How does a mineral sizer ensure uniform discharge size
Mineral sizer
Mineral sizer, as a mineral crushing equipment, features a unique double-roller design that can effectively control the size of the finished material during the production process, ensuring that the material meets the expected particle size requirements. Through the dual forces of squeezing and shearing, the input material is gradually crushed into particles of the required size.
Design factors to ensure finished materials uniform size
Adjustable crushing rollers spacing
The spacing between the crushing rollers of Mineral sizer can be adjusted according to the characteristics of different materials and the specific requirements of actual production. Through this spacing adjustment, the particle size range of the crushed materials can be effectively controlled, thereby ensuring that the particle size of the final product meets the expected standards and production requirements.
Stable crushing process
The crushing process of Mineral sizer is stable and reliable. In terms of power transmission, the two crushing toothed rollers are respectively connected by motors, hydraulic couplings, reducers and couplings. Synchronous gears are installed behind the toothed rollers to keep the roller bodies rotating at a constant speed, so that the extrusion and shearing forces can continuously and evenly act on the materials, preventing excessive local force from causing over-crushing of the materials. Or large particles left due to insufficient force.
Pre-screening
The pre-screening function of Mineral sizer is achieved through the gap between two toothed rollers and the distance between the toothed rollers and the crushing chamber, enabling the early separation of small and large pieces of material. In the structural design of the toothed roller of Mineral sizer, a specific-sized gap is reserved in the middle and on both sides of the toothed roller. When the material enters the crushing chamber, small pieces of material smaller than the gap do not need to go through subsequent crushing processes and are directly and quickly discharged from the gap, reducing the retention time of small pieces of material in the crushing chamber and avoiding excessive crushing caused by repeated squeezing and shearing. It also reduces invalid loads.
Tooth profile design
The large-sized rolling teeth of Primary mineral sizer, whose tooth height and tooth pitch are designed according to the size of the crushed materials, can grasp large pieces of materials. The spiral arrangement enables the materials to be evenly distributed on the roller body during the grasping process, avoiding local accumulation and ensuring the balanced force of the large pieces of materials. As the large teeth rotate, the crushed materials fall into the crushing chamber. It was further crushed and refined.
Secondary mineral sizer adopts a dense layout with small pitch and multiple tooth heads, and the tooth profiles of adjacent tooth rollers are in an interlaced meshing state. It can conduct secondary crushing on the materials after primary crushing. Through the precise coordination between the teeth, the particles that do not meet the standards can be further crushed to the target size. Meanwhile, the interlaced tooth shape will form multiple independent crushing units, preventing the materials from sliding during the crushing process and ensuring that each particle can be subjected to uniform shear force.
The main structure of Mineral sizer
Mineral sizer is mainly composed of an electric motor, a hydraulic coupling, a connecting cover, a reducer, a body, a roller bracket, a centralized lubrication system and an electrical control system, etc.
(1)Electric motor
The electric motor is the power source of the mineral sizer and it is driven by two electric motors.
(2) Hydraulic coupling
The connection between the motor and the reducer adopts a torque-limiting hydraulic coupling to reduce the impact and vibration during startup and provide overload protection.
(3) Connecting cover
The connecting cover is welded with steel plates. Its function is to integrate the motor and the reducer into one, bear the weight and protect the hydraulic coupling. There is an observation hole on the connecting cover, through which the operation of the hydraulic coupling can be observed.
(4) Reduction motor
The input shaft of the Mineral sizer reducer is connected to the hydraulic coupling by splines, and the output shaft is connected to the gear roller on the body through a self-aligning gear coupling. The reducer adopts three-stage cylindrical gear transmission. The gear material is alloy steel, which undergoes carburizing and quenching treatment. The gears are ground. The reducer has smooth transmission and low noise.
(5) Organism
The body is the core component of the Mineral sizer. To achieve the purpose of adjusting the distance between the two toothed rollers, a suspended bearing housing was designed. Two toothed rollers are installed in the bearing housing and suspended together on four large shafts that serve to guide and tensioning. The machine body is equipped with a hand pump and an oil cylinder. The oil cylinder is connected to the suspended bearing housing. Through the oil cylinder, the distance between the two toothed rollers can be adjusted to meet the requirements of different output particle sizes.
(6) Centralized lubrication system
Mineral sizer uses a grease pump to centrally lubricate the bearings of the toothed rollers, changing the manual regular oiling method, which is convenient and fast.
(7) Electrical control system
The electrical control system of Mineral sizer adopts PLC control and uses inductive sensors to monitor the operation of the gear rollers. When the gear mixing is jammed by a hard object and stops rotating, the inductive sensor immediately sends a signal, and the electrical control device stops the motor to achieve overload protection. All electrical devices are installed in the electrical control cabinet. The microcomputer is equipped with interfaces, which can be networked with the feeding and discharging systems to achieve centralized control.
Overall features of Mineral sizer
(1) Two toothed rollers are respectively driven by two motors and reducers, featuring strong crushing force, smooth operation, low noise, compact structure and beautiful appearance.
(2) The adjustment of the output particle size is carried out by hydraulic means and with a reverse stop device, which is convenient and fast. During operation, the distance between the two toothed rollers remains unchanged, ensuring the stability of the output particle size.
(3) Dual overload protection is adopted. First, a torque-limiting hydraulic coupling is installed between the motor and the reducer, which not only reduces the impact and vibration during startup but also provides overload protection. Second, an inductive sensor is used to monitor the operation of the gear roller. When the gear roller is stuck by a hard object during operation, the inductive sensor issues an instruction to the electrical control device to stop the motor, achieving overload protection. These two levels of protection ensure the reliability of the mineral sizer.
(4) PLC is adopted to achieve program control of Mineral sizer and its feeding, discharging and equipment operation processes, with a high degree of automation.
(5) The Mineral sizer tooth plate is cast from alloy steel, and high-quality wear-resistant materials are surfacing on the tooth surface, which extends the service life.
