Everything You Need To Know To Find The Best direct driven single toggle jaw crusher

A sectional view of the single-toggle type of jaw crusher is shown below. In one respect, the working principle and application of this machine are similar: the movable jaw has its maximum movement at the top of the crushing chamber, and minimum movement at the discharge point. The motion is, however, a more complex one than the Dodge motion, being the resultant of the circular motion of the eccentric shaft at the top of the swing jaw. combined with the rocking action of the inclined toggle plate at the bottom of this jaw. The motion at the receiving opening is elliptical; at the discharge opening, it is a thin crescent, whose chord is inclined upwardly toward the stationary jaw. Thus, at all points in the crushing chamber, the motion has both, vertical and horizontal, components.

Link to Shanbao

It will be noted that the motion is a “rocking” one. When the swing jaw is rising, it is opening, at the top, during the first half of the stroke, and closing during the second half, whereas the bottom of the jaw is closing during the entire up-stroke. A reversal of this motion occurs during the downstroke of the eccentric.

Jaw Crusher Terminology

The horizontal component of motion (throw) at the discharge point of the single-toggle jaw crusher is greater than the throw of the Dodge crusher at that point; in fact, it is about three-fourths that of Blake machines of similar short-side receiving-opening dimensions. The combination of favorable crushing angle, and non-choking jaw plates, used in this machine, promotes a much freer action through the choke zone than that in the Dodge crusher. Capacities compare very favorably with comparable sizes of the Blake machine with non-choking plates, and permissible discharge settings are finer. A table of ratings is given.

The single-toggle type jaw crusher has been developed extensively. Because of its simplicity, lightweight, moderate cost, and good capacity, it has found quite a wide field of application in portable crushing rigs. It also fits into the small, single-stage mining operation much better than the slower Dodge type. Some years since this type was developed with very wide openings for reduction crushing applications, but it was not able to seriously challenge the gyratory in this field, especially when the high-speed modern versions of the latter type were introduced.

Due to the pronounced vertical components of motion in the single-toggle machine, it is obvious that a wiping action takes place during the closing strokes; either, the swing jaw must slip on the material, or the material must slip along the stationary jaw. It is inevitable that such action should result in accelerated wear of the jaw plates; consequently, the single-toggle crusher is not an economical machine for reducing highly abrasive, or very hard, tough rock. Moreover, the large motion at the receiving opening greatly accentuates shocks incidental to handling the latter class of material, and the full impact of these shocks must be absorbed by the bearings in the top of the swing jaw.

The single-toggle machine, like the Dodge type, is capable of making a high ratio-of-reduction, a faculty which enables it to perform a single-stage reduction of hand-loaded, mine run ore to a suitable ball mill, or rod mill, feed.

Within the limits of its capacity, and size of receiving openings, it is admirably suited for such operations. Small gravel plant operations are also suited to this type of crusher, although it should not be used where the gravel deposit contains extremely hard boulders. The crusher is easy to adjust, and, in common with most machines of the jaw type, is a simple crusher to maintain.

As rock particles are compressed between the inclined faces of the mantle and concaves there is a tendency for them to slip upward. Slippage occurs in all crushers, even in ideal conditions. Only the particle’s weight and the friction between it and the crusher surfaces counteract this tendency. In particular, very hard rock tends to slip upward rather than break. Choke feeding this kind of material can overload the motor, leaving no option but to regulate the feed. Smaller particles, which weigh less, and harder particles, which are more resistant to breakage, will tend to slip more. Anything that reduces friction, such as spray water or feed moisture, will promote slippage.

Leading is a technique for measuring the gap between fixed and moveable jaws. The procedure is performed while the crusher is running empty. A lead plug is lowered on a lanyard to the choke point, then removed and measured to find out how much thickness remains after the crusher has compressed it. This measures the closed side setting. The open side setting is equal to this measurement plus the throw of the mantle.
The minimum safe closed side setting depends on:

• the character of the material.
• amount of fines in the feed.
• liner shape
• whether the crusher is operated as choke fed or regulated fed

 Crushing_Handbook and Crushing Plant Design and Layout Considerations

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  Jaw Crushers for Sale

JAW CRUSHERS

Since the jaw crusher was pioneered by Eli Whitney Blake in the 2nd quarter of the s, many have twisted the Patent and come up with other types of jaw crushers in hopes of crushing rocks and stones more effectively. Those ‘other’ types of jaw crusher inventors have given birth to 3 groups:

1. Double Toggle of the Blake Type
2. Dodge Type
3. Universal
4. Single Toggle AKA  Overhead Eccentric (also of the Blake jaw crusher family)

Heavy-duty crushing applications of hard-to-break, high Work Index rocks do prefer double-toggle jaw crushers as they are heavier in fabrication.  A double-toggle jaw crusher outweighs the single-toggle by a factor of 2X and well as costs more in capital for the same duty. To perform its trade-off evaluation, the engineering and design firm will analyze technical factors such as:

• The Abrasion Index (Ai)
• Capital cost
• The expected life of mine
• The Work Index of the ore (CWi)
• F80 feed size
• Rock’s compressive strength
• Required reduction ratio

A jaw crusher size is obtained by looking at its feed opening (gape) and length.

