1. Cone Crushers Evolution - D. Kaja

7/27/2019 1. Cone Crushers Evolution - D. Kaja

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CONE CRUSHERCONE CRUSHERDESIGN EVOLUTIONDESIGN EVOLUTION

DEAN KAJA

Global Technical Support Manager

Metso

17-19 Noviembre 2010, Santa Cruz-Chile



Gyratory Crusher Evolution

a es gyra ory crus er

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.




McCully Primary Gyratory

Gyratory was introduced with itsshorter shaft design




SUPERIOR™ Primary Gyratory

In 1951 the SUPERIOR

design was introduced whichincluded bottom discharge.




SUPERIOR™ Primary Gyratory

The SUPERIOR design

included the option of hydraulic

mainshaft positioning to

compensate for mantle and

concave wear




SUPERIOR™ MK II Primary Gyratory

In 1994, the SUPERIOR Primary

Gyratory was updated to the MK II

version with a larger relative diameter

o upper ourna w e remova o

the locking nut threads from the shaft

to provide more strength. Also

and higher operating speeds to

increase the power rating and




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




The next evolution:

- -

2010 introduction of the

SUPERIOR™ 60-110E MK-II




SUPERIOR™ 60-110E MK-II GyratoryRecent Upgrades

¾ Spider DesignUsing FEA and strain gage data, the Spider was

redesigned. The Spider now features an arched

open ng o re uce ma er a r g ng. ew arm

shields and spider cap provide improved protectionto the Spider.

9 Standard Rock Box arm shields and Spider cap

9 Arm shields wrap around and integrate into rim liners

9 New rim liner retention system requires no bolts for installation

9 Rim liner retention system ties all liners together to act as one piece





60-110 60-110E





¾ Bottomshell Design

The redesigned single piece Bottomshell reduces components and

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

new FEA models were created. Using these newly created FEA

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

9 Smart design increases strength through smooth sections andtransitions

9 Additional bracing on internal pinion arm

9 Raised mounting flange

9 Robust four arm design

9 One piece design





60-110

Two Piece

60-110E

One Piece





¾ Topshell Design

9 Redesigned using FEA models generated with strain gage data fromcrushers in use

9 High strength banded construction provides trouble-free operation and

long life

9 FEA analyzed to reduce stress concentrations

9 Tapered flanges for simplified construction

¾ Component Interchangeability

9 Spider, Bottomshell, and Topshells can be installed onto existing 60-110MK-II crushers





60-110 60-110E




SUPERIOR™ 60-110E MK-II GyratoryModel Information

¾ Largest of the SUPERIOR ™ Gyratory family

¾ Maximum of 1600 horsepower (1200 kW)

¾ Model Naming Convention:> 1st number = feed opening in inches

> 2nd number = mantle diameter in inches

1. 1.

2.




Cone Crusher Evolution

Edgar B. Symons designs the pillar

shaft gyratory crusher in 1907 while

working for Smith & Post, thepredecessor to Smith Engineering




The Symons Horizontal Disc Crusher

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

crusher. He and his brothers start a new company called, the Symons

rot ers o. to eve op an se t s new nvent on.

The horizontal disc crusher used centrifugal force and a gyrating

action to re eatedl crush the ore as it assed outward throu h the

chamber.




The Symons Vertical Disc Crusher

A later design

patented in 1915

became the Symons

Vertical Disc Crusher

crushing surface and

the centrifugal force

to spin the oreoutward through the

crushing chamber.




The Symons™ Cone Crusher


. .



“Symons” Crushing Action




Symons™ Cone Crusher

“ ” “ ”

configurations

Requires different bowl and

head assemblies

The Short Head version was’

Improvements were made

over the years to increase

e power ra ng.

Standard Short Head




7 Ft. Super Heavy Duty




The Omnicone™ Crusher

The Omnicone was developed in

’

modern crusher with the same

crushing action as the Symons cone

which would be better suited to the

mo e crus ng mar et.

