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Common Troubleshooting and Solutions

The Crusher is Noisy

Cause investigation

新增页签

Loose components. The hammer head, liner, rotor and other components inside the crusher work under high-frequency vibration for a long time, which may cause the connecting bolts to loosen.
Bearing damage. After long-term operation, the bearing may be damaged by wear, fatigue peeling and other reasons due to poor lubrication, overload and other reasons.
Material blockage. Excessive feeding or excessive material particle size may cause the material to be blocked in the crushing chamber, causing the equipment to run poorly and produce abnormal noise.
Uneven wear of the crushing chamber. Uneven wear of the liner of the crushing chamber will cause uneven force on the material during the crushing process, causing equipment vibration and noise.

Solution

新增页签

Tighten the components. After stopping the machine, carefully check the connecting bolts of each component and tighten the loose bolts according to the specified torque.
Replace the bearing. Replace the damaged bearing, and select reliable bearings, ensure correct installation, and add an appropriate amount of grease.
Clean the material. Stop feeding, clean the blocked materials in the crushing chamber, and adjust the feeding speed and material size to meet the design requirements of the equipment.
Repair or replace the liner. Check the wear of the crushing chamber liner, repair or replace the unevenly worn liner to ensure the surface of the crushing chamber is smooth.

Decreased Output

Cause investigation

新增页签

Loose components. The hammer head, liner, rotor and other components inside the crusher work under high-frequency vibration for a long time, which may cause the connecting bolts to loosen.
Bearing damage. After long-term operation, the bearing may be damaged by wear, fatigue peeling and other reasons due to poor lubrication, overload and other reasons.
Material blockage. Excessive feeding or excessive material particle size may cause the material to be blocked in the crushing chamber, causing the equipment to run poorly and produce abnormal noise.
Uneven wear of the crushing chamber. Uneven wear of the liner of the crushing chamber will cause uneven force on the material during the crushing process, causing equipment vibration and noise.

Solution

新增页签

Tighten the components. After stopping the machine, carefully check the connecting bolts of each component and tighten the loose bolts according to the specified torque.
Replace the bearing. Replace the damaged bearing, and select reliable bearings, ensure correct installation, and add an appropriate amount of grease.
Clean the material. Stop feeding, clean the blocked materials in the crushing chamber, and adjust the feeding speed and material size to meet the design requirements of the equipment.
Repair or replace the liner. Check the wear of the crushing chamber liner, repair or replace the unevenly worn liner to ensure the surface of the crushing chamber is smooth.

Energy Saving and Environmental Protection Solutions

Optimize crusher operating parameters

Adjust the crushing ratio.The crushing ratio refers to the ratio of the crusher feed size to the discharge size. By reasonably adjusting the crushing ratio, the material can reach a smaller particle size during the first crushing process, reducing the energy consumption of subsequent processing links.
Control the feeding speed.A stable and appropriate feeding speed is essential to reducing energy consumption. By installing a feeding speed monitoring device, the feeding speed can be adjusted in real time according to the operating status of the crusher to ensure that it operates within the optimal range.
Reasonably adjust the discharge port size.The discharge port size determines the particle size and output of the discharge. According to the product particle size requirements, the discharge port size is accurately adjusted to ensure that it can meet production needs and reduce energy consumption.
Use energy-saving equipment

Choose a new energy-saving crusher.The new crusher adopts advanced design concepts and manufacturing technologies, with higher crushing efficiency and lower energy consumption. The new crusher adopts an optimized crushing chamber type and hydraulic adjustment system, which can reduce energy consumption while improving product quality and production capacity.
Use high-efficiency motors.The motor is the main power source of the crusher, and its energy efficiency level directly affects the energy consumption of the crusher. According to the actual power demand of the crusher, reasonably select the motor capacity to avoid overloading or underloading the motor to improve the operating efficiency of the motor.
Use intelligent control systems.Intelligent control systems can integrate multiple sensors and control algorithms to monitor and automatically adjust the operating parameters of the crusher in real time. For example, by monitoring parameters such as motor current, bearing temperature, and material particle size, the system can automatically determine the working status of the crusher and adjust parameters such as feeding speed and rotor speed in time to keep the crusher in the best operating state and achieve the purpose of energy saving and consumption reduction.

Selection Recommendations

Material hardness

Metal materials.For metals such as scrap car shells and color steel tiles, metal crushers can be used to crush metals into uniform particles for easy transportation and recycling. For some large metal objects or frame-shaped metals, such as scrapped cars and metal barrels, double-axis shredders are more suitable and can be used for coarse crushing and volume reduction first.

Plastic steel materials.For materials such as plastic steel profiles, plastic steel crushers are equipment specially used to process such materials, which can crush plastic steel and achieve iron-plastic separation. Double-axis shredders can also process plastic steel, especially some larger pieces of plastic steel materials.

Wood materials.Wood crushers are suitable for various woods, such as round logs, wooden pallets, wood chip plywood, etc. If it is a larger size of wood or wooden furniture, the double-axis shredder can be used for coarse crushing first, and then further crushed with a wood crusher.