As an example, a monster of 79″ x 59″ (2m x 1.5m) will have its fixed jaws 79″ apart where the feed enters on a 59″ wide set of liner plates.

The factors list below will enhance crusher capacity and performance:

1. Proper selection of the jaws.
2. Proper feed gradation.
3. Controlled feed rate.
4. Sufficient feeder capacity and width.
5. Adequate crusher discharge area.
6. Discharge conveyor sized to convey maximum crusher capacity.

Double-Toggle Jaw Crushers

The Double-toggle has its moveable jaw driven via an eccentric shaft that moves the rear and front toggles down and up on each shaft revolutions resulting in the jaws closing at the downstroke and conversely open at the upstroke. A spring-loaded tension rod keeps the toggle in its seats.

Although the image below is of a single-toggle, it illustrates the shims used to make minor setting changes are made to the crusher by adding or removing them in the small space between the crusher’s mainframe and the rea toggle block.

For major crusher closed-side setting adjustment, the length of the front toggle is changed.

The jaw crusher discharge opening is the distance from the valley between corrugations on one jaw to the top of the mating corrugation on the other jaw. The crusher discharge opening governs the size of finished material produced by the crusher.

Measuring Discharge Opening:

1. Measure distance at bottom of jaws at the point of the crushing cycle when the bottom of jaws is closest together.
2. Turn flywheel so that counterweights are parallel with movable jaw.
3. Using a piece of lumber as a “feeler gauge” check the distance between the valley of the corrugations on one jaw to the crown of the corrugations on the other.

Adjusting the discharge side opening:

1. Loosen nuts (4) before making adjustments.
2. Loosen tension if the crusher is to be adjusted for finer crushing.

Crusher must be adjusted when empty and stopped. Never close crusher discharge opening to less than minimum opening. Closing crusher opening to less than recommended will reduce the capacity of crusher and cause premature failure of shaft and bearing assembly.

To compensate for wear on toggle plate, toggle seat, pitman toggle seat, and jaws additional shims must be inserted to maintain the same crusher opening. The setting adjustment system is designed to compensate for jaw plate wear and to change the CSS (closed side setting) of the jaw crusher. The setting adjustment system is built into the back frame end.

Single-toggle Jaw Crushers

The single-toggle crusher is also known as an overhead eccentric for its eccentric shaft is up above compared to the Dodge which has its shaft below/under. Here, the eccentric is integrated into the “swing” jaw plate that’s moving up/down as the flywheel rotated by the motor.  A single-toggle pivots at the base of the swing plate which is causing the jaw’s arc-like motion.  The rock pinching resulting from its flowing/passing between a fixed and a swing moveable plate causes the ore to crush as it is “between a rock and a hard place”.

Here also the toggle is kept in place by a compression spring.  Large CSS adjustments are made to the jaw crusher by modifying the length of the toggle.  Again, shims allow for minor gap adjustments as they are inserted between the mainframe and the toggle block.

By design, tramp metal will shear and break the toggle to protect the machine.

Sizing Jaw Crushers

is done considering the maximum rock-lump or large stone expected to be crushed and also includes the TPH tonnage rate needing to be crushed.  In sizing, we not that jaw crushers will only have around 75% availability and extra sizing should permit this downtime.

Here is a Guide-for-Sizing-Jaw-Crushers thanks to https://www.sagmilling.com

As a rule, the maximum stone-lump dimension need not exceed 80% of the jaw crusher’s gape. For intense, a 59″ x 79″ machine should not see rocks larger than 80 x 59/100 = 47″ or 1.2 meters across. Miners being miners, it is a certainty during day-to-day operation, the crusher will see oversized “ore” but is should be fine and pass-thru if no bridging takes place.

In large open-pit mines, the excavator too often dictated the max feed size of rocks going to the crusher.

The primary rock breaker that is most commonly used in small plants is a jaw crusher of the Blake type, a typical section of which is shown in Fig. 4.

It will be seen that the pitman (226) is suspended from an eccentric on the flywheel shaft and consequently moves up and down as the latter revolves, forcing the toggle plates outwards at each revolution. The seating (234) of the rear toggle plate (239) is fixed to the crusher frame; the bottom of the swing jaw (214) is therefore pushed forward each time the pitman rises, a tension rod (245) fitted with a spring (247) being used to bring it back as the pitman falls. Thus at each revolution of the flywheel the movable jaw crushes any lump of ore once against the stationary jaw (212) allowing it to fall as it swings back on the return half-stroke until eventually the pieces have been broken small enough to drop out. It follows that the size to which the ore is crushed.

The jaw crusher is not so efficient a machine as the gyratory crusher described in the next paragraph, the chief reason for this being that its crushing action is confined to the forward stroke of the jaw only, whereas the gyratory crusher does useful work during the whole of its revolution. In addition, the jaw crusher cannot be choke-fed, as can the other machine, with the result that it is difficult to keep it working at its full capacity— that is, at maximum efficiency.

