How does a feeder breaker work
The feeder breaker is a device that integrates “conveying” and “crushing”. Its core consists of Conveyor Parts and Crushing Unit. Through the coordinated operation of these two components, the material processing process is completed. In scenarios such as mining and large-scale infrastructure construction where a large amount of materials need to be processed, the feeder breaker, with its efficient integrated design of conveying and crushing, significantly improves operational efficiency and reduces labor and equipment costs.
The Basic Working Principle of a Feeder Breaker
Conveying stage
The input method of the materials is flexible and diverse. They can be directly unloaded into the hopper by self-unloading trucks, taking advantage of the dumping function of the trucks to achieve rapid material discharge; or they can be transported to the hopper by bulldozers or loaders, which is suitable for situations where trucks cannot directly reach or where the material storage locations are scattered.
When the conveying drive device is activated, the driving sprocket will drive the chain to move horizontally within the conveying box, and at the same time “drag” the materials forward for transportation. Unlike traditional conveyor belts that rely on surface friction to move the items, the chain structure adopts an embedded traction method.
Through the special clasps or grooves on the chain and the materials, this design can not only more stably handle large and heavy materials, but also effectively prevent problems such as slipping and deviation of the materials during transportation.
To ensure the stability of the conveying process, the internal of the conveying box is usually equipped with guiding devices. These devices can monitor the running trajectory of the chain in real time. Once there is deviation, they will automatically adjust to ensure the smooth transportation of the materials.
Crushing stage
When the chain carries the materials into the crushing box and passes through the rotating toothed rollers， the “core logic” of crushing begins to take effect.
The gap between the toothed rollers and the bottom plate is precisely calculated. This gap is like a “size screening checkpoint”， allowing only the small-sized materials that meet the requirements to pass.
To cope with the characteristics of different materials， the surface of the toothed rollers is designed with various tooth shapes， such as sawtooth and wedge-shaped. The sawtooth toothed rollers can quickly crack the brittle materials with sharp tooth edges； the wedge-shaped toothed rollers are better at handling materials with higher toughness， by squeezing and tearing， gradually breaking the large pieces of materials.
During actual operation， the high-speed rotating toothed rollers will apply “impact， compression， and tearing” combined forces to the large pieces of materials. When the materials enter the crushing area， they will first be subjected to the high-speed impact of the toothed rollers， generating initial cracks； then， the materials are compressed between the toothed rollers and the bottom plate， and the cracks further expand； finally， under the tearing action of the toothed rollers， the materials are completely broken into small pieces that can pass through the gap.
Usually， the feeder breaker can crush 800mm-1500mm large pieces of materials to 200mm-500mm medium-sized particles， meeting the requirements for subsequent processing or transportation. In addition， the equipment is also equipped with an intelligent monitoring system， which can monitor the crushing particle size in real time.
When the particle size does not meet the preset standard， the system will automatically adjust the speed or gap size of the toothed rollers to ensure a stable and reliable crushing effect.
Core Components of a Feeder Breaker
The stable operation of the feeder breaker equipment depends on the coordinated work of its various core components. Each component has its specific function and design feature: Frame
The frame is made of heavy-duty steel plates and is equipped with a large number of structural support components, which can withstand the impact loads during high-intensity operations.
To extend the service life, wear-resistant liners (fixed by welding or bolts, and the installation method is selected according to the frequency of wear) are installed on the top of the frame, on both sides of the chain, and in the area where the materials come into contact. It is like giving the equipment a “protective suit”, reducing the direct wear of the materials. Sprockets and Shafts
The head shaft and tail shaft are made of alloy steel and undergo heat treatment, tempering and stress relief processes, resulting in extremely high strength. The shaft body is paired with a shaft sleeve, allowing for adjustable tension, and can be completely disassembled through the maintenance panel for easy maintenance and replacement.
The sprocket is made of integral flame-hardened steel or a split design. The split structure can reduce maintenance costs. At the contact point between the shaft and the frame, there is an oil seal to prevent leakage. Additionally, a low-speed sensor is equipped to avoid shaft damage caused by high torque.
Chain Conveyor
According to the processing volume requirements, it is divided into two configurations: single traction and double traction. The double traction system is suitable for high processing volume scenarios (such as under large hoppers), while the single traction is suitable for smaller and medium-sized requirements.
