CRUSHER COMPRISING REPLACEABLE PROTECTIVE LINERS

Abstract

A crusher comprises at least one protective liner which is releasably fitted within the crusher so as to protect a structural element of the crusher which is subject to wear due to its contact with material passing the crushing gap, at least a part of an outwardly directed surface of the protective liner constituting a wear surface. The at least one protective liner comprises an elastic material layer and wear resistant inserts retained by the elastic material layer, wherein outwardly directed surfaces of the wear resistant inserts form part of the wear surface of the protective liner.

Claims

1. A crusher comprising: a main frame, and a crushing head mounted upon a main shaft, wherein a crushing gap is formed between an outer surface of the crushing head and an inner circumferential surface of a mantle provided within the main frame, and wherein the crusher further comprises at least one protective liner which is releasably fitted within the crusher, at least a part of an outwardly directed surface of the protective liner constituting a wear surface, wherein the at least one protective liner comprises an elastic material layer and wear resistant inserts retained by the elastic material layer, wherein outwardly directed surfaces of the wear resistant inserts form part of the wear surface of the protective liner.

2. The crusher of claim 1, wherein the protective liner is releasably fitted within the crusher by fastening the elastic material layer within the crusher.

3. The protective liner of claim 1, wherein the protective liner further comprises a carrier structure for supporting the elastic material layer, and the protective liner is releasably fitted within the crusher by fastening the carrier structure within the crusher.

4. The crusher of claim 1, wherein the protective liner further comprises at least one stiffening element for enhancing the stiffness of the elastic material layer, particularly in the vertical direction.

5. The crusher of claim 1, wherein an area of the protective liner other than the wear surface is devoid of wear-resistant inserts.

6. The crusher of claim 5, wherein means for fastening the protective liner to the crusher are provided in an area of the protective liner which is devoid of wear-resistant inserts.

7. The crusher of claim 1, further comprising a steel liner arranged so as to cover and protect a structural element of the crusher which is subject to wear, wherein the protective liner is fixed to the steel liner.

8. The crusher of claim 7, wherein the steel liner is integrally formed with or provided with supporting structures for supporting the protective liner during assembly and/or during operation of the crusher.

9. The crusher of claim 7, wherein a surface area of the protective liner is smaller than a surface area of the steel liner so that the protective liner covers only part of the surface area of the steel liner.

10. The crusher of claim 1, wherein the protective liner is assembled from several protective liner sections.

11. The crusher claim 1, wherein the main frame includes a bottom shell, and at least one protective liner is a bottom shell liner mounted to the inner circumferential surface of the bottom shell.

12. The crusher of claim 1, further comprising a drive shaft arranged to impart a gyratory motion to the crusher head, wherein the main frame includes a bottom shell comprising a shaft opening for the drive shaft to pass through, and wherein at least one protective liner is a drive shaft liner mounted so as to surround a portion of the drive shaft from above.

13. The crusher of claim 12, having the main shaft thereof mounted within a central hub, wherein at least one section of the drive shaft liner is arranged adjacent to, and preferably fixed to, the central hub.

14. The crusher of claim 12, wherein the drive shaft liner includes a first section extending along a portion of the drive shaft extending within the bottom shell.

15. The crusher of claim 1, wherein the main shaft is coupled with the crushing head via a locking nut provided at an upper end of the main shaft, wherein at least one protective liner is a locking nut liner provided on an outer circumferential surface of the locking nut.

16. (canceled)

17. A protective liner for a crusher, the crusher comprising: a main frame, and a crushing head mounted upon a main shaft, wherein a crushing gap is formed between an outer surface of the crushing head and an inner circumferential surface of a mantle provided within the main frame, wherein the protective liner is arranged so as to be releasably fitted within the crusher, at least a part of an outwardly directed surface of the protective liner constituting a wear surface, wherein the protective liner comprises an elastic material layer and wear resistant inserts retained by the elastic material layer, wherein outwardly directed surfaces of the wear resistant inserts form part of the wear surface of the protective liner.

18. The protective liner of claim 17, wherein the elastic material layer includes means for releasably fitting the protective liner within the crusher.

19. The protective liner of claim 17, wherein the protective liner further comprises a carrier structure for supporting the elastic material layer, and the carrier structure includes means for releasably fitting the protective liner within the crusher.

20. The protective liner of claim 17, further comprising at least one stiffening element for enhancing the stiffness of the elastic material layer, particularly in the vertical direction.

21. The protective liner of claim 17, wherein an area of the protective liner other than the wear surface is devoid of wear-resistant inserts.