Tables 5 and 6 give particulars of different sizes of jaw crushers. The capacity figures are based on ore weighing 100 lb. per cubic foot; for a heavier ore, the figures should be increased in direct proportion to its weight in pounds per cubic foot.

Product sizes correspond approximately to the discharge opening measured from the tip of a corrugation on one jaw plate to the bottom of the corrugation on the other when the jaws are open.

Google Patents and Wills’ Mineral Processing Technology as well as www.metso.com and www.miningandconstruction.sandvik.com

The JAW crusher and the GYRATORY crusher have similarities that put them into the same class of crusher. They both have the same crushing speed, 100 to 200 R.P.M. They both break the ore by compression force. And lastly, they both are able to crush the same size of ore.

In spite of their similarities, each crusher design has its own limitations and advantages that differ from the other one. A Gyratory crusher can be fed from two sides and is able to handle ore that tends to slab. Its design allows a higher-speed motor with a higher reduction ratio between the motor and the crushing surface. This means a dollar saving in energy costs.

A Jaw crusher on the other hand requires an Ely wheel to store energy. The box frame construction of this type of crusher also allows it to handle tougher ore. This design restricts the feeding of the crusher to one side only.

Another prime consideration is the space that each takes up. The Jaw crusher tends to end up working underground because of its smaller size and its single feed point.

The Jaw crusher gets its name from the type of crushing surface used. This surface is literally two jaws. One of which is a STATIONARY OR FIXED JAW. The other is called a SWING JAW.

The ore enters from the top and the swing jaw squeezes it against the stationary jaw until it breaks. The broken ore then falls through the crusher to be taken away by a conveyor that is under the crusher. Although the jaws do the work, the real heart of this crusher is the TOGGLE PLATES, the PITMAN, and the PLY WHEEL.

Forced Feed Jaw Crushers

These jaw crushers are ideal for small properties and they are of the high capacity forced feed design. On this first Forced Feed Jaw Crusher, the mainframe and bumper are cast of special alloy iron and the initial cost is low. The frame is ribbed both vertically and horizontally to give maximum strength with minimum weight. The bumper is ruggedly constructed to withstand tremendous shock loads. Steel bumper can be furnished if desired. The side bearings are bronze; the bumper bearings are of the antifriction type.

This bearing arrangement adds both strength and ease of movement. The jaw plates and cheek plates are reversible and are of the best-grade manganese steel. The jaw opening is controlled by the position of an adjustable wedge block. The crusher is usually driven by a V-to-V belt drive, but it can be arranged for either V-to-flat or fiat belt drive. The 8″x10″ size utilizes a split frame and maybe packed for muleback transportation. Cast steel frames can be furnished to obtain maximum durability.

This second type of forced feed rock crusher is similar in design to the Type H listed above except for having a frame and bumper made of cast steel. This steel construction makes the unit lighter per unit of size and adds considerable strength. The bearings are all of the special design; they are bronze and will stand continuous service without any danger of failure. The jaw and cheek plates are manganese steel; and are completely reversible, thus adding to their wearing life. The jaw opening is controlled by the position of an adjustable wedge block. The crushers are usually driven by V-to-V but can be arranged for V-to-flat and belt drive. The 5″x6″ size and the 8″x10″ size can be made with sectionalized frame for muleback transportation. This crusher is ideal for strenuous conditions. Consider a multi jaw crusher.

Bulldog Jaw Crusher

Some jaw crushers are on-floor, some aboveground, and others underground. This in many countries, and crushing many kinds of ore. The Traylor Bulldog Jaw crusher has enjoyed worldwide esteem as a hard-working, profit-producing, full-proof, and trouble-free breaker since the day of its introduction, nearly twenty years ago.  To be modern and get the most out of your crushing dollars, you’ll need the Building breaker. We’d value the privilege of telling you why by letter, through our bulletins, or in person. Write us now – today -for a Blake crusher with curved jaw plates that crush finer and step up production.

Traylor Jaw Crusher

When a machine has such a reputation for excellence that buyers have confidence in its ability to justify its purchase, IT MUST BE GOOD! Take the Type G Traylor Jaw Crusher, for instance. The engineers and operators of many great mining companies know from satisfying experience that this machine delivers a full measure of service and yields extra profits. So they specify it in full confidence and the purchase is made without the usual reluctance to lay out good money for a new machine.

The success of the Type G Traylor Jaw Crusher is due to several characteristics. It is (1) STRONG almost to superfluity, being built of steel throughout; it is (2) FOOL-PROOF, being provided with our patented Safety Device which prevents breakage due to tramp iron or other causes of jamming; it is (3) ECONOMICAL to operate and maintain, being fitted with our well-known patented Bulldog Pitman and Toggle System, which saves power and wear by minimizing friction—power that is employed to deliver increased production; it is (4) CONVENIENT to transport and erect in crowded or not easily accessible locations because it is sectionalized to meet highly restrictive conditions.

