EP3658286B1 - Crusher with a wear element and a method for producing a wear element of a crusher - Google Patents

Description

The invention relates to a crusher with a stationary crushing element and a movable crushing element, the stationary crushing element comprising a wear element. The invention also relates to a method for producing a wear element of a stationary crushing element of a crusher.

For the comminution of materials such as limestone, oil shale, marl, clay, oil sand or similar mineral materials, usually crushers, in particular gyroscopic crusher, jaw crusher, cone crusher or jaw crusher are used. From the WO2014 / 187713 A1 such a cone crusher is known, for example. From the US 2008 041 995 A1 Exchangeable wear protection elements of a cone crusher are known which consist at least partially of metal carbides.

Crushers such as gyratory crusher, jaw crusher, cone crusher or jaw crusher have a crushing space which is delimited by a stationary crushing element and a movable crushing element. The movable crushing element is driven to rotate eccentrically so that the crushing gap is periodically enlarged and reduced. The crushing elements are usually made of wear-resistant steel with a high degree of hardness. Such hard steels harden under pressure and impact loads to a hardness of, for example, about 500HB. In this hardened state, the hard steel is relatively wear-resistant and at the same time has a high elongation at break in the core. In the event of high loads during the crushing process, such as occur, for example, due to unbreakable objects in the crushing space, deformation of the crushing elements therefore occurs.

In particular when using hard steel, such as manganese steel, with very fine crushed goods, such as oil sand, for example, the hard steel does not harden while the crushing elements are in use. As a result, the surface of the breaking elements wears out relatively quickly and maintenance or replacement of the breaking elements is necessary. The use of a harder and thus less wear-resistant material, however, also leads to a decrease in the elongation at break, which results in failure of the crushing elements in the case of an unbreakable object in the crushing space.

Based on this, it is the object of the present invention to provide a crusher which has crushing elements which have a particularly high wear resistance with a simultaneous high elongation at break. It is also the object of the present invention to specify a method for producing a breaking element of a crusher with high wear resistance and high elongation at break.

According to the invention, this object is achieved by a device with the features of independent device claim 1 and by the features of independent method claim 8. Advantageous developments result from the dependent claims.

According to a first aspect, a crusher for comminuting material comprises a crushing space with a feed area into which the material to be comminuted is fed, and a crushing gap for breaking the material, the crushing space tapering from the feed area to the crushing gap. The crusher has a stationary crushing element and a movable crushing element, which delimit the crushing space, the stationary crushing element having a plurality of wear protection elements, each made of a metal matrix composite material with a metal matrix material and a wear protection insert made of a hard metal and / or ceramic . The wear protection insert has a porous structure and is at least partially cast into the wear protection element, so that the metal matrix material is at least partially infiltrated into the wear protection insert.

The metal matrix composite material preferably has a metal matrix material which at least partially or completely surrounds the wear protection insert and is infiltrated into it. The metal matrix material is, for example, high-temperature resistant steel and / or a steel with a hardness of approximately 150-400 HB (Brinell). A high-temperature-resistant steel is to be understood as a heat-resistant steel with a high chromium-nickel content, which has a temperature resistance of up to 650 ° C, in particular up to 1000 ° C. Such steels are, for example, austenitic chromium-nickel steels, such as GX25CrNiSi18-9, GX40CrNiSi25-12, GX40NiCrSiNb35-26. High-temperature-resistant steels up to 600 ° C are, for example, steels according to DIN EN 10213. High-temperature-resistant steels up to 1200 ° C are, for example, steels according to DIN EN 10295.

