Video

Sure , where to?

double row roller bearing? Don't use bearings on heavy machines! The bearing breaks before, as than breaker head.

@Richard Horvath , If you look at my reply to Dru Bradley a few comments above I address the misconception of too many moving parts. It obviously appears that way as the comment has come up a number of times but in comparison to other cam/Lever type cone/gyratory crushers this design has fewer moving parts.Remember motion does not mean the component is moving in relation to its fixture. design

@@montaguable And the power effects? While here a huge outer ring carries the force, in another type, the central bearing can withstand the force in that direction better. In other words, centrifugal and vector forces are better for a machine with a centric bearing, taking into account the direction of the force. Maybe it's not like that? Also, isn't the moving and planetary mass too big in this case?

@@richardhorvath7237 If you are talking about power consumption in operation consider these these.In this design the power is transmitted via a belt (other options possible) from the power source (Electric motor usually) directly to the rotating assembly , which is the only rotating part that rotates in roller bearings.In conventional cam and lever type cone/gyratory crushers the drive is usually from the power source via belts or a coupling onto a pulley.This pulley/coupling turns a shaft running through bushes or bearings with a pinion gear at the end. The pinion gear meshes with a crown wheel and transmits the energy at 90 degrees into the eccentric, the eccentric then slides around a shaft to deliver the gyratory motion in the shaft , this is then transmitted to the mantle. Which one has more friction ? Which one has has more direction of power flow changes? Then consider that on conventional cam/lever crushers the column of material flowing through the crusher is lifted and dropped on every rotation as the moving crushing face is moving in the opposite direction of the flow of the material , in this type of cone the moving face of the crushing chamber moves in the same direction as the material flow thus not requiring the constant lifting of the material. Consider also that the oil flow required to lubricate and cool these bearings is around 5% that of a bush type crusher and pumping this oil also consumes energy. Consider that with this design there is a flywheel that is part of the rotating assembly,This means we do not have to fit a drive to meet spikes in power requirements but only enough power to meet average short period peaks. So depending on application this can result in a lower power drive being required. Inner vs outer position of bearings and force vectors.It is commonly accepted that in a crushing chamber of a cone/gyratory the compression pressures are developed in a roughly 30 degree rotating segment , with the peak pressures being in the sizing zone of the parallel faces at the bottom of the crushing chamber. Now if your bearing is placed in the inner position the forces generated in the crushing chamber that are acting in +-30 degree wedge are being concentrates into a smaller and smaller area as you reduce the diameter of the bearing. Inversely when you place the bearing in the outer position the forces generated in the crushing chamber are obviously still in the same +- 30 degree wedge but you now have this same force diluted over a larger area.So in effect if the rollers are of the same size you would for instance have 3 rollers on an inner type bearing having to support the forces that 10 rollers on an outer type bearing would. Then there is this very important consideration as well , with the inner type bearings on a cone crusher these bearings are usually positioned around the shaft below the mantle head. This is typically below the sizing zone thus the pressure in the sizing zone is not only concentrated to a smaller area of the lesser diameter it is further transferred via a shaft to the lower positioned bearing thus by way of leverage amplifying peak pressure even more. On the outer bearing position it is possible to position the bearings in line and perpendicular to the sizing zone so there is no leverage disadvantage. The pressure is transferred directly in compression through the housing with no bending moment as with a shaft inner bearing set up. The planetary mass that is rotating is an eccentric fixed to a heavier flywheel that is pocketed to create one rotating assembly that is virtually 100% balanced. Richard , if you are interested you may email the address at the end of the animation and it will be passed on to me. We could share more information if you would like. What you see in the animation is just a replication of the real units that have been working in the field in extremely harsh applications. This is not just an idea it is a reality that has been put in to operation. Very simple to operate and minimal maintenance required.