Jaw Crusher Foolproof

Whenever mining men need a crusher that is thoroughly reliable and big producer (which is of all time) they almost invariably think first of a Traylor Type “G” Jaw Crusher. By experience, they know that this machine has built into it the four essentials to satisfaction and profit- strength, foolproofness, economy, and convenience.

Maximum STRENGTH lies in the liberal design and the steel of which crusher’s parts are made-cast steel frame, Swing Jaw, Pitman Cap and Toggles, steel Shafts and Pitman rods and manganese steel Jaw Plates and Cheek Plates. FOOLPROOFNESS is provided by our patented and time-tested safety Device which prevents breakage due to packing or tramp iron. ECONOMY is assured by our well-known Bulldog Pitman and Toggle System, which saves power and wear by minimizing friction, the power that is used to deliver greater productivity. CONVENIENCE in transportation and erection in crowded or not easily accessible locations is planned for in advance by sectionalisation to meet any restrictive conditions.

How Does A Jaw Crusher Work?

A jaw crusher is a type of mechanical equipment that is used in the mining and construction industry to crush rocks and large materials into smaller pieces. The jaw crusher works by using a moving jaw and a fixed jaw to crush and grind the rocks. The material is fed into the jaw crusher by a vibrating feeder, and then it is crushed between the two jaws.

The jaw crusher is made up of several parts, including a fixed jaw, a moving jaw, and a toggle plate. The fixed jaw is mounted to the frame of the jaw crusher, and the moving jaw is mounted to the pitman. The pitman is a moving component that is connected to the toggle plate by a series of levers. The toggle plate is responsible for transmitting the power from the pitman to the moving jaw.

The moving jaw is mounted on an eccentric shaft, which allows it to move up and down in a circular motion. As the moving jaw moves down, it crushes the material against the fixed jaw. The material is then discharged from the bottom of the jaw crusher, and it is ready for further processing.

There are several types of jaw crushers available on the market, including single-toggle jaw crushers, double-toggle jaw crushers, and overhead eccentric jaw crushers. Single-toggle jaw crushers are the most common type, and they are designed with a large feed opening and a simple toggle mechanism. Double-toggle jaw crushers are more advanced, and they have a more complex toggle mechanism that allows for more precise control of the crushing process. Overhead eccentric jaw crushers are less common, but they are designed with an eccentric shaft that causes the moving jaw to move in a more circular motion, which allows for a more efficient crushing process.

The working principle of a jaw crusher is that when the jaw rises, the angle between the fixed jaw and the moving jaw becomes larger, and the materials can be crushed. All jaw crushers feature two jaws: one of which is fixed while the other moves. The working principle of jaw crushers is based on the reciprocating movement of the movable jaw that compresses and crushes the rock or ore between itself and the fixed jaw, as the material enters the zone between the jaws.

The crushing process takes place when the feed material between the two jaws is compressed and crushed by the moving jaw. As the moving jaw moves away from the fixed jaw, the crushed material is discharged from the crusher at the bottom, with the size of the discharged material determined by the gap between the jaws.

The crushing action of a jaw crusher is caused by the motion of its swing jaw. The swing jaw moves back and forth by a cam or pitman mechanism, acting like a nutcracker or a class II lever. The volume or cavity between the two jaws is called the crushing chamber. The movement of the swing jaw can be quite small, since complete crushing is not performed in one stroke. The inertia required to crush the material is provided by a weighted flywheel that moves a shaft creating an eccentric motion that causes the closing of the gap.

Jaw crushers are usually constructed in sections to ease the process transportation if they are to be taken underground for carrying out the operations. Jaw crushers are classified on the basis of the position of the pivoting of the swing jaw. Blake crusher-the swing jaw is fixed at the upper position; Dodge crusher-the swing jaw is fixed at the lower position; Universal crusher-the swing jaw is fixed at an intermediate position.

Jaw Crusher VS. Impact Crusher VS. Cone Crusher

Jaw crusher, impact crusher, and cone crusher are widely used in the mining and construction industries for crushing various materials. Each type of stone crusher has its unique characteristics and advantages, making them suitable for specific applications.

This article presents a comprehensive comparison between jaw crusher, impact crusher and cone crusher, highlighting their differences in terms of structure, working principles, crushing capabilities, and applications.

1. Structure and Working Principle

Jaw Crusher: Jaw crushers have a fixed jaw plate and a movable jaw plate. The movable jaw plate moves back and forth against the fixed jaw plate, crushing the material by compressing it between the two plates.

Impact Crusher: Impact crushers consist of a rotor with hammers or blow bars that spin at high speed. When the material enters the crushing chamber, it is struck by the hammers or blow bars and thrown against the impact plates, breaking it into smaller pieces.

Cone Crusher: Cone crushers have a conical-shaped crushing chamber with a mantle and a concave. The material is fed into the chamber and crushed between the mantle and concave as the mantle gyrates within the chamber.

2. Application Range

Jaw Crusher: Jaw crushers are commonly used for primary crushing in various industries, including mining, quarrying, and recycling.