The crusher was more compact,

better balanced and had modern

hydraulics to provide setting

adjustment, tramp release and

cavity clearing




The Omnicone™ Crusher

,

crusher became popular because it

used one bowl and head for all

crushing cavities and provided the

crushing capacity in a more compact

machine than the Symons cone

adjustment, tramp release and

clearing meant that the crusher was

able to have higher availability and to

opera e a e op mum se ng




HP™ and MP™ Cone

a en

The use of higher speed and

throw allowed the increase incapacity and power without

,

crusher




Prototype MP1000

wau ee ac ory n




MP Series Cone Crusher

The MP1000 was designed as a

combination of the Omnicone

st le internal com onents and a

Symons 7 Ft. Super HD Cone

Crusher

ery g crus ng orce

capability with the advantages of

modern hydraulics

First unit tested starting in 1985

The MP800 was introduced in

of the MP1000

Over 200 MP cones produced




The HP™ Series Cone Crusher

The HP cone crusher was

It now includes the

HP100, HP200, HP300,

HP400, HP500 and

HP800 size crushers




HP700 and HP200




The HPX Series Cone Crusher

The HPX Series crushers

have larger throw and higher

it ideal for fine crushing

applications

The power rating for a given

machine size is increased by

30% over the same size HP




The next evolution:

or erg cone crus er

MP1000 and MP800

¾ Using the proven Symons principle of crushing,ϖFt

the new MP1250 builds on the high pivot point

and increased throw concepts to further

enhance crusher performance

α FcFcx

¾ The benefits of the MP1250 can be obtained in

either a new crusher or retrofit kit to existing

MP1000 crushers

cy




Nordberg MP™1250 cone crusher

New Features

ncrease ower apac y

¾ Redesigned Mainframe¾ Reduced No-Load Head Spin

eavy uty ounterwe g t

¾ Sleeved Eccentric

¾Gradation Auto-Setting (Optional)mprove ramp e e ystem

¾ Higher Speed Bowl Adjust

¾ Improved Drive Ring Brackets

¾ New Mantle Locknut





Increased Power and Capacity

Higher Fulcrum Point

Increased Throw

¾ Up to 30% Increase in capacity

¾ Increased power to 1250 hp

¾ More work performed in each

crushing cycle

¾ More efficient use of power





Improved Mainframe

¾ Same footprint as MP1000

¾ Reduced stress concentrations¾ Less than 1% weight increase





Reduced No-Load Head Spin

¾ Patent Pending design of Socket and

Upper Head Bushing

¾ New design reduces no-load head

s in without the anti-s in mechanism





Head Spin Comparison

¾ MP1250 without new socket ¾ MP1250 with patent pending

es gn

¾ No anti-spin mechanism

new soc e es gn

¾ No anti-spin mechanism




Nordberg MP®1250 cone crusher

Heavy Duty Counterweight and Guard

¾ Unique, heavy-duty counterweight limits

unbalanced dynamic forces (patent pending)

¾ One-piece guard bolts on for easy replacement

¾ Tight tolerance guard also restricts debris from

entering underneath the head





Sleeved Eccentric

¾ Increased throw eccentric

¾ Improved bearing surface finish

¾ Protects eccentric in overloadcon ons

¾ Reduced replacement costs, if

necessary





Gradation Auto-Setting System (Optional)

¾ Eliminates the need for frequent ¾ Automatically adjusts the crusher

¾ Continually monitors product size ¾ More consistent crushing

operation and product output





Improved Tramp Relief System

¾ Constant pressure / force limited

¾ Fast-acting relief valves to minimize

pressure spikes during tramp events





Improved Bowl Adjust System

¾ Utilizes (3) hydraulic adjust motors

rather than (4)

¾ 30% faster bowl removal & adjustment

¾ Faster hydraulic re-pressurization

¾ Reduced maintenance





Improved Drive Ring Brackets

¾Replaces roller bearings

¾ Increases lon evit

Wear Pad

¾ Impervious to the elements

¾ Reduces maintenance timeSupport Bracket

(no greasing)

¾ Reduces maintenance costs





TC-1000 Automation System Features

¾ Com lete crusher station control

¾ PLC control is adaptable to any crushing plant application

¾ Overload warning and protection

asy o rea u co or sp ay

¾ Simple navigation through user-friendly screens

¾ Liner wear detection without leaving the control room¾ Integrated feed rate control based on power and cavity

level utilizing multiple PID loop calculations





TC-1000 Automation System Functions

¾ Lubrication System

¾ Crusher main drive motor

¾ Feed device

¾Upstream and downstream





Retrofit Kit

¾ As few as five new parts arerequired per retrofit

¾ Machines designed for anti-spin

will also require a new socket

¾ Anti-spin device must be removed,if applicable

¾ Existing motor (1000 hp) may be

used depending on application

details and amperage draw





Retrofit Kit

¾ Anti-spin designed machines

also require a new socket

¾ Foundation analysis required to

confirm safety factor

recommended


1. Cone Crushers Evolution - D. Kaja

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