Hi Conor. Yes under Crushforce Prototype testing on CZcams you will find 2 more. Please feel free to send me a mail on leon@crushforce.co.za or call 084 960 3003. In short, yes we have machines in very harsh conditions and are running successfully. Please contact me for further info.

Hi Conor , email me quentin@crushforce.co.za or leon@crushforce.co.za .I'll forward you info.

I can see there are replies but they don't appear! Perhaps you need to change a setting?

@@malin-beg email leon@crushforce.co.za or quentin@crushforce.co.za

@Njorar Sigurar , your take/opinion is noted and it is good to hear constructive criticism because it enables opinions outside your own circle to be considered but also an opportunity to address misconceptions. Your major points being (1) Too many moving parts. (2) Will be a nightmare to work on. Ill address those but first I want to point out that this animation was produced after lab size proof of concept units were manufactured and produced. The animation you are commenting on is almost an exact illustration of the 1st prototype produced for real world testing. The original prototype has thousands of hours testing on it in various applications , mostly in very demanding applications. So my observations are realistic and based on experience not conjecture. If you are interested at the end of the animation there is an email address you can use to make contact (Not mine ) but it will be passed on to me and I can supply you with a lot of real world info. (1) Too many moving parts. As I have stated in this comment section before it may appear that way but in fact this approach only has one moving assembly. An anti spin torque arm and bearings. This is under half the moving parts of the standard cam and lever cone crushers produced by Metso and Sandvik.Component wise this approach has under 1/4 the number of pieces of cam and lever cone crushers. So although it obviously does appear to some that this is a complex and sophisticated machine the fact is it is a far simpler design with way fewer moving parts and way fewer overall components. (2) Will be a nightmare to work on. One artisan can strip this unit to every single component in one shift quite easily. All but the gap setting cylinder , its bottom plate and transducer are accessed from the top. Moving parts and working components are all above and about the crushing zone making access very simple and safe. Compared to other cone crushers this unit is actually very simple. I need to reiterate that this is not conjecture , it was a design objective and has been achieved in real world practice. Now as to Metso , Sandvik being " stuff that works" sure they do but compared to this unit they have too many moving parts and are a nightmare to work on. That is the reality and this can be demonstrated in real world if you want to engage. As to the design being that of a new engineer I understand that conclusion given the misconception and misunderstanding. Nevertheless this is not accurate and the design brief was a simpler more robust design and thus far this has been met after thousands of hours of testing. The truth is that there has been little progress in the last 100 years as to cone crusher design other than automation , advanced metallurgy and computer simulation/modelling and control.Have a look at cross section of an early 19th century cone and compare to the latest Metso or Sandvik .They are remarkably similar. So why reinvent the wheel , well there are are increasing diminishing returns on the incremental changes the leading producers are making. The reason is that there are physical constraints that just box them in to what can be achieved with a typical cam and lever cone crusher where most working components need to be contained with in an envelope below the crushing head. There is just so much that can be achieved when you have those limits placed on you. That is the reason advanced metallurgy and computer aided simulations have incrementally improved performance and reliability over the last 100 years but no huge leaps. The Russians and later Sandvik did peruse the vibrating mantle designs with some degree of success but at scale this proved extremely difficult to control and was abandoned as far as I am aware. So if you are at all truly interested , make contact and I will make some real world applications available for you to verify.

