AU2021104346A4 - A mantle liner of a cone crusher - Google Patents

Abstract

A MANTLE LINER OF A CONE CRUSHER ABSTRACT Disclosed is a mantle liner of a cone crusher. The mantle liner is generally conical and configured to define, in conjunction with a corresponding concave liner of the crusher, a crushing zone in which materials fed into the crusher are subjected to compression and crushed between the liners by relative movement thereof. The crushing zone extends between an inlet for receiving the materials fed into the crusher and an outlet leading to a discharge zone from which the crushed materials exit the crusher. The mantle liner includes a crushing portion corresponding to the crushing zone and a discharge portion corresponding to the discharge zone. The crushing portion includes one or more zones having a higher resistance to abrasion than the discharge portion thereby to provide the crushing portion with increased abrasion resistance. 100 106 110 114 102 104 FEED MATERIAL 108 116 CRUSHED MATERIAL 112 CSS CRUSHING ARE 118 12210 12010 FIGURE 1

Description

106 110 114 102 104 FEED MATERIAL

108

116

CRUSHED MATERIAL

112 CSS CRUSHING ARE

118 12210 12010

FIGURE 1

A MANTLE LINER OF A CONE CRUSHER

Field

[0001] The present invention pertains to wear parts of a cone crusher, in particular, to a wear liner of a cone crusher.

[0002] The invention has been developed primarily as a mantle liner of a cone crusher and will be described with reference to this application. However, it will be appreciated that the invention is not limited to this application.

Background

[0003] Cone crushers are used to crush raw materials such as ores and rocks to intermediate or fine particle sizes.

[0004] The materials to be crushed (the feed) are crushed within a crushing zone provided within the gap formed between a generally conical mantle and a concave liner. The mantle is configured to gyrate with respect to the concave liner in an eccentric manner. The eccentric motion of the mantle alters the gap between the mantle and concave liner such that at any time the gap is smallest at one point while greatest at the opposite point, thus crushing the feed at the point where the gap is smallest. The feed is also compressed against each other.

[0005] The smallest distance between the mantle and the concave liners measured as the mantle moves defines a final crushing zone following which the crushed materials exit the crusher from a zone called the discharge zone. Said smallest distance between the mantle and the concave accordingly determines the maximum product size. In practice, the smallest distance can be adjusted by altering the relative position of the mantle to the concave liner.

[0006] The mantle and concave liners are crusher components subjected to high wear. In order to extend the service life of the liners it is desirable to increase the abrasion resistance thereof, for example, by adding a protective surface to the liners. However, a protective surface can present risks such as liner failure or even cause damage to the crusher in some circumstances.

[0007] It is an object of the present invention to substantially overcome, or at least ameliorate, one or more disadvantages of existing arrangements.

Summary

[0008] According to one aspect of the present disclosure, there is provided a mantle liner of a cone crusher, the mantle liner being generally conical and configured to define, in conjunction with a corresponding concave liner of the crusher, a crushing zone in which materials fed into the crusher are subjected to compression and crushed between the liners by relative movement thereof, the crushing zone extending between an inlet for receiving the materials fed into the crusher and an outlet leading to a discharge zone from which the crushed materials exit the crusher, wherein the mantle liner includes a crushing portion corresponding to the crushing zone, and a discharge portion corresponding to the discharge zone; and wherein said crushing portion includes one or more zones having a higher resistance to abrasion than the discharge portion thereby to provide the crushing portion with increased abrasion resistance.

[0009] In some embodiments, the discharge portion of the mantle liner extends into the crushing zone.

[0010] In some embodiments, the crushing portion of the mantle liner includes a first portion corresponding to an upstream portion of the crushing zone and a second portion corresponding to a downstream portion of the crushing zone.

[0011] In some embodiments, the second portion of the mantle liner has an outer surface layer and a substrate layer. In some embodiments, the surface layer has a higher resistance to abrasion than the discharge portion to thereby provide said one or more zones. In some embodiments, the surface layer has a higher resistance to abrasion than the substrate layer. In some embodiments, the surface layer has a profile that matches an abrasion profile of a worn mantle liner.