Impact Crusher: Impact crushers are versatile and suitable for primary, secondary, and tertiary crushing. They are widely used in mining, quarrying, and construction.

Cone Crusher: Cone crushers are commonly used for secondary and tertiary crushing in applications such as quarrying, mining, and aggregate production.

3. Crushing Efficiency and Particle Shape

Jaw Crusher: Jaw crushers are known for their high crushing efficiency and can produce a relatively coarse particle shape. They are suitable for primary crushing of hard and abrasive materials.

Impact Crusher: Impact crushers are efficient in crushing materials with high compressive strength. They produce a cubical particle shape and are suitable for secondary and tertiary crushing applications.

Cone Crusher: Cone crushers are renowned for their ability to produce a well-graded and cubical particle shape. They are suitable for secondary and tertiary crushing, offering excellent particle shape control.

4. Capacity

Jaw crushers have a relatively lower capacity compared to cone crushers and impact crushers. They are suitable for small to medium-sized rocks and materials. The capacity of a jaw crusher is determined by the size of the feed opening and the eccentric throw of the movable jaw.

Generally speaking, impact crushers have a higher capacity compared to jaw crushers but a lower capacity compared to cone crushers. They are suitable for primary, secondary, and tertiary crushing. The capacity of an impact crusher is determined by the rotor diameter, rotor speed, and the gap between the impact plates and blow bars.

Contact us to discuss your requirements of direct driven single toggle jaw crusher. Our experienced sales team can help you identify the options that best suit your needs.

Cone crushers have a higher capacity compared to jaw crushers and impact crushers. They are designed for efficient secondary and tertiary crushing and can handle large volumes of material. The capacity of a cone crusher is determined by the closed side setting (CSS) and the size and shape of the crushing chamber.

5. Input Size

Jaw crushers can accept larger feed sizes compared to cone crushers and impact crushers. They have a larger feed opening, which allows for the entry of larger-sized rocks and materials.

Impact crushers have a smaller feed opening compared to jaw crushers and cone crushers. They are designed to accept smaller-sized rocks and materials. The input size of an impact crusher depends on the type of rotor and the configuration of the crushing chamber.

Cone crushers can accept a wide range of feed sizes. They have a conical-shaped crushing chamber that gradually narrows as the material progresses towards the bottom. This design allows for the entry of various-sized rocks and materials.

6. Output Size

The output size of a jaw crusher is determined by the distance between the jaws at the top and the bottom of the crushing chamber. Jaw crushers are capable of producing a relatively coarse output size. The final product size can be controlled by adjusting the gap between the jaws.

Impact crushers produce a cubical output size. The final product size is determined by the gap setting between the impact plates and blow bars, as well as the rotor speed. Impact crushers are capable of producing a range of output sizes, depending on the specific application and desired end product.

Cone crushers are known for producing a well-graded and cubical output size. The final product size is determined by the CSS and the position of the mantle in relation to the concave. Cone crushers provide excellent control over the particle shape and size distribution.

7. Maintenance and Operating Costs

Jaw Crusher: Jaw crushers have relatively low maintenance requirements and operating costs. However, they consume more power compared to impact and cone crushers.

Impact Crusher: Impact crushers require moderate maintenance and have moderate operating costs. They are energy-efficient and offer good cost-effectiveness.

Cone Crusher: Cone crushers have higher maintenance requirements but generally lower operating costs compared to jaw and impact crushers. They are energy-efficient and can provide cost savings in the long run.

Jaw crushers, impact crushers, and cone crushers have distinct characteristics andadvantages that make them suitable for different crushing applications. Jaw crushers excel in primary crushing of hard and abrasive materials, while impact crushers are efficient in secondary and tertiary crushing, offering a cubical particle shape. Cone crushers provide excellent particle shape control and are suitable for secondary and tertiary crushing.

Factors such as crushing capacity, maintenance requirements, operating costs, and application range should be considered when selecting the appropriate crusher for a specific task. It is important to consult industry experts and review product specifications to make informed decisions regarding crusher selection.

How To Reduce The Operating Cost Of Jaw Crusher?

Jaw crusher is critical machines in the mining and quarrying industries, responsible for the essential first stage of size reduction. These robust, reliable crushers play a pivotal role in transforming raw mined materials into valuable commodities. However, to maintain profitability and competitiveness, mining operations must constantly seek ways to optimize the performance and reduce the operating costs associated with the jaw crusher.

This comprehensive guide explores various strategies and best practices to help mining operators lower the overall costs of running jaw crushers. By addressing key factors such as energy consumption, wear part management, maintenance, and process optimization, this article provides a roadmap for enhancing the efficiency and cost-effectiveness of jaw crusher operations.

Energy Consumption Optimization

Reducing the energy consumption of jaw crushers is a primary focus for cost savings, as electricity can account for up to 50% of the total operating costs.

• Implement Energy-Efficient Motors
• Optimize Crusher Settings
• Implement Variable Frequency Drives (VFDs)
• Improve Feed Consistency
• Conduct Regular Maintenance

Wear Parts Management

Effective management of wear parts is crucial for controlling costs and maintaining the crusher's performance.