The materials to be crushed are, for example, mineral crushed goods such as oil sands, coal and ores such as iron ore and nickel ore or cement clinker. The crusher is, for example, a gyratory crusher, jaw crusher, cone crusher or a jaw crusher, the movable crushing element being driven to an eccentric rotation and the crushing gap being periodically reduced and enlarged during operation of the crusher. The material is crushed in the crushing gap by means of pressure crushing. The stationary breaking element preferably has a breaking surface which is formed by the surface of the wear protection element. In particular, the wear protection element has exactly one wear protection insert, the wear protection insert being designed in one piece. Each wear protection element preferably has a plurality of wear inserts which are cast into the metal matrix material. For example, the plurality of wear protection inserts comprises a plurality of particles, in particular hard metal, carbide or ceramic particles or diamonds. A wear protection insert, which is formed from a particle, preferably has a size of 0.2-6 μm, the particles being produced, for example, by means of carburizing tungsten with carbon. Each wear protection insert preferably consists of exactly one particle, the wear protection insert being arranged in a disordered manner in the matrix material. In particular, the wear protection insert forms at least part of the crushing surface of the stationary crushing element. The area of the wear protection element facing away from the breaking surface is used, for example, to fasten the wear protection element and is preferably formed exclusively from the metal matrix material. For example, the stationary crushing element has a carrier which has at least one wear protection element on its surface facing in the direction of the crushing space. The wear protection elements are preferably attached to the carrier, in particular screwed, welded, glued, soldered or mechanically wedged.

It is also conceivable that a wear protection element or a plurality of wear protection elements are attached to the surface of the movable breaking element, in particular a carrier, in order to protect it from wear.

A wear protection element made of a metal matrix composite material with a wear protection insert made of a hard metal or ceramic offers the advantage of a high wear resistance of the wear protection insert, the metal matrix material that surrounds the wear protection insert and is infiltrated into it having a relatively high elongation at break has, so that there is no failure of the crushing element even with high loads, such as those caused by an unbreakable object in the crushing space.

The stationary crusher element has a plurality of wear protection elements. The surfaces of the wear protection elements preferably form the breaking surface of the stationary breaking element. The crushing surface of the stationary crushing element is understood to mean the surface of the stationary crushing element which comes into contact with the material to be crushed and is therefore exposed to high wear. The wear protection elements are preferably attached to one or a plurality of carriers. This offers a simple way of replacing worn anti-wear elements, with no need to replace the entire breaking element.

According to a further embodiment, the thickness of the wear protection inserts of different wear protection elements is different from one another. In particular, the thickness of the wear inserts increases from the feed area in the direction of the crushing gap. The wear protection elements arranged at the crushing gap preferably have the greatest thickness. For example, the wear protection insert has a thickness of approximately 5 mm to 150 mm, preferably 20 mm to 80 mm, in particular 50 mm. It is also conceivable that the thickness of the wear protection insert increases over the length of the wear protection element, in particular in the direction of the crushing gap. For example, the wear resistance of the wear protection inserts of different wear protection elements varies, so that wear protection elements are attached to areas of the breaking surface that are subject to relatively low wear and tear, which have a wear protection insert made of a material with a lower wear resistance than wear protection inserts on an area of the breaking surface that is exposed to high wear .

According to a further embodiment, the wear protection elements are plate-shaped. For example, the wear protection element has fastening devices on the side facing away from the breaking surface in order to fasten the wear protection element, for example, to a carrier. The wear protection insert is preferably plate-shaped and extends in particular over the entire surface of the wear protection element that forms the breaking surface. A plate-shaped wear protection element or a plate-shaped wear protection insert are relatively simple and inexpensive manufacturable. According to a further embodiment, the wear protection insert is arranged on the surface of the wear protection element. The wear insert is preferably arranged exclusively in the area of the surface facing in the direction of the crushing space, the opposite area of the wear protection element exclusively comprising the metal matrix material. For reasons of cost, the expensive hard metal or the ceramic of the wear protection insert is not attached to the entire wear protection element, but exclusively to the wear surface. The remaining area of the wear protection element is advantageously cast from the cheaper material, such as steel of the metal matrix material.