[0012] In some embodiments, the second portion includes a substrate and a plurality of cavities each extending from an opening in a wear face of the substrate and receiving at least one abrasion resistant insert. In some embodiments, wherein the at least one abrasion resistant insert has a higher resistance to abrasion than the discharge portion to thereby provide said one or more zones. In some embodiments, the plurality of cavities has differing depths.

[0013] According to another aspect of the present disclosure, there is provided a cone crusher comprising: a concave liner; and a generally conical mantle liner, the mantle liner and the concave liner defining a crushing zone in which materials fed into the crusher are subjected to compression and crushed between the liners by relative movement thereof, the crushing zone extending between an inlet for receiving the materials fed into the crusher and an outlet leading to a discharge zone from which the crushed materials exit the crusher, wherein the mantle liner includes a crushing portion corresponding to the crushing zone, and a discharge portion corresponding to the discharge zone; and

[0014] wherein said crushing portion includes one or more zones having a higher resistance to abrasion than the discharge portion thereby to provide the crushing portion with increased abrasion resistance.

[0015] In some embodiments, the discharge portion of the mantle liner extends into the crushing zone.

[0016] In some embodiments, the crushing portion of the mantle liner includes a first portion corresponding to an upstream portion of the crushing zone and a second portion corresponding to a downstream portion of the crushing zone.

[0017] In some embodiments, the second portion of the mantle liner has an outer surface layer and a substrate layer. In some embodiments, the surface layer has a higher resistance to abrasion than the discharge portion to thereby provide said one or more zones. In some embodiments, the surface layer has a higher resistance to abrasion than the substrate layer. In some embodiments, the surface layer has a profile that matches an abrasion profile of a worn mantle liner.

[0018] In some embodiments, the second portion includes a substrate and a plurality of cavities each extending from an opening in a wear face of the substrate and receiving at least one abrasion resistant insert. In some embodiments, the at least one abrasion resistant insert has a higher resistance to abrasion than the discharge portion to thereby provide said one or more zones. In some embodiments, the at least one abrasion resistant insert has a higher resistance to abrasion than the substrate. In some embodiments, the plurality of cavities has differing depths.

Brief Description of Drawings

[0019] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0020] Figure 1 is a cross-sectional view of a cone crusher;

[0021] Figure 2 is a schematic cross-sectional view illustrating the abrasion of a mantle liner of the cone crusher of Figure 1;

[0022] Figure 3 is a schematic cross-sectional view illustrating the building up of feed in the cone crusher of Figure 2;

[0023] Figure 4 is a cross-sectional view of a cone crusher according to an embodiment of the present invention;

[0024] Figure 5A is a cross-sectional view of a mantle liner according to an embodiment of the present invention; and

[0025] Figure 5B is a cross-sectional view of a mantle liner according to another embodiment of the present invention.

Detailed Description

[0026] Referring to Figure 1, a cone crusher 100 comprises a generally conical mantle liner 102 and a corresponding concave liner 104. The mantle liner 102 is typically mounted to a rotatable main shaft (not shown) having a shaft axis 106. A central axis 107 of the mantle liner is offset relative to the shaft axis 106 so as to cause eccentric oscillation, nutation or both eccentric oscillation and nutation of the mantle liner 102.

[0027] The mantle liner 102 and concave liner 104 define a crushing zone 108 extending between an inlet 110 and outlet 112. The distance between the mantle liner 102 and the concave liner 104 decreases towards the outlet 112 from the inlet 110. As the mantle liner 102 gyrates with respect to the concave liner 104 in an eccentric manner around the central axis 106, materials to be crushed (the feed) 114 are crushed by the movement of the mantle against the concave liner as well as against each other.