• Utilize Wear-Resistant Liners
• Implement a Planned Replacement Program
• Monitor Wear Patterns

Maintenance And Downtime Optimization

Scheduled and unplanned downtime present significant opportunities for cost reduction through effective maintenance strategies.

• Condition Monitoring
• Preventive Maintenance
• Maintenance Optimization
• Component Standardization
• Outsourcing

Process Optimization

Crushing-circuit design impacts productivity and costs. Periodic reviews identifying areas for:

• Improved Material Flow
• Optimal Sizing
• Scalping Inclusion
• Lubricant Selection
• Impact-Attachment Usage

Ways To Improve The Performance Of Jaw Crusher

Everyone wants to make the most of their equipment, and jaw crusher operators are no exception. There are several factors that will affect the performance of the crusher, thereby affecting the entire circuit. Here are some ways to help you avoid production losses.

Avoid Bridging

Continuous bridging of the feed zone of the jaw crusher is a common problem.

Bridging refers to stones that prevent water from entering or moving down to the crushing chamber. This may be because there is only one stone larger than the feed opening, or many stones of average size cross each other and block the feed of the crusher.

Bridging can result in major production losses that are often overlooked. Note that the bridging of the feed area of ​​the primary crusher is relevant, as it may take several minutes to resolve the problem (large rocks are removed, broken, or directly into the chamber). If it happens ten times a day, it will quickly cause one hour of production loss.

If this happens, for example, in one of our crusher models, C130 has a working capacity of 352 short tons per hour (stph), and assuming $12 per short ton, the daily loss can easily increase to Dollar.

Through strict control of the blasting grid to avoid the generation of excessively large materials, bridges can be avoided, truck loader operators are trained to separate the oversized materials in the pit, as well as the primary crushing equipment operators, by changing the feeder speed and using the installation in the The hydraulic hammer in the area visualizes the material flow to the crusher and controls the speed and direction of the stone.

Apply the Correct Jaw Mold Shape

Having a suitable jaw mold shape can save more than 20% of production capacity, otherwise it will be a loss.

There are many types of rocks, and there are differences in crushability, wear resistance, and flake shape. Choosing the best combination of fixed jaw and movable jaw mold shapes will help optimize production when crushing difficult-to-process materials. Rocks with lower crushability require closer occlusal angles to maintain the designed bearing capacity. Highly abrasive rocks require thicker, heavier, and longer-life jaw molds to avoid production losses caused by frequent replacements. The flake rock needs a tooth-shaped jaw mold to crush it into more cubes to avoid stopping by bridging and belt cutting along the crushing circuit.

Monitor the Condition of the Jaws

In addition to being an important part of machine performance, the jaw of the jaw crusher is also responsible for the protection of the front frame and the swing jaw. Wear is usually due to increased crushing angle, tooth profile loss, CSS reduction to compensate for possible laminar effects, etc., resulting in production losses. This is why the crusher needs to be monitored throughout its life cycle.

Since excessive wear can result in a 10-20% reduction in output, it is very important to find the best time for jaw rotation or replacement from a cost and benefit point of view.

Jaw Crusher Parts

Jaw crushers are essential pieces of equipment in the construction, mining, and quarrying industries. They are used to crush large materials into smaller pieces, which can then be processed for further use or disposal.

The main parts of a jaw crusher include:

• Frame
• Flywheel
• Jaw Plates

• Toggle Plate
• Cheek Plates
• Pitman

• Eccentric Shaft
• Adjustment Wedge

1. Frame

The frame is the main structural component of the jaw crusher and is responsible for supporting the other parts of the machine. It is typically made of welded steel or cast iron and is subjected to a great deal of stress and strain during operation. The frame supports the eccentric shaft, which is a rotating shaft driven by an electric motor or a diesel engine. The eccentric shaft is connected to the flywheel, which helps to balance the load on the crusher and transmit the power from the motor to the crushing mechanism.

2. Flywheel

The flywheel is a large, heavy wheel that is attached to the end of the eccentric shaft. It helps to balance the load on the crusher and transmit the power from the motor to the crushing mechanism. The flywheel is typically made of cast iron or steel and is subjected to a great deal of wear and tear during operation.

3. Jaw Plates

The jaw plates are the primary wear parts of the jaw crusher and are responsible for crushing the material as it is fed into the crushing chamber. They are typically made of manganese steel or another hard material and are subjected to a great deal of wear and tear during operation. The jaw plates are designed to be easily replaceable, so that they can be replaced when they become worn or damaged.

4. Toggle Plate

The toggle plate is a component that connects the pitman to the cheek plates and helps to transfer the force from the pitman to the cheek plates during the crushing process. It is typically made of cast iron or steel and is subjected to a great deal of wear and tear during operation. The toggle plate is an important safety feature of the jaw crusher, as it helps to prevent accidents by breaking the connection between the pitman and the cheek plates if the crusher becomes overloaded.