22. The protective liner of claim 17, wherein means for fastening the protective liner to the crusher are provided in an area of the protective liner which is devoid of wear-resistant inserts.

23. The protective liner of claim 17, wherein the protective liner includes several protective liner sections.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The above, as well as additional objects, features and advantages of the present invention will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present invention, with reference to the appended drawing, where the same reference numerals will be used for similar elements, wherein:

[0042] FIG. 1 shows schematically a crusher equipped with protective liners according to the present invention.

[0043] FIG. 2 is a perspective view of a bottom shell of a crusher, equipped with a protective liner of the invention.

[0044] FIG. 3 illustrates a steel liner and a protective liner used for the bottom shell of FIG. 2.

[0045] FIG. 4a shows the configuration of the protective liner without the steel liner.

[0046] FIG. 4b is a front view, side view and perspective view of a vertical stiffening member.

[0047] FIG. 5 is a perspective view of a bottom shell of a crusher equipped with a bottom shell liner and a driveshaft liner of the invention.

[0048] FIG. 6 shows a first element of the driveshaft liner.

[0049] FIG. 7 shows a second element of the driveshaft liner.

[0050] FIG. 8 shows a third element of the driveshaft liner.

[0051] FIG. 9 illustrates a driveshaft from below in a state in which it is equipped with a driveshaft liner.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0052] Embodiments of protective liners according to the present invention will now be described in detail with reference to the drawings.

[0053] FIG. 1 schematically illustrates a crusher in section. The crusher comprises a main frame 1 which is assembled from several parts, including a top shell and a bottom shell designated 2. A crushing head 3 is mounted upon a vertically extending main shaft (not illustrated). At its lower end, the main shaft is mounted within a central hub 4. At its upper end, the main shaft is coupled with the crushing head 3 via a locking nut 5.

[0054] A crushing gap G is formed between an outer surface of the crushing head 3 and an inner circumferential surface of a mantle 9 assembled within the main frame 1. The crushing head is supported so as to perform a gyratory motion relative to the inner circumferential surface of the mantle 9. The material to be crushed is fed via the top of the crusher and is crushed in the crushing gap G between the outer surface of the crushing head 3 and the inner surface of the surrounding mantle 9. The crushed material is discharged from the bottom of the crusher.

[0055] During operation, the crushing head 3 performs a gyratory motion. A drive shaft 6 is arranged to impart the gyratory motion to the crusher head 3. This is done, in a manner known as such, by means of an eccentric arrangement (not illustrated) provided on the inside of the crushing head 3. Reference numeral 7 designates a shaft opening formed in the bottom shell 2 for the drive shaft 6 to pass through.

[0056] In accordance with the invention, the crusher illustrated in FIG. 1 is equipped with protective liners to protect surfaces within the crusher which are subject to wear due to their contact with the material being processed in the crusher. Each of the protective liners includes an elastic material layer which has wear-resistant parts embedded at least in a surface area thereof which forms a wear surface. Each wear resistant part has an outwardly directed surface forming part of the wear surface of the protective liner. The remainder of each wear resistant part is immersed in the elastic material layer. As explained further above, the elastic material layer can be a polymer layer, and the wear-resistant parts can be ceramic inserts. One possible implementation would be a layer made from a composite polymer-ceramics material. Therefore, the wear surface of the protective liner will also be referred to as a polymer-ceramics layer in the following.

[0057] A first protective liner 10 is mounted to the inner circumferential surface of the bottom shell 2, with a steel liner being interposed between the inner circumferential surface of the bottom shell 2 and the protective liner 10.

[0058] Reference numeral 8 designates a steel cover of the driveshaft. This steel cover surrounds the drive shaft 6, at least from above, in the area between the inner circumference of the bottom shell 2 and the outer circumference of the central hub 4, i.e. in the area where the drive shaft 6 is exposed to material which has passed the crushing gap G. The steel cover 8 terminates in a first collar adjacent to the bottom shell 2, which is visible in the Figure, and a second collar adjacent to the central hub 4, which is hidden from view. A second protective liner 20 is mounted so as to surround a portion of the drive shaft 6or the steel cover 8 covering the drive shaft 6, respectivelyfrom above.

[0059] A third protective liner 80 is provided on an outer circumferential surface of the locking nut 5.

[0060] These protective liners will now be described in detail.

[0061] 1. Bottom Shell Liner

[0062] The protective liner 10 on the inner circumferential surface of the bottom shell 2 is illustrated in FIGS. 2 to 4.