[0028] The eccentric gyration of the mantle liner 102 with respect to the concave liner 104 results in the distance therebetween being smallest at one point while greatest at an opposite point at any time. Of course it will be appreciated that these points move circumferentially as the mantle liner 102 gyrates. As described above, the minimum distance between the mantle liner and the concave liner of a crusher measured when the crusher operates is known as the closed side setting (CSS). In the example of Figure 1, the CSS defines afinal crushing zone 116. Below the final crushing zone 116 is a zone called the discharge zone 118 from which the crushed materials exit the crusher. Accordingly, the CSS determines the maximum product size.

[0029] The cone crusher 100 can have a plurality of configurations, each configuration corresponding to a different CSS. For a given configuration, the gap between the mantle and concave liners undesirably increases as they abrade away over time, resulting in an increase in the maximum product size. It is possible to adjust the relative position of the mantle liner 102 to the concave liner 104 to reduce the gap therebetween, thereby retaining a desirable CSS (i.e., desirable maximum product size). The adjustment is called CSS adjustment. In some arrangements, the CSS may be adjusted by lowering the concave liner. In some other arrangements, the CSS may be adjusted by lifting the main shaft, thereby lifting the mantle liner.

[0030] However, such an adjustment can be detrimental due to non-uniform abrasion in the liner. For example, a portion 120 of the mantle liner 102 in the discharge zone 118 from which the crushed materials exit the crusher is subjected to less abrasion compared to a portion 122 in the crushing zone 108 where the feed is crushed. Accordingly, the portion 120 abrades away slower than the portion 122. The issue is exacerbated when the mantle liner 102 includes wear resistant materials since the portion 120 abrades away even more slow than the portion 122, resulting in the portion 120 having a greater thickness than the portion 122 over time, as shown in Figure 2. When the mantle liner 102 is brought closer to the concave liner 104 for CSS adjustment, part of the portion 120, including a bump 224 formed due to the non-uniform thickness, will enter the crushing zone 108. With the bump 224 in the crushing zone 108, the crushed materials tend to build up and, in some instances, lead to a blockage, as shown in Figure

3. Blockage of the crushing zone further cause the abrasion to concentrate more in the crushing zone 108 than in the discharge zone 118, thereby forming a hollow 326 in the portion 122. Due to the hollow shape, a phenomenon called stress concentration will likely occur in the crushing zone, resulting in an unpredictable wear profile. An unpredictable wear profile can present a risk of mantle and/or concave liner failure or even damage to the crusher.

[0031] Additionally, due to the non-uniform abrasion, a reduction in the thickness of the protective surface is less apparent in the discharge zone 118 than in the crushing zone 108. However, the severity of wear is often determined by inspection of the appearance of the discharge zone. Therefore, when the portion 122 already abrades away severely whilst the exposed portion of the mantle liner in the discharge zone 118 is still in good shape, it may be determined based on the appearance of exposed portion that the severity of wear is moderate. Continuing to use the liner will then cause severe damage to the main shaft of the crusher.

Cone Crusher

[0032] Referring to Figure 4, a cone crusher 400 is shown. The crusher 400 comprises a generally conical mantle liner 402 configured to define, in conjunction with a corresponding concave liner 404 of the crusher 400, a crushing zone 406 in which materials fed into the crusher (feed) are subjected to compression and crushed by relative movement thereof. The crushing zone 406 extends between an inlet 408 for receiving the fed and an outlet 410 leading to a discharge zone 412, downstream of the crushing zone 406, from which the crushed materials exit the crusher. The mantle liner 402 includes a crushing portion 414 corresponding to the crushing zone 406. The crushing portion 414 has a higher resistance to abrasion than a discharge portion 416 corresponding to the discharge zone 412.

[0033] The mantle liner 402 is mounted to a rotatable main shaft (not shown) having a shaft axis 413. A central axis 415 of the mantle liner is offset relative to the shaft axis 413 so as to cause eccentric oscillation, nutation or both eccentric oscillation and nutation of the mantle liner 402.