5. Cheek Plates

The cheek plates are located on either side of the jaw crusher and are used to crush material against the stationary jaw. They are typically made of manganese steel or another hard material and are subjected to a great deal of stress and strain during operation. The cheek plates are an important part of the jaw crusher, as they help to guide the material as it is fed into the crushing chamber and prevent it from falling out.

6. Pitman

The pitman is the main moving component of the jaw crusher and is responsible for transferring the force from the toggle plate to the crushing mechanism. It is typically made of cast iron or steel and is subjected to a great deal of stress and strain during operation. The pitman is connected to the eccentric shaft via the toggle plate and is supported by the cheek plates. It moves up and down as the eccentric shaft rotates, crushing the material as it passes through the crushing chamber.

7. Eccentric Shaft

The eccentric shaft bearings are located at the ends of the eccentric shaft and help to support the shaft as it rotates. They are typically made of high-quality bearings and are subjected to a great deal of wear and tear during operation. The eccentric shaft bearings help to reduce the friction between the eccentric shaft and the frame, allowing the crusher to operate smoothly and efficiently.

8. Adjustment Wedge

Adjustment Wedge: The adjustment wedge is a component of the jaw crusher that is used to adjust the size of the discharge opening. It is made of high-strength steel and is responsible for moving the toggle plate and the toggle plate seat.

In conclusion, the main parts of a jaw crusher include the frame, the eccentric shaft, the flywheel, the toggle plate, the cheek plates, the jaw plates, the pitman, the eccentric shaft and adjustment wedge. These components work together to crush large materials into smaller pieces, which can then be processed for further use.

Six Major Differences Between Jaw Crusher And Impact Crusher

Jaw crusher and impact crusher are common equipment used in aggregates industry. But a lot of people may not know them very well, especially for users starting in this field.

We often get asked this question, today we'll talk about the difference between these two crushers.

The obvious difference between jaw crusher and impact crusher is in structure and working principle.

The working mode of the former is flexural extrusion, and the material is crushed in crushing chamber composed of moving jaw and fixed jaw. The latter adopts the principle of impact crushing. The material is repeatedly smashed between the rotor (plate hammer) and the counter plate.

Many people should be familiar with the principle. So today we will focus on the analysis of their differences in actual production.

1. Different Scope of Application

1) Hardness of materials

Jaw crusher can crush materials with various harnesses, compressive strength between 300-350MPA. And the impact crusher is suitable for crushing low toughness, brittle material such as limestone. If we use impact crusher to process hard stone, it will cause great damage to the vulnerable parts and shorten the service life of crusher.

2) Material size

Generally, jaw crusher is more suitable for processing large stone materials, whose input size is no more than 1 meter (depending on the type of equipment and the manufacturer). So it’s widely used in mines and quarries. While impact crusher is usually used to crush small stone materials, and its input size is less than that of jaw crusher.

2. Different Applications

It is well known that in the production line of crushing, sand making and ore dressing, jaw crusher is used for coarse crushing as a primary crushing equipment (fine jaw crusher can be used for medium or fine crushing), while impact crusher is usually used for medium or fine crushing as a secondary or tertiary crushing equipment.

3. Different Capacity

The capacity of jaw fracture is greater than that of impact crusher. Generally speaking, the output of jaw break can reach 600-800T per hour (depending on the manufacturer and product model), and the output of impact crusher is about 260-450T per hour.

4. Different Fineness of Discharging

As coarse crushing equipment, the fineness of jaw crusher is large, generally below 300-350mm (depending on the manufacturer and product model). As a medium or fine crushing equipment, the discharge fineness of impact crusher is smaller.

Of course, it should be noted that due to different material properties, the discharging of different equipment may have errors.

5. Different Particle of Discharging

The grain shape of finished products of jaw crusher is not good with too much elongated and flaky particles. While the finished products of impact crusher has good grain shape, and its particle is better than cone crusher.

Therefore, jaw crusher is usually configured after the impact crusher for further shaping in the actual production. This is also more common collocation.

6. Different Prices

In general, the price of jaw crusher is lower than impact crusher, as a traditional crushing equipment, jaw crusher is more stable in some aspects like performance, quality, power consumption. This can meet the user's requirements, so this kind of cost-effective equipment is easier to attract the attention of users.

How To Select The Right SBM Jaw Crusher For Your Needs

When it comes to enhancing the crushing capabilities of your mining or aggregates operations, choosing the right stone crusher provider is of utmost importance. SBM jaw crushers have gained a reputation for their reliable performance and efficient crushing capabilities. This article provides valuable insights and guidance on how to select the right SBM jaw crusher for your specific needs.

Understanding SBM's Jaw Crusher Product Lines

SBM, with years of experience in the industry, offers a range of jaw crushers designed to meet diverse crushing needs. Our jaw crusher product lines include models such as the C6X series, C5X series, PE series and the PEW series. These product lines have proven themselves in various mining and aggregate applications.

