What is the working principle of smooth roll crusher? The working principle of the smooth-surface roller crusher is based on the squeezing and grinding action generated by the relative rotation of two rollers. Uniform crushing of materials is achieved by controlling the gap between the rollers.
What is the working principle of smooth roll crusher
1. Core Crushing Mechanism
Material Entrapping and Compression
Material falls from the feed inlet between the two rollers and is drawn into the gap by roller surface friction. The two rollers (fixed and movable) rotate at low speeds in opposite directions (typically <4 m/s linear velocity), applying high compressive pressure to the material. This generates internal fractures and causes fragmentation.
Smooth Roll Characteristics: Featuring a smooth roll surface, this mechanism primarily relies on compression and grinding forces. It is suitable for medium-hard or brittle materials (e.g., limestone, coal), producing well-shaped particles with low over-crushing rates.
Overload Protection Mechanism
When non-crushable objects (e.g., iron pieces) enter, the movable roll automatically retracts via springs or a hydraulic system, widening the roll gap to discharge foreign objects before resuming its original position, preventing equipment damage.
Discharge Control
Crushed material discharges from beneath the roll gap, with particle size directly determined by the gap width (typically adjustable from 1-50 mm). A narrower gap produces finer output.
2. Key Structural Components
Crushing Rollers
Roller Shell Material: Huashengming employs high-chromium manganese steel or special alloys (hardness HRC ≥ 60), ensuring a wear-resistant lifespan of ≥ 2 years and reducing replacement frequency.
Roll Diameter to Width Ratio: Roll diameter is typically 9-22 times the material size (e.g., φ225-550 mm rolls for 25 mm material). The width-to-diameter ratio (L/D) ranges from 0.3 to 0.7 to ensure crushing efficiency.
Adjustment Mechanism
Mechanical Adjustment: Manually adjust the roll gap by adding or removing bearing housing shims (for compact models).
Hydraulic Adjustment: Huashengming mid-to-high-end models feature a hydraulic system with ±1 mm precision, enabling real-time dynamic adjustment.
Transmission and Drive
Dual Motor Drive: Each roller is driven by an independent motor, achieving counter-rotation via belts or gears to enhance crushing stability.
Long-Tooth Gear Protection: Traditional designs use long-tooth gears for power transmission, allowing roller gap adjustment during overload without gear damage but resulting in high noise and wear. New models adopt universal joints or dual-motor direct drive.
3. Particle Size Adjustment Mechanism
| Adjustment Methods | Principle | Applicable Scenarios |
|---|---|---|
| Adding or Removing Shims | Manually adjust the number of shims between bearings to physically alter the roll gap width | Small spring machines |
| Hydraulic Pressure Adjustment | Dynamically control the roll gap by adjusting hydraulic cylinder pressure in real time (accuracy ±1 mm) | Medium-to-large hydraulic presses |
| Intelligent Control System | The new Huashengming model features sensors that monitor material hardness, automatically adjusting the roll gap and rotational speed to maintain optimal crushing performance | High-end automated production lines |
4. Distinctive Technologies of Huashengming Products
Low-Speed High-Torque Design
Roll speed controlled at 75 r/min (e.g., 610×400 model) ensures thorough material compression, minimizes energy waste, and achieves 30%-45% lower specific power consumption than impact crushers.
Wear-Resistant Reinforcement
Roll shells utilize patented alloy materials with thickened treatment (60-80 mm thickness). Axial micro-adjustment (adding/removing retaining rings) prevents groove formation on roll surfaces, extending service life by over 3 times.
Intelligent Monitoring System
Real-time monitoring of temperature, pressure, current, and other parameters. Automatic alarm or shutdown upon anomalies. Supports remote control and data feedback.
5. Applicable Scenarios and Limitations
Suitable Materials:
Medium-hardness or softer brittle materials (compressive strength ≤160 MPa), such as limestone, coal, gypsum, glass waste, etc. Minimal sticking occurs when moisture content ≤8%.
Optimal Applications:
Building material sand production (output 1-3 mm, gradation meets Class II sand standards);
Glass recycling (crushing to 2-5 mm particles, over-crushing rate <10%).
Limitations:
Not suitable for high-hardness ores (e.g., granite requires specialized heavy-duty models);
Feed must be evenly distributed to prevent uneven roller surface wear.