[0034] The cone crusher 400 can have a plurality of configurations, each configuration corresponding to a different CSS. Over time, the mantle liner 402 and concave liner 404 wear down due to abrasion, resulting in an increase in the gap therebetween. The CSS, being the minimum distance between the mantle liner 402 and the concave liner 404 for a corresponding configuration, will need to be adjusted to maintain a desired maximum product size. Depending on the type of the crusher, the CSS can be adjusted by moving the mantle liner 402 towards the concave liner 404, for example, by lifting the main shaft of the crusher 400, or moving the concave liner 404 towards the mantle liner 402, for example, using a threaded adjusting mechanism whereby rotation of the concave liner 406 causes the concave liner 406 to be raised or lowered. By bringing the mantle liner 402 closer to concave liner 404, part of the discharge portion 416 can enter the crushing zone 406.

[0035] The crushing zone 406 includes an upstream portion 418 towards the inlet 408 for initial crushing and a downstream portion 420 towards the outlet 410 for finer secondary crushing. The crushing portion 414 of the mantle liner 402 includes a first portion 419a corresponding to the upstream portion 418 of the crushing zone and a second portion 419b corresponding to a downstream portion 420 of the crushing zone.

[0036] As shown in Figure 4, the concave liner 404 is also generally conical and has an inlet opening 422 for receiving the feed and an outlet opening 424 for discharging the crushed materials. The concave liner 404 is positioned relative to the mantle liner 402 such that a boundary between the crushing portion 414 and the discharge portion 416 of the mantle liner 402 is aligned with the outlet opening 424 of the concave liner 404. Assuming the distance between the inlet opening 422 and outlet opening 424 of the concave liner 404 is Hi and the distance between the inlet opening 422 and a bottom face 426 of the mantle liner 402 is H, the first portion 419a and second portion 419b of the crushing portion 414 are such that the distance between the inlet opening 422 and a boundary between the first portion 419a and the second portion 419b is 1/3 H.

Mantle Liner

[0037] Referring to Figure 5A, there is shown a mantle liner 500 of a crusher, for example, the crusher 400 of Figure 4. The mantle liner 500 is generally conical and configured to define, in conjunction with a corresponding concave liner of the crusher (for example, the concave liner 404 of Figure 4), a crushing zone in which materials fed into the crusher are subjected to compression and crushed by relative movement thereof. The crushing zone extends between an inlet for receiving the materials fed into the crusher and an outlet leading to a discharge zone from which the crushed materials exit the crusher. The mantle liner includes a crushing portion 502 corresponding to the crushing zone and a discharge portion 504 corresponding to the discharge zone. The crushing portion includes one or more zones having a higher resistance to abrasion than the discharge portion thereby to provide the crushing portion with increased abrasion resistance. For instance, the crushing portion 502 is formed of a base material in a substrate layer and a material of higher abrasion resistance in an outer surface layer. In another instance, the crushing portion 502 is formed of a base material in a substrate and a material of higher abrasion resistance in a plurality of cavities formed in the substrate.

[0038] In use, the mantle liner 500 is mounted to a main shaft (not shown) of the crusher. Over time, the mantle liner 500 wears down due to abrasion. The CSS, being the minimum distance between the mantle liner 500 and the concave liner in operation, will need to be adjusted to maintain a desired maximum product size. Depending on the type of the crusher, the CSS can be adjusted by moving the mantle liner 500 towards the concave liner, for example, by lifting the main shaft of the crusher, or moving the concave liner towards the mantle liner 500, for example, using a threaded adjusting mechanism whereby rotation of the concave liner causes the concave liner to be raised or lowered. Therefore, the discharge portion 504 can enter the crushing zone as a result of CSS adjustment.

[0039] As discussed with reference to Figure 2, the crushing portion 502 is subjected to higher wear and accordingly abrades at a higher rate compared to the discharge portion 504. With a higher resistance to abrasion in the crushing portion 502 than in the discharge portion 504, the disparity in abrasion rate is reduced, resulting in a relatively uniform wear (i.e., a relatively level surface profile) in used mantle liner. As such, when the discharge portion 504 extends into the crushing zone as a result of CSS adjustment, entry of the discharge portion 504 into the crushing zone is less likely or unlikely to cause building up of feed or blockage of the crushing zone. Accordingly, adjustment of the CSS is less likely or unlikely to cause damage to the crusher.