The steel scraper of the conveyor is connected to the engineering-grade chain through a pin shaft to ensure that the materials do not slip or fall off during transportation.
Conveyor Drive System
There are two options: hydraulic drive and electric drive:
Hydraulic drive: It can flexibly adjust the speed and has a “buffering effect”, which can alleviate the load caused by the impact of the materials.
Electric drive: A torque control coupling is installed between the motor and the reducer. When the conveyor is blocked, it can protect the components from damage; at the same time, it is equipped with an automatic reverse system, which can automatically reverse to clear the blockage when it occurs, until the fault is resolved or the preset retry times are reached.
Drive Device
It is divided into two modules: the crushing drive and the conveying drive. Both are composed of “motor – coupling – reducer”:
The coupling of the crushing drive transmits torque through the change of liquid momentum, reducing the impact force during startup and preventing overload of the motor and the crusher.
The coupling of the conveying drive connects the transmission device with the conveyor, ensuring synchronous rotation of both and stable power transmission.
Crushing Rollers
The design of the crushing roller is not a simple squeezing process. Instead, it uses a toothed roller with a rotational direction consistent with the flow of the material. As the material passes through, it is subjected to the “synergistic force” of multiple crushing teeth, and is broken along the natural fracture surface.
The roller body is equipped with replaceable hard alloy blades (fixed by retaining rings or spacer rings), and the blades are arranged in a spiral pattern. The layout of the blades and the spacing of the disc can be adjusted according to the material characteristics. In addition, the roller body is equipped with a flywheel to enhance the crushing force, which can handle high-hardness materials and reduce the risk of downtime.
The Characteristics and Advantages of a Feeder Breaker
Fully Customizable to Fit Your Operation
Every site has unique demands. Our systems are skid-mounted for precision placement and can be tailored with adaptable hoppers or bins for truck and vehicle unloading.
Advanced Drive Options
Choose from Variable Frequency Drive or Direct Hydraulic Drive to match your throughput and operational needs.
Labor and Cost Savings
The extended loading area eliminates manual labor associated with stockpiling and reduces downtime.
Heavy-Duty Construction for Reliability
Featuring conveyor decking with chromium carbide overlay , a corrosive-resistant galvanized frame, and high-strength alloy steel chain with A514 T1 steel flights, this system is built to last in the toughest environments.
Maintenance Made Easy
Optional catwalks and automatic grease circuits simplify ongoing maintenance and enhance operator safety.
Material Control and Sizing
Available with integrated breakers and manual or hydraulically operated flow gates, giving you full control over material sizing and flow.
The Application Scenarios of a Feeder Breaker
The feeder breaker, with the integrated advantages of “conveying + crushing”, is widely applied in the following scenarios:
Mining industry
It processes large chunks of raw ore extracted from coal mines and metal mines, and crushes them to a suitable particle size for transportation or beneficiation.
Metallurgical industry
It crushes raw materials such as iron ore and steel slag to provide qualified materials for the smelting process.
Building materials industry
It processes building raw materials such as limestone and sandstone to meet the particle size requirements for building production.
Coal industry
At coal mine entrances or coal washing plants, the feeder breaker crushes the raw coal and conveys it to the subsequent washing or transportation processes.
Large engineering sites
Such as open-pit mining sites and tunnel construction sites, it handles large chunks of rocks after blasting to reduce transportation costs.
How to Choose Feeder Breaker for Mining
Processing capacity
Processing capacity is the most crucial factor in choosing a feeder breaker. The feeder breakers produced by our company can be used for crushing and feeding block materials such as coal and ore. In the coal field, the maximum processing capacity of our equipment can reach 5000t/h. The size of the processing capacity directly markets the selection of feeder breaker.
Feed size of crushed materials
The maximum feed size of the feeder breaker produced by our company is 2,050×2,050, the maximum height of the material is 2050, and its crushing compressive strength can reach 200mpa. In addition, this heavy-duty continuous crushing system is widely used in industrial sectors such as mining, metallurgy, building materials and coal.