[0063] FIG. 2 is a perspective view of the bottom shell 2 equipped with the protective liner 10. The bottom shell liner 10 is provided on the inner circumferential surface of the bottom shell 2, i.e. in an area below the mantle 9 (cf. FIG. 1) defining the crushing gap G. More particularly, the bottom shell liner 10 is made up from several sections 10 arranged adjacent to each other about the inner wall of the bottom shell 2, so that the sections 10 together define a cylindrical shape. The protective liner sections 10 are fitted to a steel liner which clads the inner circumferential surface of the bottom shell 2, much like the steel liners used in the prior art.

[0064] The steel liner and the bottom shell liner 10 are illustrated in more detail in FIG. 3, which includes a top view of the steel liner, designated 11, to which the sections 10 forming the bottom shell liner 10 are fitted. The Figure also includes a sectional view along the line A-A in the top view, and an enlarged illustration of a detail designated B in the sectional view.

[0065] As shown in the sectional view, protruding hooks 12 are provided to the inner circumferential surface of the steel liner 11, e.g. by welding. These hooks 12 support the protective liner sections 10 during assembly by engaging lower edges of the protective liner sections 10. In this embodiment, the hooks 12 are spaced apart regularly about the inner circumference of the steel liner 11.

[0066] It becomes apparent from the drawing that a surface area of the protective liner 10 is smaller than a surface area of the steel liner 11, i.e. the protective liner 10 covers only part of the surface area of the steel liner 11. The surface area of the steel liner 11 is larger than the actual wearing zone, whereas the protective liner 10 or its wear surface, respectively, basically covers the actual wearing area. As a consequence, the protective liner 10 will be worn across substantially its entire wear surface so that the maximum possible use is made of the protective liner 10. In a way, it can be said that the protective liner 10 protects the steel liner 11 which in turn protects the bottom shell 2.

[0067] In an area near the upper edge of the bottom shell liner 10, a series of through openings are provided to the sections 10, which are spaced apart from each other in regular intervals about the circumference of the bottom shell liner 10. The through openings have a rectangular shape in this embodiment. In this embodiment, the number and spacing of the through openings corresponds to the number and spacing of the hooks 12, but this must not necessarily be the case.

[0068] On the inner circumferential surface of the steel liner 11, protruding portions are formed, which have a shape corresponding to the shape of the through openings in the protective liner sections 10. The protruding portions can be added to the steel liner 11, e.g. by welding, or formed as an integral part with the steel liner 11, e.g. by casting.

[0069] In order to assemble the protective liner sections 10 to the steel liner 11, the protective liner sections 10 are fitted to the steel liner 11 so that the lower edges of the protective liner sections 10 engage with the hooks 12 provided on the steel liner 11, while the protruding portions formed on the steel liner 11 are made to engage with the through openings formed in the protective liner sections 10. The protective liner sections 10 are thereby coupled to the steel liner 11 both via the hooks 12 engaging with the lower edges thereof and via the protruding portions engaging with the through openings thereof.

[0070] The enlarged detailed view in FIG. 3 shows how the sections 10 of the bottom shell liner 10 are then ultimately fixed to the steel liner 11. In this detailed view, 13 designates one of the protruding portions of the steel liner 11. The protective liner section 10 has a through opening as described above. From the detailed view it becomes apparent that the through opening has a stepped configuration: on the side of the protective liner section 10 which faces the steel liner 11, the rectangular through opening has a first height H1 and a first width (not visible in the detailed view because this width extends perpendicular to the paper plane). On the side of the protective liner section 10 which faces away from the steel liner 11, the through opening has a second height H2 which is larger than the first height H1. On this side, the through opening also has a second width which is larger than its first width.

[0071] A liner clamp 14 is provided, which has a width and height larger than the first width and heigth H1 of the through opening in the protective liner section 10 but smaller than the second width and height H2 thereof, so that the liner clamp 14 contacts the stepped section within the through opening. By means of a bolt 15 which penetrates the liner clamp and is fit into the protruding portion 13 of the steel liner 11, the protective liner section 10 is clamped to the steel liner 11.

[0072] As a result, the protective liner 10 can be easily replaced, without there being the necessity to release any permanent connections such as welded connections.

[0073] The configuration of the bottom shell liner 10without the steel liner 11is apparent in more detail from FIG. 4a, which illustrates one of the several sections 10 of the bottom shell liner 10 in a front view and several sectional views along lines A-A, B-B and C-C of the front view. The section 10 is constituted by a rubber plate 16, which includes the aforementioned rectangular and stepped through openings near its upper edge, the through openings being designated 17 here.