According to a further embodiment, the wear protection element is produced by a casting process. The wear protection insert is preferably positioned in a casting mold that corresponds to the negative shape of the wear protection element, and the metal matrix material, such as steel, is then poured into the casting mold. The metal matrix material penetrates at least partially into the wear protection insert, in particular the metal matrix material infiltrates into the porous wear protection insert. The production of the wear protection unit by casting offers a very simple and inexpensive production method, it also being possible to produce complex shapes easily.

According to a further embodiment, the wear protection insert comprises tungsten carbide, ceramic, titanium carbide, boron carbide, niobium carbide or chromium carbide or a mixture of these materials. These materials offer high wear resistance. The wear protection insert is preferably produced from a powdery and / or granular mixture of the above-mentioned materials, the mixture being heated, in particular gassed and baked. In particular, the mixture is heated in a, for example, flexible form which corresponds to the negative form of the wear protection insert. The mixture then cools down and hardens to form a very wear-resistant body with a porous structure.

According to the invention, the wear protection insert is at least partially cast into the wear protection element, in particular into the metal matrix material of the wear protection element. For example, the wear protection insert is designed in such a way that the metal matrix material, in particular steel, infiltrates into the wear protection insert and thus a material connection is established.

According to the invention, the wear protection insert has a porous structure. For example, the wear protection insert has a honeycomb structure. This offers the advantage that the metal matrix material from which the wear protection element is cast infiltrates into the wear insert and a particularly strong connection is established between the wear protection insert made of hard metal and / or ceramic and the metal matrix material.

According to a further embodiment, the crusher is a gyratory crusher, jaw crusher or cone crusher, the stationary crushing element being a crusher housing and the movable crushing element being a crushing cone and the crushing space being formed between the crushing cone and the crusher housing. The crushing space is preferably a circumferential annular space which tapers in the direction of the annular crushing gap. The feed area of the gyratory crusher, jaw crusher or cone crusher is formed by an annular edge, the surface of which is preferably made entirely of wear protection elements. For example, the wear protection insert of the wear elements in the feed area has a greater thickness than the wear protection inserts of the wear protection elements between the feed area and the crushing gap of the crusher housing.

The crusher can also be, for example, a jaw crusher, the jaw crusher having a stationary and a movable crushing element and the crushing elements are essentially plate-shaped and form a crushing gap between them. The breaking elements of a jaw crusher are arranged in a V-shape to one another, the movable breaking element being driven eccentrically, for example via a drive motor with an eccentric shaft, and the upper end of the movable breaking element being attached to the eccentric shaft. The lower end of the movable crushing element on the crushing gap side is connected to a hydraulic device, for example via a pressure plate. The breaking elements of the jaw crusher each have, for example, a plurality of wear protection elements.

• Positionieren einer Verschleißschutzeinlage mit einer porösen Struktur aus einem Hartmetall oder aus Keramik in einer Gussform zum Gießen des Verschleißschutzelements, und
• Gießen des Verschleißschutzelements, sodass die Verschleißschutzeinlage zumindest teilweise von dem Gussmaterial des Verschleißschutzelements umschlossen wird, und dies zumindest teilweise in die Verschleißschutzeinlage infiltriert ist.

The invention also comprises a method for producing a wear protection element of a stationary crushing element of a crusher, comprising the steps:

• Positioning a wear protection insert with a porous structure made of a hard metal or of ceramic in a casting mold for casting the wear protection element, and
• Casting the wear protection element, so that the wear protection insert is at least partially enclosed by the casting material of the wear protection element, and this is at least partially infiltrated into the wear protection insert.

The advantages and explanations described with reference to the crusher with the wear protection element also apply to the method for producing a wear protection element of a stationary crushing element of a crusher.