I have heard the comment of too many moving parts before but it actually just appears that way. There is in fact only 1 rotating assembly. That is the eccentric , flywheel/drive sheave and these are fixed together and rotate as one assembly.The concave is actually just following a gyratory path and is not a moving part. There are also the 4 bearings that have moving rollers I suppose. Then there is the anti-spin "torque arm" that moves on one end. That's it . In total there are around 38 parts/components in the crusher as opposed to 160 + in most every other cone. The contact points where movement occurs are 2 roller bearing pairs , one slide bush and 2 seals. Sealing on this unit has been very simple , first of all the oil flow required for lube is around 15% that of a similar size bush type cone. Also all working/moving parts are located above the actual crushing zone so not in the actual worst areas dust wise. We have had oil samples analyzed at 2000h intervals and these have come back with contaminant levels in the very lowest of the end of scale with no need to change oil. The oil visually is indiscernible from new oil and these areas are never openly exposed to the environment even during liner changes the bearing arrangements remain 100% sealed. We built the first working models 250mm mantle in lab size as proof of concept. A few have been taken in to lab application and used there but that is a pretty mild endurance test. We have had a couple of the lab units put in to industrial applications on silica sand and more recently a 7 month stint crushing metal slag. Feed 18mm down to -3mm. A tremendously tough challenge and manganese liners wear the scars of just how tough it is but the lab unit surprised us all and took it in its stride. On the 600mm mantle prototype we have mainly tested it in the slag crushing industries. There are a couple of reasons. First being that is such a tough environment there is way less reluctance to test something new as they dont have economic solutions for crushing to -3mm and this unit manages. Another reason is that it is also simple and quick to change the wear liners which in the chrome slag industry can be a couple of times a week so a 30 min liner change is very appealing. We were planning to enter that market commercially last year but the covid shutdowns shut all testing down so we only really started again a few months ago and are delivering our first order of a 600mm mantle machine in the next week. The client tested the prototype and then hired it for 6 months. Our prototype has a bunch of on site trials lined up. If you are interested in some more detailed info you can email Leon , his email address is at the end of the animation. There are some old videos of the prototype in operation here czcams.com/video/B3_k9SYc7Mk/video.html and here czcams.com/video/d93XKZSWQ7s/video.html .

@@montaguable Rogerthat. Me and the bosses were watching this, and now, reading this, and will be covered on next Monday's meeting and likely watched again. .The liner change out time being reduced, either from wear or fractures has killed production uncountable times, and always in the worst of times. That really screws up the pace of all party's involved. Thank you for the input. Are you located in the USA and are you open to a team of our people to come meet with you and see some your demo's in a working condition. We normally do not need such a capable device, but asphalt plants taking on a chunk and either busting the system or stopping the process is exceptionally costly. In approx two years, there are 3 contracts that will require this safety measure over what was proven to fail.. Two years may sound like a long time, but testing as you know is time consuming.. Will be in touch.. Thank you for the reply.

@@drubradley8821 We are located in South Africa , we have fairly advanced plans of doing business in the US. Where exactly are you based ?

@@montaguable We are in the USA. We had our meeting late, on Wednesday, instead of Monday. I apologize, for the late reply. Parts of conveyor are becoming difficult to source in large quantity's and has consumed a large portion of my week. There is instructions for the other engineers to dig further into looking at these further this week end, to be further up to speed for this coming Monday's meeting.. I know they will do as instructed, as we all know, that this campaign we ar on with the units we have now, is killing. Abrasion resistant plate is going up in cost, especially the 500 series, pre cut templates do help with the speed of install, but does nothing for the removal of the old cracked or broken off plates. Pardon the venting here, but, it just never ends with the units we have now. Please note, it is not the crushers fault, per say, we know they are just past their usefulness of life cycle. There are no parts to be had from the manufacture as the are long gone. The company that purchased them, dropped that series all together. Which is in part what I think how the original company got out of the claims, by means of selling off, and the new ownership dropping the line. BUT.. do offer services to pay for the entire process to start production if we do want their parts, LOL.. Christ, I can rip the units out that I have now and buy 4 new units for that cost to help them start up the casting foundry for them...LOL... I should have better answers for you on late Monday to Tuesday. pending the social climate on a few of Africa's issues, is not a worry for us, as each on of us at one time of another lived in a few country's in Africa. so the social stresses you are dealing with really doesn't create any worry on our end, other then, pending you you guys are, if that country will permit us to come in, in regards to further talks. Good luck and be safe. I will touch base with you next week.

