Bowl AdjustHigher Speed Bowl Adjust

¾

¾ Improved Drive Ring BracketsImproved Drive Ring Brackets

¾

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N

or

db

e

rg MP

™™

1250

cone crusher

Increased Power and Capacity

Higher Fulcrum Point Higher Fulcrum Point Increased Throw Increased Throw

¾

¾ Up to 30% Increase in capacityUp to 30% Increase in capacity ¾

¾ Increased power to 1250 hpIncreased power to 1250 hp ¾

¾ More work performed in eachMore work performed in each crushing cycle

crushing cycle ¾

¾ More efficient use of power More efficient use of power

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N

or

db

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rg MP

™™

1250

cone crusher

Improved Mainframe

¾

¾ Same footprint as MP1000Same footprint as MP1000

¾

¾ Reduced stress concentrationsReduced stress concentrations

¾

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N

or

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rg MP

™™

1250

cone crusher

Reduced No-Load Head Spin

¾

¾ Patent Pending design of Socket andPatent Pending design of Socket and Upper Head Bushing

Upper Head Bushing

¾

¾ New design reduces no-load headNew design reduces no-load head s

s in in wwitithhouout tt thhe ae anntiti-s-s in in memechchananisismm

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N

or

db

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rg MP

™™

1250

cone crusher

Head Spin Comparison

¾

¾ MP1250 without new socketMP1250 without new socket ¾¾ MP1250 with patent pendingMP1250 with patent pending e

ess ggnn

¾

¾ No anti-spin mechanismNo anti-spin mechanism

n

neew w ssoocc e e eess ggnn

¾

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N

or

db

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rg MP

®®

1250

cone crusher

Heavy Duty Counterweight and Guard

¾

¾ Unique, heavy-duty counterweight limitsUnique, heavy-duty counterweight limits

unbalanced dynamic forces (patent pending) unbalanced dynamic forces (patent pending)

¾

¾ One-piece guard bolts on for easy replacementOne-piece guard bolts on for easy replacement

¾

¾ Tight tolerance guard also restricts debris fromTight tolerance guard also restricts debris from entering underneath the head

entering underneath the head

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N

or

db

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rg MP

®®

1250

cone crusher

Sleeved Eccentric

¾

¾ Increased throw eccentricIncreased throw eccentric

¾

¾ Improved bearing surface finishImproved bearing surface finish

¾

¾ Protects eccentric in overloadProtects eccentric in overload c

coonn oonnss

¾

¾ Reduced replacement costs, if Reduced replacement costs, if necessary

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N

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rg MP

®®

1250

cone crusher

Gradation Auto-Setting System (Optional)

¾

¾ Eliminates the need for frequentEliminates the need for frequent ¾¾ Automatically adjusts the crusher Automatically adjusts the crusher

¾

¾ Continually monitors product sizeContinually monitors product size ¾¾ More consistent crushingMore consistent crushing operation and product output operation and product output

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N

or

db

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rg MP

®®

1250

cone crusher

Improved Tramp Relief System

¾

¾ Constant pressure / force limitedConstant pressure / force limited

¾

¾ Fast-acting relief valves to minimizeFast-acting relief valves to minimize pressure spikes during tramp events pressure spikes during tramp events

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N

or

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®®

1250

cone crusher

Improved Bowl Adjust System

¾

¾ UtilizeUtilizes (3) s (3) hydrauhydrauliclic adjust adjust motorsmotors rather than (4)

rather than (4) ¾

¾ 30% faster bowl removal & adjustment30% faster bowl removal & adjustment ¾

¾ Faster hydraulic re-pressurizationFaster hydraulic re-pressurization ¾

¾ Reduced maintenanceReduced maintenance

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®®

1250

cone crusher

Improved Drive Ring Brackets

¾

¾ Replaces roller bearingsReplaces roller bearings ¾

¾ InIncrcreaeaseses ls lonon evevitit

Wear Pad Wear Pad

¾

¾ Impervious to the elementsImpervious to the elements ¾

¾ Reduces maintenance timeReduces maintenance time Support BracketSupport Bracket (no greasing)

(no greasing) ¾

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N

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rg MP

®®

1250

cone crusher

New Mantle Locknut

a

acc -- o o ss y e y e oocc nng g nnuu

¾

¾ Only basic hand tools required!Only basic hand tools required!

Jack-Bolts Jack-Bolts

¾

¾ Constant holding forceConstant holding force

¾

¾ Quick & easy installation andQuick & easy installation and removal

removal

Thrust Plate Thrust Plate

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N

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®®

1250

cone crusher

TC-1000 Automation System Features

¾

¾ ComCom lelete cte crurushsher ser statatition coon contntroroll ¾

¾ PLC control is adaptable to any crushing plant applicationPLC control is adaptable to any crushing plant application ¾

¾ Overload warning and protectionOverload warning and protection a

assy y o o rreea a u u ccoo oor r sspp aayy ¾

¾ Simple navigation through user-friendly screensSimple navigation through user-friendly screens ¾

¾ Liner wear detection without leaving the control roomLiner wear detection without leaving the control room ¾

¾ Integrated feed rate control based on power and Integrated feed rate control based on power and cavitycavity level utilizing multiple PID loop calculations

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N

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®®

1250

cone crusher

TC-1000 Automation System Functions

¾

¾ Lubrication SystemLubrication System ¾

¾ Crusher main drive motor Crusher main drive motor ¾

¾ Feed deviceFeed device ¾

¾ Upstream and downstreamUpstream and downstream

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™™

1250

cone crusher

Retrofit Kit

¾

¾ As few as five new parts are As few as five new parts are required per retrofit

required per retrofit ¾

¾ Machines designed for anti-spinMachines designed for anti-spin will also require a new socket will also require a new socket ¾

¾ Anti-spin device must be removed, Anti-spin device must be removed, if applicable

if applicable ¾

¾ Existing motor (1000 hp) may beExisting motor (1000 hp) may be used depending on application used depending on application details and amperage draw details and amperage draw

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®®

1250

cone crusher

Retrofit Kit

¾

¾ Anti-spin designed machines Anti-spin designed machines also require a new socket also require a new socket

¾

¾ Foundation analysis required toFoundation analysis required to confirm safety factor

confirm safety factor recommended

recommended

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