Feeder Breaker Conveying Section Pre-screening Design and Function

Introduction

The Feeder Breaker provides a heavy-duty continuous crushing system that combines initial feeding, crushing, and discharge on the same horizontal plane, forming a continuous horizontal material flow crushing process. It integrates the functions of conveying, screening, and crushing equipment. The conveying section uses a heavy-duty plate or chain plate structure, the screening section uses a static screening + dynamic screening structure, and the crushing section uses a hammer or roller structure.

How Feeder Breaker Works

The variable frequency motor drives the drive wheel of the conveyor transmission through the conveyor drive device. The drive wheel drives the driven wheel to rotate through the meshing of the sprocket and the circular chain. At the same time, it drives the conveyor chain plate connected to the circular chain to move horizontally in the conveyor box. The conveyor chain plate drags the material in the conveyor box for material conveying. When the horizontally moving conveyor chain plate and the material pass through the rotating crushing toothed roller in the crushing box, large pieces of material cannot pass through the specific space between the crushing toothed roller and the conveyor chain plate.

The large pieces of material will be hit, squeezed, stretched and broken by the rotating toothed roller until they are crushed. Small pieces of material smaller than the required output particle size can pass through the crushing toothed roller without being crushed. Finally, the crushed material is discharged through the discharge port of the crushing device. By adjusting the frequency of the variable frequency drive and changing the speed of the variable frequency motor, the running speed of the conveyor chain plate can be changed, and the processing capacity of the entire equipment can be adjusted to a certain extent. By adjusting the center height of the crushing toothed roller, the crushed output particle size can be adjusted to meet the needs of different customers.

The main structure of the Feeder Breaker

Scraping conveyor

Transmission device

Composed of an electric motor, elastic pin coupling, reducer, assembled sprocket, main drive shaft support seat, support seat device. The floating drive device frame connects the electric motor, coupling, and reducer into a whole. The reducer is installed on the side of the drive head of the frame. The hollow output shaft of the reducer is connected to the input shaft of the sprocket head group with a locking plate and is fixed with an axial end baffle. The sprocket head group is connected to the drive head of the frame with a support seat using bolts.

Conveyor box body

Composed of several conveyor small box bodies arranged in a row to form the conveyor box body. Its main function is to connect the head and tail of the machine and support the conveyor chain to slide within it for transporting materials.

Conveyor chain

Composed of ring chain, conveyor chain plate and connecting bolts, etc., is the coal transportation component of the heavy-duty scraper feeder.

Frame tail guide device

Composed of a guide main shaft with two guide wheels installed on the tail of the frame through two sliding bearing seats. Its main function is to change the running direction of the heavy-duty chain, making the running precise and smooth.

Crushing part

Crushing drive

Mainly consists of explosion-proof electric motor, small pulley, connected narrow V-belt, large pulley. This part is the source of crushing power. When installing the equipment, it is necessary to ensure that the axes of all equipment are on the same horizontal plane (allowable error less than 0.5mm)

Crushing tooth roller

Mainly composed of tooth roller shaft, tooth roller bearing, tooth roller sleeve, movable tooth head, etc. The rotating crushing tooth roller will crush the horizontally transported materials. During the use of the equipment, it is necessary to check the wear of the crushing teeth to avoid severe wear of the crushing teeth causing oversize. The crushing box body supports and fixes the crushing tooth roller and the crushing drive.

Pre-screening

Static Screening

It is usually arranged at the front of the conveying section, and is composed of fixed screen bars installed by reserving screen hole positions on both sides of the conveying box. When the conveying chain plate moves the materials through the static screening section， the fine materials that meet the particle size requirements will directly pass through the sieve gap and be discharged from the equipment without entering the subsequent crushing process. This not only reduces the load of the crushing part， reduces energy consumption， but also avoids excessive crushing of fine materials， improving the rationality of the output gradation. The static screening structure is simple， without additional drive， and has lower maintenance costs， making it suitable for working conditions with a stable proportion of fine materials and less prone to blockage of sieve holes.

Dynamic Screening

It is generally arranged in the non-receiving section and adopts the roller screening method. The steel plate is connected to the box body， and holes are opened on the side of the box body to combine with the roller sieve. An additional drive device is configured to drive the sieve shaft to rotate， causing the materials to roll and pass through the sieve holes. The fine materials that meet the particle size requirements will be promptly discharged from the sieve holes， while the large pieces that do not meet the requirements will remain on the conveying chain plate and enter the subsequent crushing process. Compared with static screening， dynamic screening has a more stable sieve shaft rotation， less likely to have blocked sieve holes and materials stuck， and higher screening efficiency. It is more adaptable to working conditions with high water content of sludge and fluctuating proportions of fine materials.

Feeder Breaker Conveying Section Pre-screening (Optional)

The feeding section’s pre-screening system features differentiated screening schemes based on the material’s receiving state. The receiving section uses static screening, while the non-receiving section utilizes dynamic agitation screening.

Static Grate Screen

The static grate screen in the receiving section employs a mounting structure where steel rails are directly fixed to the conveyor box. This installation and screening combination offers high permeability and structural strength, capable of withstanding the impact loads of large materials during receiving. It is particularly suitable for pre-screening large-sized materials such as large-particle raw stones and large pieces of construction waste, efficiently separating materials that meet particle size requirements and avoiding unnecessary crushing.

Dynamic Roller Screen

The non-receiving section utilizes a dynamic screening solution, integrating a specially designed roller screen onto the conveyor box body. This design addresses the common problem of clogging when screening small-particle, muddy, or sticky wet materials. The entire roller screening system adopts a single-motor centralized drive scheme. Each set of screening rollers is equipped with an independent transmission unit, ensuring stable and reliable power transmission. The motor and reducer in the drive unit use a direct-drive combination structure, resulting in higher transmission efficiency, a more compact overall structure, less space occupation, and a reduced probability of transmission failure. The screening plates are made entirely of high-wear-resistant NM400 wear-resistant steel plates, offering excellent wear resistance and a longer service life. The modular installation structure simplifies screen plate replacement during routine maintenance, effectively reducing equipment operation and maintenance time costs.

Conclusion

The Feeder Breaker features a reasonable design, simple structure, and convenient operation. It can operate in harsh environments, has a large conveying capacity, and can pre-screen qualified materials to improve crushing efficiency. It can transport large materials ranging from 1400-3000 mm in size. Through single-roller crushing, it integrates conveying, screening, and crushing operations, facilitating installation and maintenance. It can be widely used in the transportation, screening, and crushing systems of large ground materials in industries such as coal and metallurgy.