[0074] Note that the protective liner section 10 is illustrated having a plane shape in the drawings according to FIG. 4a. In order for the section 10 to be mounted to the crusher, it will be brought into a curved shape adapted to the curvature of the structure to which it is fixed, i.e. the bottom shell 2 or the steel liner 11 provided thereon.

[0075] A multitude of ceramic inlays 18 are enclosed in the rubber material on one side of the rubber plate 16, thereby configuring a wear surface below the series of through openings 17. In the mounted state of the sections 10, the wear surface will face towards the inside of the crusher so as to be exposed to the material passing the crusher. The area near the upper edge of the rubber plate 16 which includes the through openings 17 is devoid of such ceramic inlays. A narrow area near the lower edge of the rubber plate 16 is also free from ceramic inlays.

[0076] Each wear resistant insert 18 has an outwardly directed surface forming part of the wear surface of the protective liner 10. The remainder of each insert 18 is immersed in the rubber material.

[0077] On its side opposite the ceramic inlays 18, the rubber plate is backed up by a series of vertically extending stiffening elements 19 (illustrated in dashed lines in the front view and also visible in all of the sectional views). The stiffening elements 19 are provided at the locations of the through openings 17 and are spaced apart from each other accordingly.

[0078] The stiffening elements 19 can for example be made from sheet metal. They serve for enhancing the stiffness of the liner sections 10 in the vertical direction. In the horizontal direction, the sections 10 have a certain flexibility in order for them to be brought into the curved shape as mentioned above.

[0079] FIG. 4b shows one of the stiffening elements 19 in a front view, side view and perspective view. The stiffening element includes a first, frame-shaped part 19a having an approximately square outline and intended to be positioned surrounding one of the through holes 17 in the manner illustrated in FIG. 4a. The stiffening element 19 also includes a narrow strut-shaped second part 19b extending vertically downwards from the first part 19a. In this embodiment, the second part 19b extends essentially to the lower edge of the liner section 10, and the material thickness of the second part 19b is larger than the material thickness of the frame-shaped first part 19a.

[0080] 2. Drive Shaft Liner

[0081] FIG. 5 is another perspective partial view of a crusher. The crusher is equipped with a bottom shell liner 10 for the bottom shell 2 as described above, and also with a protective liner 20 for protecting the driveshaft 6 from material hitting the driveshaft 6 after passing through the crushing gap G. This driveshaft liner 20 will now be described in detail with reference to FIGS. 5 to 9.

[0082] The driveshaft liner 20 is made up from three different sections which are mounted to the crusher in a particular order and disassembled therefrom in the reverse order. A first archway-shaped element 30 of the driveshaft liner 20 is provided for covering the driveshaft 6 from above in an area near the central hub 4or, in this embodiment, for covering an existing steel cover 8 (cf. FIG. 1) of the drive shaft 6 from above in this area because the drive shaft 6 is not directly exposed to the crushed material. A second bridge-shaped element 40 of the driveshaft liner 20 is arranged above the first element 30 and is coupled to a ring-shaped steel sleeve 41 surrounding the central hub 4. Immediately adjacent to the first element 30 is a third element 50, also archway-shaped, for covering the driveshaft 6or more particularly the steel cover 8from above.

[0083] The first element 30 of the driveshaft liner 20 is illustrated in more detail in FIG. 6, which includes a perspective view, a front view as well as a sectional view along the line A-A in the front view. The element 30 is provided for covering a first portion of the driveshaft 6 from above. The section 30 includes a polymer-ceramics element which in this embodiment has the configuration of an archway, including an arch-shaped element 31 and two narrow plate-shaped extensions 32 extending vertically downwards from both ends of the arch 31. In the mounted state, the arch-shaped part 31 of the first element 30 will cover the drive shaft 6 from above, whereas the plate-shaped wall elements 32 will also guide the falling material past the drive shaft 6. The first element 30 generally extends in a direction along the driveshaft 6 in the mounted state.

[0084] In the area of the arch-shaped polymer-ceramics part 31, the first element 30 of the driveshaft liner 20 further includes a carrier structure supporting the polymer-ceramics element. The carrier structure is provided in the form of a metal frame, the shape and configuration of which is best apparent from the sectional view in FIG. 6: an inner frame part 33 supports the inner circumferential surface of the arch-shaped polymer-ceramics part 31. The inner frame part 33 is connected with the polymer-ceramics part 31 e.g. by gluing and/or using self-tapping screws as indicated at 39. Narrow reinforcing metal stays 34 are provided to the surface of the inner frame part 33 which faces in the direction of the drive shaft 6 in the mounted state.