[0040] In some implementations, the crushing zone includes an upstream portion towards the inlet for initial crushing and a downstream portion towards the outlet for finer secondary crushing. Correspondingly, the crushing portion 502 of the mantle liner 500 includes a first portion 510 corresponding to the upstream portion of the crushing zone and a second portion 512 corresponding to the downstream portion of the crushing zone.

[0041] In the arrangement of Figure 5A, the second portion 512 of crushing portion 502 has an outer surface layer 506 and a substrate layer 508. The surface layer 506 has a higher resistance to abrasion than the discharge portion 504, thereby providing the one or more zones having a higher resistance to abrasion than the discharge portion 504. The surface layer 506 has a higher resistance to abrasion but less toughness than the substrate layer 508. For example, the surface layer 506 is made of titanium alloy while the substrate layer 508 is made of manganese steel. The substrate layer 508 may be made of the same material as the discharge portion 504, or alternatively of a different material. The surface layer 506 may be of a uniform thickness or varying thickness. In some implementations, for instance as shown by the hatched areas in Figure 5A, the surface layer 506 has a profile that matches an abrasion profile of a worn mantle liner in accordance with the method described in Australian Patent Application No. 2020256420.

[0042] In an alternative arrangement shown in Figure 5B, the second portion 512 includes a substrate 514 and a plurality of cavities extending from an opening in a wear surface 516 of the substrate. Each cavity receives at least one abrasion resistant insert 518. The abrasion resistant inserts 518 has a higher resistance to abrasion than the discharge portion 504, thereby providing the one or more zones having a higher resistance to abrasion than the discharge portion 504. The abrasion resistant inserts 518 have a higher resistance to abrasion but less toughness than the substrate 514. For example, the abrasion resistant inserts 518 are made of titanium alloy while the substrate 514 is made of manganese steel. The substrate 514 may be made of the same material as the discharge portion 504, or alternatively of a different material. In some implementations, the cavities are in the form of an aperture. The abrasion resistant inserts 518 may be of a uniform length or varying length. In some implementations, for instance as shown by the hatched areas in Figure 5B, the inserts 518 have differing lengths that are determined based on an abrasion profile of a worn mantle liner in accordance with the method described in Australian Patent Application No. 2020256420.

[0043] As will be appreciated, the first portion 510 is subjected to abrasion albeit less severe than the second portion 512. Therefore, in some implementations, the surface layer 506 or the abrasion resistant inserts can extend into the first portion 510.

[0044] Disclosed above is a mantle liner and a cone crusher comprising such a mantle liner. As will be appreciated, the higher resistance to abrasion in the crushing portion of the mantle liner than in the discharge portion can reduce the likelihood of or avoid CSS adjustment causing liner failure or damage of the crusher. As will also be appreciated, the relatively lower resistance to abrasion in the discharge portion allows less disparity in abrasion rate between the discharge portion and the crushing portion, resulting in a relative uniform wear across the liner. Therefore, during an inspection for abrasion, the likelihood of misdetermination of the severity of wear is reduced.

[0045] Although specific embodiments of the invention are illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternative and/or equivalent implementations exist. It should be appreciated that the exemplary embodiment or exemplary embodiments are examples only and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing at least one exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents. Generally, this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.

[0046] It will also be appreciated that in this document the terms "comprise", "comprising", "include", "including", "contain", "containing", "have", "having", and any variations thereof, are intended to be understood in an inclusive (i.e. non-exclusive) sense, such that the process, method, device, apparatus or system described herein is not limited to those features or parts or elements or steps recited but may include other elements, features, parts or steps not expressly listed or inherent to such process, method, article, or apparatus. Furthermore, the terms "a" and "an" used herein are intended to be understood as meaning one or more unless explicitly stated otherwise. Moreover, the terms "first", "second", etc. are used merely as labels, and are not intended to impose numerical requirements on or to establish a certain ranking of importance of their objects.