This machine is mainly used under silos and funnels with certain bin pressure to uniformly and continuously crush, screen and transport various bulk materials over short distances. Our company has conducted multiple studies and improvements on its structure in response to problems such as easy clogging during the year.
Our feeder breaker can achieve one-time crushing of sticky and wet materials, soft and hard materials, etc. We have also developed an automatic reversing system to address the issue of metal material jamming. When metal items get stuck, the equipment can be flipped by clicking to remove the metal materials.
Working environment
Feeder breaker is a device with strong adaptability to complex and harsh working environments. It can be used in open-pit mining without any cover. The working environment temperature is -30℃ to +45℃, and the conveyed materials should be various irregular raw coal and ores with a bulk density of less than 2.0t/m³. The nature of the work is capable of continuous crushing and feeding operation for 24 hours without interruption.
Spatial layout
The size and layout of the production site will affect the selection of crushers. If the site space is limited, our feeder breaker is a compact and space-saving crushing equipment that can be combined with mineral sizer and screen to form a continuous crushing station for joint operation.
Infrastructure construction requirements
Feeder breaker is a device with extremely low requirements for infrastructure construction. It can be installed on flat ground without foundation construction or on a platform composed of steel structures. It has less vibration, saves construction costs, and can achieve feeding and unloading without a pit.
Replacement of vulnerable parts
The vulnerable parts of the feeder breaker, such as the hammerhead, liner, and belt, will gradually wear out during use and need to be replaced regularly. Therefore, the replacement of vulnerable parts during the selection process is very convenient.
We have gradually established spare parts supply warehouses all over the world, which can quickly provide customers with spare parts suitable for their equipment. The replacement of vulnerable parts of our equipment is simple and quick, which can reduce the downtime of the equipment and improve production efficiency.
Maintenance Best Practices for Feeder Breakers
Lubrication Maintenance
Good lubrication is an important part of feeder breaker maintenance. Ensuring adequate lubrication of machine components can reduce wear, lower energy consumption, and extend equipment lifespan. Here are some key maintenance steps:
Regular oil replacement: Based on the usage of the crusher, regular oil replacement is necessary. According to the manufacturer’s recommendations, ensure that the appropriate lubricating oil for the machine model is selected and replace it on time.
Clean the oil circuit system: Regularly inspect and clean the oil circuit system of the crusher to remove impurities and contaminants, ensuring the smooth operation of the lubrication system.
Temperature control: Ensure that the temperature of the lubricating oil is within the normal range to avoid adverse effects on the machine due to overheating or undercooling. A temperature controller can be installed to monitor and control the temperature of the lubricating oil.
Maintenance Key Points
Regularly inspect the components of the equipment and replace them promptly if any damage or deterioration is found, especially for vulnerable parts such as broken blades and bearings.
Pay attention to checking the working conditions of components such as the motor, transmission belt, and lubrication system. Address any abnormalities promptly.
Regularly clean the inside and outside of the equipment to prevent dust and debris from blocking and corroding the equipment. 4. Perform maintenance and repair while the equipment is off to ensure the safety of operators.
Daily Inspection and Cleaning
The feeder breaker should be inspected and cleaned regularly during daily use to ensure the normal operation of its mechanical components.
First, check the tightness of each part of the crusher, including the transmission device and connecting bearings. If the fastening parts are loose, they need to be tightened promptly. Secondly, clean the dust and dirt inside and outside the crusher to keep the components clean. Especially for the accumulated materials around the crushing chamber and the feed opening, thorough cleaning is necessary to avoid affecting the crushing effect.
Adjust the settings of the crusher
During the use of the feeder breaker, it is necessary to adjust the settings according to the hardness and particle size of different ores to achieve the best crushing effect.
During maintenance, it is necessary to regularly check and adjust the size of the discharge port and the inlet port of the crusher to ensure that the gap between them and the crushing teeth plate is appropriate.
In addition, the rotor speed and crushing angle of the crusher should also be adjusted according to the actual situation to improve the crushing efficiency and output.
Summary
Through the above discussion on the working principle, structure, advantages, application, selection, and maintenance of feeder breakers, it is clear to understand how feeder breakers function in the material handling process – they are not only a combination of “transportation” and “crushing”, but also a key equipment for improving the production efficiency in industries such as mining and metallurgy.