@@drubradley8821 Contact a book publisher for your next "reply". 🙄

Those are tough heavy machines , still a lot of them around. They however are not very energy efficient and working on them is dirty , difficult and can be dangerous. This from what I have seen and I have seen these units in the field being tested. They are very simple to operate and maintain. Can run empty for days and handles tramp like no other machine I have seen.

And what is the feeding size capacity of ur machine

@@immakexporters3780 Rock Salt is a soft mineral , you dont need a compression crusher. A simple small roll sizer will work just fine. It can be crushed by this type of crusher and those fractions.They have a very small 250mm size unit that should give you those fractions at 2tph .Feed size on this 250mm machine is -19mm if I recall.

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Yes you are correct , the secret is to get the speed of the opening up and closing just right. If its too fast then the material flows too slowly through the crusher and the capacity per hour suffers , if running too slowly too much material falls through what is termed the open side. Now in practice after comming out the bottom of the crusher the product is usually screened/sived and the pieces that are still bigger than desired are directed through the crusher again.

You can either sieve and recirculate the bigger pieces back through the crusher, direct the output of the first crusher into a secondary crusher, or size the crusher such that the largest piece that can pass through the open side is still within range for the first stage of your grinding circuit. The mine I used to work at had the primary crusher underground, output loaded in skips and brought to surface, then hauled to the concentrator and fed into the secondary. After that it went to grinding (rod mill then ball mill), then to flotation (several circuits, since we produced Pb/Zn/Cu). Finally, the result was dried, and the 3 concentrates were deposited as a fine powder in individual piles in storage sheds, eventually to be transported to the smelter.

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Hi Abdullah , regarding the stress on components the reality is that this design can handle higher pressures than any other cone. It is the ideal machine for hard rock. If you consider the bearings are not size compromised in order to be small enough to fit under the crusher head . They are oversized to fit on the outside of the whole crushing chamber around 5 times larger than other cone crushers. Additionally they are positioned directly in line with the sizing zone where the highest pressures are generated. On other cones the bearings have to compensate for the amplifying of forces due to leverage because they are on a shaft positioned not directly in line with the sizing zone. Likewise the main shaft does not have to accomodate any rotational bearing assemblies so it can be cheaply manufactured to about 4 times the size of main shafts in like sized cones. The prototype spent months on various sites crushing dolerite which is very similar to basalt . It has also crushed chrome slag in volumes. This is the unit crushing dolarite czcams.com/video/B3_k9SYc7Mk/video.html See also somewhere in this video where a hardened steel pin was thrown in to the machine on purpose czcams.com/video/d93XKZSWQ7s/video.html . It has a very simple and effective tramp Iron release. Perhaps you are thinking of other components that may be vulnerable , if so let me know and we can discuss. I think these will start being commercialised in the next year or so.

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At the end of the video there is an e-mail address that you can use to get hold of the distributor.

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A jaw crusher is better suited , there are many on the market that can do that. Have a look at this czcams.com/video/h-utJcj_EOM/video.html I belive it works well in that application.

Master Q *** Thanks Captain, Ill take the tour.

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Are you asking if it can crush down to +0mm ,-5mm with fines (0.075mm) no more than 18%? Then I think its possible . If you are require 0,075mm then no , but I know they have a very small cone for micro plants where the cone crushes 80% less than 0,75mm. For more detailed info e-mail Leon@crushforce.co.za

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Anatoliy , how many moving parts do you see? This is a very simple design from what I know and have seen. In reality very few moving parts , only one rotating assembly. That is the eccentric , flywheel assembly. Then the "Torque arm" moves slightly to compensate for the wobbling motion pendulum motion of the concave assembly in relation to the mainframe. In reality less moving parts than any other cone crusher I am aware of.

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Yes , hammer mills have their place but not for hard rock. In China along the coast where most development has historically taken place they are effective. With development moving more and more inland the geology is is more hard you need a compression not an impact crusher.

for info you can e-mail leon@crushforce.co.za

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