Description of the drawings

• Fig. 1 zeigt eine schematische Darstellung eines Kreiselbrecher in einer Schnittansicht gemäß einem Ausführungsbeispiel.
• Fig. 2 zeigt eine schematische Darstellung eines Verschleißschutzelementes eines Brechers in einer perspektivischen Ansicht gemäß einem Ausführungsbeispiel.
• Fig. 3 zeigt eine schematische Darstellung eines Verschleißschutzelementes eines Brechers in einer Rückansicht gemäß dem Ausführungsbeispiel der Fig.2.
• Fig. 4 zeigt eine schematische Darstellung eines Verschleißschutzelementes eines Brechers in einer Schnittansicht gemäß dem Ausführungsbeispiel der Fig.2 und 3.
• Fig. 5 zeigt eine schematische Darstellung eines Verschleißschutzelementes eines Brechers in einer perspektivischen Ansicht gemäß einem Ausführungsbeispiel.
• Fig. 6 zeigt eine schematische Darstellung eines Verschleißschutzelementes eines Brechers in einer Schnittansicht gemäß dem Ausführungsbeispiel der Fig.5.

The invention is explained in more detail below on the basis of several exemplary embodiments with reference to the accompanying figures.

• Fig. 1 shows a schematic representation of a gyratory crusher in a sectional view according to an embodiment.
• Fig. 2 shows a schematic representation of a wear protection element of a crusher in a perspective view according to an embodiment.
• Fig. 3 shows a schematic representation of a wear protection element of a crusher in a rear view according to the embodiment of FIG Fig. 2 .
• Fig. 4 FIG. 11 shows a schematic representation of a wear protection element of a crusher in a sectional view according to the exemplary embodiment of FIG Fig. 2 and 3 .
• Fig. 5 shows a schematic representation of a wear protection element of a crusher in a perspective view according to an embodiment.
• Fig. 6 FIG. 11 shows a schematic representation of a wear protection element of a crusher in a sectional view according to the exemplary embodiment of FIG Fig. 5 .

Fig. 1 shows a crusher 10, in particular a gyratory crusher 10, with a movable crushing element, namely a crushing cone 12 and a stationary crushing element, namely a crusher housing 14. For the sake of simplicity, for example, the drive, the bearing and the foundation of the rotary crusher 10 are not shown. The gyratory crusher 10 is essentially rotationally symmetrical, the crusher housing 14 having the shape of a hollow cone and the crushing cone 12 being arranged within the hollow conical crusher housing 14. The crusher housing 14 has a feed area 16 into which the material to be comminuted is fed. The feed area 16 is arranged on the upper side of the gyratory crusher 10 and the crusher housing 14 has the largest diameter at the feed area 16. The crusher housing 14 tapers in the axial direction from top to bottom, so that the lower region of the crusher housing 14 has the smallest diameter. The lower area of the crusher housing 14 forms the outlet 18 through which the comminuted material leaves the rotary crusher 10.

Within the crusher housing 14, the crushing cone 12 is arranged, which has a conical shape and tapers in the axial direction from bottom to top. The crushing cone 12 is arranged coaxially to the crusher housing 14, the axis of rotation of the crushing cone 12 running eccentrically to the central axes of the crushing cone 12 and the crusher housing 14.

A circumferential crushing space 20 is formed between the crushing cone 12 and the crusher housing 14, in which the material to be crushed is at least partially crushed. The crushing space 20 tapers downwards in the direction of the outlet 18 and forms an annular crushing gap 22 in the area with the smallest diameter. The upper edge of the crushing space 20 forms the feed area 16 of the rotary crusher 10.

During operation of the gyratory crusher 10, the crushing cone 12 is driven to an eccentric rotation, the axis of rotation running parallel to the central axis of the crushing cone 12. The crushing cone 12 is driven to perform a rotational tumbling movement, the crushing gap periodically narrowing and enlarging its circumference, so that material can flow from above into the crushing gap 22 and can be crushed there.

The radially inwardly facing surface of the crusher housing 14 has a plurality of wear protection elements 24 which are arranged next to one another and form the crushing surface of the crusher housing 14 which comes into contact with the material to be crushed. The crusher housing 14 has a carrier which is shown in Fig. 1 comprises, for example, two carrier elements 26, 28. The carrier segments 28, 28 are each, for example, essentially circular educated. It is also conceivable that the crusher housing 14 has only one carrier segment or more than two carrier segments 26, 28, on each of which at least one wear protection element 24 is attached.