Gusset plate materials.The gusset plate crusher is designed for gusset plate materials, with a simple structure and easy operation, and can effectively crush the gusset plate. If the gusset plate is mixed with other debris, the double-shaft shredder can be used for preliminary processing, and then the gusset plate crusher can be used for refinement.

Other materials that need to be sorted.The eddy current separator is mainly used to separate non-ferrous metals such as copper and aluminum from mixed materials. It is usually used in conjunction with other crushers. After the metal crusher, double-shaft shredder, etc. crush the materials, the eddy current separator is used to sort the non-ferrous metals.

Output requirements

Small output.The output per hour is less than 5 tons, which can be met by a small metal crusher, a small wood crusher, a small plastic steel crusher or a small double-shaft shredder, with small land occupation and low investment.

Medium output.The output per hour is 5-20 tons, which can be met by a medium-sized metal crusher, a plastic steel crusher, a wood crusher, or a double-shaft shredder with a higher configuration.

Large output.The output per hour is more than 20 tons, which requires a large metal crusher, a wood crusher, etc., or a combination of multiple equipment and an automated production line.

Site conditions

Limited space.Choose small and compact crushers, such as small metal crushers, small double-shaft shredders, etc. These devices occupy a small area, are easy to install and maintain, can operate in limited spaces, and are suitable for small recycling stations and processing points in cities.

Open space. You can choose large crushers and fixed crushing production lines, or consider mobile crushing stations, which are highly flexible and can be moved at any time. They are suitable for different sites and working conditions, such as large open-air metal recycling sites, wood processing bases, etc.

Intelligent Upgrade Solution

Hardware upgrade

Sensor installation and upgrade.Install various high-precision sensors such as vibration sensors, temperature sensors, pressure sensors, particle size sensors, etc. for existing crushers to achieve comprehensive monitoring of equipment operating status and material characteristics. For crushers already equipped with sensors, upgrade the sensors according to actual needs and technological development to improve their measurement accuracy and reliability.
Control system upgrade.Upgrade the traditional crusher control system to an intelligent control system. The new system should have powerful data processing capabilities and communication interfaces, and be able to efficiently interact with sensors, actuators, and remote monitoring platforms for data and control command transmission.

Software system construction

Intelligent control software research and development.Develop control software specifically for intelligent crushers. The software should have functions such as data acquisition, analysis and processing, parameter optimization, fault diagnosis, and remote monitoring. Through advanced algorithms and models, automatic adjustment and optimization of crusher operating parameters, as well as accurate early warning and diagnosis of equipment failures can be achieved. The software interface should be simple and intuitive, easy for operators to use and understand.
Remote monitoring platform construction.Build a remote monitoring platform based on the Internet or the Internet of Things to achieve remote real-time monitoring and management of intelligent crushers. The remote monitoring platform should have data visualization function, and intuitively display the operation data and status information of the crusher in the form of charts, curves, etc. At the same time, the platform should provide functions such as user authority management, alarm information push, historical data query, etc., to facilitate enterprise managers to conduct remote monitoring and decision-making analysis.
3. Data analysis and management system.Establish a data analysis and management system to conduct in-depth analysis of the large amount of data generated during the operation of the intelligent crusher. Through data mining and machine learning technology, the equipment operation rules are discovered, the production process is optimized, and equipment failures are predicted, providing data support and decision-making basis for the company's production management and equipment maintenance.

Personnel training and technical support

Operator training.Organize intelligent system operation training for crusher operators to make them familiar with the operation process, functional characteristics and precautions of the intelligent crusher. Through training, improve the skill level and operation proficiency of operators to ensure that the intelligent crusher can operate normally and efficiently.
Technical maintenance personnel training.Provide technical maintenance training for the company's technical maintenance personnel on the intelligent crusher to enable them to master the hardware structure, software system, fault diagnosis and maintenance methods of the equipment. The training content should include the installation and debugging of sensors, maintenance and upgrading of control systems, and repair and maintenance of actuators.
Technical support service.Establish a professional technical support team to respond to users' technical needs in a timely manner to ensure that problems encountered by users in the process of using the smart crusher can be solved in a timely manner. At the same time, based on user feedback and actual application, continuously optimize the performance and functions of the smart crusher to enhance user experience.

Application in Different Scenarios

Crushing Metal

The crushers operate in an orderly manner in the workshop, biting the metal raw materials with great force. The metal twists and breaks under heavy pressure, turning into uniform fragments. Efficient crushing drives production forward steadily.

Crushed Wood

The wood crusher operates efficiently, breaking up the logs continuously and converting them into uniform fragments quickly through internal cutting tools to meet production needs.

Crushed Rubber

The gusset crusher crushes the waste tires one by one. The thick rubber blocks are crushed and cut layer by layer to produce rubber fragments and particles that meet the requirements, preparing for subsequent processing.

Crushing Various

The crusher has excellent performance and is suitable for a variety of waste processing. From metal to wood, to rubber, etc., it can be accurately crushed according to different characteristics, effectively helping waste recycling and reuse.

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