[0085] An arch-shaped face plate 35 is provided to the front face of the element 30 which so as to face the central hub 4 in the mounted state. Outer brackets 36 are provided on a surface of the arch-shaped face plate 35 which faces away from the central hub 4 in the mounted state.

[0086] Inner brackets 37 are provided on an inner surface of the inner frame part 33. The inner brackets 37 include recesses which are adapted to become seated on matching protrusions, particularly protruding studs, provided on a supporting element within the crusher, such as the steel cover 8 of the drive shaft 6 which will be described once again in more detail below with reference to FIG. 9. As a consequence, the drive shaft liner 20 covers the steel cover which in turn covers the drive shaft 6.

[0087] Elements 33 to 38 form the said metal frame of the first element 30 of the drive shaft liner 20.

[0088] The second element 40 of the driveshaft liner 20 is illustrated in more detail in FIG. 7 (front view, top view and rear view). The second element 40 includes three polymer-ceramics layers: a front face layer 41, which has a rectangular shape with a half circular cut-out for the drive shaft to extend through in the mounted state, and two rectangular plate-shaped side layers 42.

[0089] The polymer-ceramics layers 41, 42 are supported by a metal frame 43. The polymer-ceramics layers 41, 42 can e.g. be plug-welded onto this metal frame 43.

[0090] The metal frame 43 has a front surface which extends essentially perpendicular to a longitudinal axis of the drive shaft 6 in the mounted state. The first polymer-ceramics layer 41 is attached to the front surface. The metal frame also has a roof surface 44 extending at right angles to the front surface. The front edge of the roof surface 44, which is joined to the front surface, is straigth. The rear edge of the roof surface 44, which is joined to the central hub 4 in the mounted state, has a curvature adapted to the curvature of the outer circumferential surface of the central hub 4.

[0091] The metal frame 43 further includes two side surfaces to which the two polymer-ceramics elements 42 are attached. The side surfaces extend at right angles to the roof surface 44 and at an angle to the front surface equipped with the first polymer-ceramics layer 41.

[0092] A stay 45 is provided along the rear edge of the roof surface 44 of the frame 43. By means of this stay 45, the second element 40 of the driveshaft liner 20 can be fastened to the central hub 4 or a surrounding ring 41 thereof, respectively. This could e.g. be done by welding the stay 45 to the central hub 4, and/or by using fastening elements such as screws or bolts.

[0093] Brackets 46 are provided to an upper portion of the metal frame 43.

[0094] The third element 50 of the driveshaft liner 20 is illustrated in more detail in FIG. 8. It is configured basically similar as the first element 30 illustrated in FIG. 6, i.e. includes a polymer-ceramics structure 51, 52 similar to the one 31, 32 of the first element 30, and metal frame parts 53, 54 similar to the metal frame parts 33, 34, including inner brackets 57 with recesses 58 to sit on a supporting structure such as the steel cover 8 of the drive shaft 6. Screws, which are also similar to the screws 39 of the first element 30, are designated 59. Other than in the case of the first element 30, the metal frame does not comprise the arch-shaped face plate 35 nor the brackets 36. Lifting eye bolts 56 are provided, though.

[0095] The brackets 36, 46 and the lifting eye bolts 56 are provided for the purpose of lifting the elements 30, 40 and 50 of the driveshaft liner 20, which can be relatively heavy, during installation and disassembly.

[0096] FIG. 9 shows the driveshaft 6 from below in a state in which it is equipped with the driveshaft liner 20 described above. The first element 30 and the third element 50 of the driveshaft liner 20 are illustrated including their respective polymer-ceramics elements 31, 51 and inner brackets 37, 57. Also illustrated is the above described steel cover 8. As explained above, recesses 38, 58 are formed in the inner brackets 37, 57. The recesses 38, 58 engage with short protruding studs 81 provided on the steel cover 8.

[0097] 3. Locking Nut Liner

[0098] The protective liner of the present invention can be used for any arbitrary other structural element of the crusher which is subject to wear due to its contact with material passing the crusher. In order to mention a further possible example, reference is made once again to FIG. 1, which illustrates the locking nut 5 as another structural part within the crusher which can be equipped with a protective liner according to the invention. In this embodiment, the locking nut liner 80 is arranged so as to cover a cylindrical outer circumferential surface of the locking nut 5. The locking nut liner 80 is releasably fixed to the outer circumferential surface of the locking nut 5.