The wear protection elements 24 are, for example, arranged next to one another in four circumferentially extending rows and attached, in particular detachably, to the carrier segments 26, 28, for example screwed to the respective carrier segment 26, 28. The wear protection elements 24 are essentially plate-shaped with a quadrangular cross-section, in particular the wear protection elements of the edge areas of the crushing space, such as the feed area 16 and the outlet 18, having a curvature. For example, the crushing cone also has wear protection elements 24, these in FIG Fig. 1 are not shown.

Fig. 2 , 3 and 4 show a wear protection element 24 for attachment to the stationary crushing element 14 or the movable crushing element 12 of the crusher 10 Fig. 1 . The wear protection element 24 is formed from a metal matrix composite material which has a wear protection insert 30 and a metal matrix 32. The wear protection insert 30 is arranged on the surface of the wear protection element 24, which corresponds to the installed state of the Fig. 1 at least a part of the crushing surface of the crusher housing 14 forms. The wear protection insert 30 is formed, for example, from a hard metal, such as tungsten carbide, titanium carbide, boron carbide, niobium carbide or chromium carbide, or from ceramic or a combination of these materials. In particular, the wear protection insert 30 has a honeycomb structure. Further porous structures of the wear protection insert 30 are also conceivable, this being designed in such a way that infiltration of the metal matrix material 32 into the wear protection insert 30 is made possible. The wear protection insert 30 is formed in one piece and has, for example, a thickness of 150 mm, preferably 20 mm to 80 mm, in particular 50 mm. Each of the wear protection elements 24 has, for example, exactly one wear protection insert. The wear protection insert 30 is essentially plate-shaped and the metal matrix material is cast into the wear protection insert.

The wear protection element 24 is formed from the metal matrix material 32, the wear protection insert 30 being at least partially enclosed by a metal matrix material 32, in particular being cast into it. The metal matrix material 32 is For example, high-temperature resistant steel and / or a steel with a hardness of about 150 - 400 HB (Brinell). A high-temperature-resistant steel is to be understood as a heat-resistant steel with a high chromium-nickel content or a high manganese content, which has a temperature resistance of up to 650.degree. C., in particular up to 1000.degree. Such steels are, for example, austenitic chromium-nickel steels, such as GX25CrNiSi18-9, GX40CrNiSi25-12, GX40NiCrSiNb35-26. High-temperature-resistant steels up to 600 ° C are, for example, steels according to DIN EN 10213. High-temperature-resistant steels up to 1200 ° C are, for example, steels according to DIN EN 10295. An example is the area of the wear protection element 24 that has no contact with the material to be shredded, made exclusively of the metal matrix material educated.

The thickness of the wear protection insert 30 is different, for example over the breaking surface of the crusher housing 14. The wear protection elements 24, which are arranged in an area in the crushing space 20 with a high wear load, such as the crushing gap or the feed area, preferably have a thicker wear protection insert 30 than the wear protection elements 24 outside these areas. The thickness of the wear protection insert 30 increases, for example, in the direction of the crushing gap 22, the wear protection elements 24 that form the crushing gap 22 each having a wear insert 30 with the greatest thickness.

During the manufacture of the wear protection element 24, a wear protection insert 30 made of hard metal, such as tungsten carbide, titanium carbide, niobium carbide, boron carbide or chromium carbide, or made of ceramic or a combination of these materials, is positioned, for example fastened, in a casting mold for casting the wear protection element 24. The wear protection insert 30 has, for example, a plate shape and is positioned on the breaking surface, in particular in the casting mold on the outwardly facing surface of the wear protection element 24. The wear protection element 24 is then cast from the metal matrix material so that the wear protection insert 30 is at least partially enclosed by the casting material of the wear protection element, the casting material infiltrating into the porous structure of the wear protection insert 30, for example. In particular, the wear protection insert 30 is completely enclosed by the casting material.