Key Factors for Selecting SBM Jaw Crushers

To choose the right SBM jaw crusher for your needs, consider the following factors:

• 1. Crushing Capacity: Determine the required capacity based on the desired throughput and production goals of your operation. Select a jaw crusher with sufficient capacity to handle the anticipated workload.
• 2. Feed Size: Evaluate the maximum size of the feed material and ensure that the jaw crusher can effectively accommodate it. A larger feed opening is desirable for processing larger rocks and achieving higher productivity.
• 3. Adjustability of Output Size: Consider the range of output sizes you need for your specific application. The jaw crusher should have adjustable settings to control the desired size of the final product.
• 4. Portability: Depending on your operational needs, consider whether a stationary or mobile jaw crusher is more suitable. SBM offers options for both configurations, allowing you to select the most convenient setup for your operation.

Specific Features of SBM Jaw Crusher

• 1. Advanced Crushing Technology;
• 2. High Productivity and Efficiency;
• 3. Easy Maintenance;
• 4. Durability and Reliability;

Jaw Crusher Wear Liners: Maximizing Wear Life

Jaw crusher is one of the most widely used types of primary crushers in the mining, quarrying, and construction industries. These robust machines are renowned for their ability to handle large, hard, and abrasive materials, reducing them to smaller, more manageable sizes.

At the heart of a jaw crusher's operation are the wear liners, critical components that protect the crushing chamber from the intense forces and wear associated with the crushing process, which need to be monitored and replaced in a timely manner to ensure the efficient and cost-effective operation of your jaw crusher.

Types of Jaw Crusher Wear Liners

Jaw crusherprimarily have two types of replaceable wear parts - fixed and movable jaw liners.

Fixed jaw liners (also called concave liners) line the outer wall of the crushing chamber forming the stationary breaking surface. They are thick, smooth and curved to match the throw motion of the swing jaw.

Movable jaw liners (also called jaw dies) are thinner and endure greater impact forces as they move in and out of the crushing cavity. Jaw dies usually come as a removable plate welded to the bottom of the swing jaw.

Some manufactures offer alloyed steel liners for enhanced oxidation resistance in slag or ferrous applications. Compound profiled liners can increase nip angles for improved comminution.

Factors Affecting Jaw Crusher Wear

The wear rate of jaw crusher wear liners is influenced by a variety of factors, including the feed material characteristics, crusher operating conditions, and maintenance practices. Understanding these factors is crucial for optimizing wear life and minimizing operating costs.

1. 1. Feed Material Characteristics
2. 2. Crusher Operating Conditions
3. 3. Maintenance Practices
4. 4. Crusher Design and Configuration

Maximizing Jaw Crusher Wear Liner Performance

Effective monitoring and maintenance of jaw crusher wear liners are crucial for maximizing their service life, minimizing downtime, and reducing overall operating costs.

1. 1. Regular Inspections
2. 2. Wear Measurement and Tracking
3. 3. Proactive Maintenance
4. 4. Liner Replacement and Handling

Application Of Jaw Crusher In Sand Production Line

With the development of the economy, the country continues to promote the construction of various basic designs. The demand for aggregates has increased. Due to the growing shortage of natural sand resources, machine-made sand has become the main building material in infrastructure construction. The gravel production line is a special production line equipment for the production of sand and stone for construction. The production line can be equipped with jaw crusher, vibrating screen, sand making machine, etc. according to the production needs. It can put rock, gravel, river pebble and other materials. It is made into various particle sizes that meet the requirements of construction sand. The sand made from sand and gravel production line has uniform grain size and high compressive strength. It is far more suitable than the sand produced by natural sand and ordinary hammer sander. Building quality.

The sand production line has the characteristics of reliable performance, reasonable design, convenient operation and high work efficiency. In the sand production line, the jaw crusher is used for primary crushing of large stones. There are many options for the jaw crusher model, which can accept different feed sizes. The stone material is uniformly sent to the jaw crusher by the vibrating feeder for coarse breaking. The material after the coarse crushing is transported by the belt conveyor to the fine crushing jaw crusher for further crushing, and the finely crushed material is sent to the vibrating screen for screening. The material that meets the particle size requirements of the finished product is sent to the sand washing machine for cleaning. The material that does not meet the particle size requirements of the finished product is returned from the vibrating screen to the sand making machine for re-machining to form a closed circuit for multiple cycles. Finished product granularity can be combined and graded according to user needs.

Jaw crusher is divided into large, medium and small according to the width of the feed port. The feed port width is greater than 600MM for large machines, and the feed port width is 300-600MM for medium-sized machines. The feed port width is smaller than 300MM is a small machine. The jaw crusher has a simple structure, is easy to manufacture, reliable in operation, and convenient to use and maintain. The fineness of the jaw crusher can be varied from 10mm to 105mm, and it can be adjusted according to customers' needs. Jaw crusher prices vary according to model and production capacity.

At present, there are many crusher manufacturers in the mining industry. If you want to invest in crusher equipment, you must first understand the manufacturer and customize a reasonable crushing production line according to your actual production needs. Shanghai Shibang is the leading manufacturer of crusher equipment in the country. If you need technical support or other needs in this area, we have experts to help you.

For more jaw crusher equipmentinformation, please contact us. We will provide professional answers.