Claims (21)

1. A mantle liner of a cone crusher, the mantle liner being generally conical and configured to define, in conjunction with a corresponding concave liner of the crusher, a crushing zone in which materials fed into the crusher are subjected to compression and crushed between the liners by relative movement thereof, the crushing zone extending between an inlet for receiving the materials fed into the crusher and an outlet leading to a discharge zone from which the crushed materials exit the crusher, wherein the mantle liner includes a crushing portion corresponding to the crushing zone, and a discharge portion corresponding to the discharge zone; and wherein said crushing portion includes one or more zones having a higher resistance to abrasion than the discharge portion thereby to provide the crushing portion with increased abrasion resistance.

2. The mantle liner of claim 1, wherein the discharge portion of the mantle liner extends into the crushing zone.

3. The mantle liner of claim 1 or 2, wherein the crushing portion of the mantle liner includes a first portion corresponding to an upstream portion of the crushing zone and a second portion corresponding to a downstream portion of the crushing zone.

4. The mantle liner of claim 3, wherein the second portion of the mantle liner has an outer surface layer and a substrate layer.

5. The mantle liner of claim 4, wherein the surface layer has a higher resistance to abrasion than the discharge portion to thereby provide said one or more zones.

6. The mantle liner of claim 4 or 5, wherein the surface layer has a higher resistance to abrasion than the substrate layer.

7. The mantle liner of any one of claim 4 to 6, wherein the surface layer has a profile that matches an abrasion profile of a worn mantle liner.

8. The mantle liner of claim 3, wherein the second portion includes a substrate and a plurality of cavities each extending from an opening in a wear face of the substrate and receiving at least one abrasion resistant insert.

9. The mantle liner of claim 6, wherein the at least one abrasion resistant insert has a higher resistance to abrasion than the discharge portion to thereby provide said one or more zones.

10. The mantle liner of claim 8 or 9, wherein the plurality of cavities has differing depths.

11. A cone crusher comprising: a concave liner; and a generally conical mantle liner, the mantle liner and the concave liner defining a crushing zone in which materials fed into the crusher are subjected to compression and crushed between the liners by relative movement thereof, the crushing zone extending between an inlet for receiving the materials fed into the crusher and an outlet leading to a discharge zone from which the crushed materials exit the crusher, wherein the mantle liner includes a crushing portion corresponding to the crushing zone, and a discharge portion corresponding to the discharge zone; and wherein said crushing portion includes one or more zones having a higher resistance to abrasion than the discharge portion thereby to provide the crushing portion with increased abrasion resistance.

12. The cone crusher of claim 11, wherein the discharge portion of the mantle liner extends into the crushing zone.

13. The cone crusher of claim 11 or 12, wherein the crushing portion of the mantle liner includes a first portion corresponding to an upstream portion of the crushing zone and a second portion corresponding to a downstream portion of the crushing zone.

14. The cone crusher of claim 13, wherein the second portion of the mantle liner has an outer surface layer and a substrate layer.

15. The cone crusher of claim 14, wherein the surface layer has a higher resistance to abrasion than the discharge portion to thereby provide said one or more zones.

16. The mantle liner of claim 14 or 15, wherein the surface layer has a higher resistance to abrasion than the substrate layer.

17. The mantle liner of any one of claims 14 to 16, wherein the surface layer has a profile that matches an abrasion profile of a worn mantle liner.

18. The cone crusher of claim 13, wherein the second portion includes a substrate and a plurality of cavities each extending from an opening in a wear face of the substrate and receiving at least one abrasion resistant insert.

19. The cone crusher of claim 18, wherein the at least one abrasion resistant insert has a higher resistance to abrasion than the discharge portion to thereby provide said one or more zones.

20. The cone crusher of claim 18 or 19, wherein the at least one abrasion resistant insert has a higher resistance to abrasion than the substrate.

21. The cone crusher of any one of claims 18 to 20, wherein the plurality of cavities has differing depths.

Parksen Group Pty Ltd

Patent Attorneys for the Applicant/Nominated Person

SPRUSON&FERGUSON