The wear protection element 24 has, for example, a plurality of shoulders 34 and recesses 36 on the surface facing the carrier of the crusher housing 14. These serve to fasten the wear protection element to the carrier of the crusher housing 14. In particular, the wear protection element 24 is wedged or clamped to the carrier via the shoulders 34 and recesses 36, the carrier having complementary shoulders and recesses into which the wear protection element 24 with the shoulders 24 and recesses 36 engages. The shoulders 34 and recesses 36 also serve to create a distance between the wear protection element 24 and the carrier of the crusher housing 14.

This in Figs. 2 to 4 The wear protection element 24 shown has an essentially flat surface and is arranged, for example, in the central area of the crusher housing 14 between the feed area 16 and the outlet 18.

Figures 5 and 6 show a further embodiment of a wear protection element 24, which is arranged, for example, on the crushing gap 22 or the feed area 16 of the crusher housing. The wear protection element 24 corresponds essentially to the wear protection element 24 of FIG Figs. 2 to 4 with the difference that it has a curved shape. The surface of the wear protection element 24 is curved inwardly in the direction of the crushing space 20, for example.

List of reference symbols

10

Gyro crusher

12th

movable crushing element / crushing cone

14th

stationary crushing element / crusher housing

16

Task area

18th

Outlet

20th

Crushing room

22nd

Crushing gap

24

Wear protection elements

26th

Carrier segment

28

Carrier segment

30th

Wear protection insert

32

Metal matrix material

Claims (8)

1. Crusher (10) for comminuting material, having a crushing space (20) with a feeding region (16), into which material to be comminuted is fed, and a crushing gap (22) for crushing the material, wherein the crushing space (20) tapers from the feeding region (16) towards the crushing gap (22),
   wherein the crusher (10) has a stationary crushing element (14) and a movable crushing element (12), which delimit the crushing space (20),
   wherein the stationary crushing element (14) has a plurality of wear protection elements (24), each of which is formed from a metal matrix composite material comprising a metal matrix material and from a wear protection insert (30) composed of a hard metal and/or ceramic,
   characterized in that
   the wear protection insert (30) has a porous structure and is cast in at least partially in the wear protection element (24), with the result that the metal matrix material is infiltrated at least partially in the wear protection insert (30).
2. Crusher (10) according to Claim 1,
   wherein the thickness of the wear protection inserts (30) of different wear protection elements (24) differ from one another.
3. Crusher (10) according to either of the preceding claims, wherein the wear protection element (24) is of plate-like form.
4. Crusher (10) according to one of the preceding claims, wherein the wear protection insert (30) is arranged on the surface of the wear protection element (24) .
5. Crusher (10) according to one of the preceding claims, wherein the wear protection element (24) is produced by a casting process.
6. Crusher (10) according to one of the preceding claims, wherein the wear protection insert (30) comprises tungsten carbide, ceramic, titanium carbide, boron carbide, niobium carbide or chromium carbide, or a mixture of these materials.
7. Crusher (10) according to one of the preceding claims, wherein the crusher is a cone crusher, a gyratory crusher or a jaw-type gyratory crusher, wherein the stationary crushing element (14) is a crusher housing and the movable crushing element (12) is a crushing cone, wherein the crushing space is formed between the crushing cone and the crusher housing.
8. Method for producing a wear protection element (24) of a stationary crushing element (14) of a crusher (10), having the following steps:

   - positioning a wear protection insert (30), which has a porous structure and is composed of a hard metal and/or ceramic, in a casting mould for the purpose of casting the wear protection element (24), and

   - casting the wear protection element (24), with the result that the wear protection insert (30) is enclosed at least partially by the cast material of the wear protection element (24) and said wear protection element is infiltrated at least partially in the wear protection insert (30).

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