Maintenance Suggestions of Rotor for Hammer Crusher

The impact of the rotor for hammer crusher on the crusher is indeed very significant, so it is very necessary to maintain it. In our company's long-term rotor repair work, we have found that many times customers do not pay enough attention to maintenance and use, resulting in short rotor service life and easy damage. In order to make users more clear about the necessity of rotor for hammer crusher maintenance and the benefits of rotor repair, AGICO proposes 8 questions regarding rotor for hammer crusher maintenance to explain this issue in detail, hoping to help customers of crushers.

1. Where are the main danger zones of the rotor for hammer crusher located?

According to the stress analysis cloud map simulated by finite element structural analysis, the main danger zones of the rotor for hammer crusher are mainly distributed in the hammer handle, hammer disc shaft hole, hammer disc external support, hammer shaft, main shaft bearing seat shoulder, and so on.

2. Why should rotor work analysis, life prediction, and planned major maintenance be carried out regularly?

The hammer crusher crushes limestone by the high-speed rotation of the hammer head. Due to the long-term impact and friction of materials during operation, the rotor components are inevitably worn, deformed, and damaged, which leads to the loss of normal working ability. If the rotor working state is not analyzed and the service life is not predicted, and planned maintenance and major repairs are not done, once a sudden event occurs, it will cause serious losses to the enterprise and lead to a complete production shutdown.

3. What are the main failure manifestations of the rotor for hammer crusher with transitional wear?

The main failure manifestations of the hammer crusher are severe wear of the hammer disc shaft hole and outer edge, hammer shaft fracture, hammer disc cracking, lock failure, main shaft displacement, bearing heating, and serious bearing damage or main shaft deformation and even fracture.

4. What are the benefits of regular rotor maintenance?
As the saying goes, "prevention is better than cure." Regular rotor maintenance can greatly extend the service life of the rotor, reduce the failure rate of the crusher, improve the utilization rate of the crusher, and effectively increase the crusher output.

5. What are the main contents of rotor major maintenance?

The main contents of rotor major maintenance are: inspection and bending repair of hammer shaft and main shaft of the hammer crusher, inspection and repair of locking device, repair of the outer edge of the hammer disc or replacement of the hammer disc, repair or replacement and grading of the hammer head of the hammer crusher, and cleaning and maintenance of bearings, bearing seats, and sealing devices.

6. What are the main contents and precautions of main shaft repair of the rotor?

Due to the large size of the shaft neck, it is difficult to heat and the heating time is long. Moreover, the temperature is not easy to control uniformly. Therefore, attention should be paid to the following five points during straightening:

a. The straightening force should not be too strong to prevent the main shaft from cracking at the hidden cracks.

b. When the bending amount is large, it should be straightened in several times.

c. The correction value should be appropriately larger than the bending value of the shaft to eliminate the influence of the rebound deformation of the shaft after the straightening force is removed.

d. During the straightening process, a certain amount of time should be allowed after applying the straightening force. At the same time, the shaft surface should be gently tapped with a small hammer to eliminate the internal stress and prevent the occurrence of post-straightening deformation.

e. The straightening process should be carried out by professionals who have received relevant training and have rich experience in this field.

7. What is the main content of repairing the hammer plate of a hammer rotor for hammer crusher?

The main content is to install the hammer plate, paying attention to checking the fit of the key and keyway, and ensuring that each hammer plate is close to each other. It is necessary to check the locking device according to the regulations, and replace it if necessary to prevent the hammer plate from shifting and the main shaft from displacing.

8. What are the advantages of processing, repairing, and transforming the rotor of a crusher?

Based on the mechanical characteristics of the crushing process of the crusher, AGICO Cement widely uses design analysis software and finite element calculation technology to carry out strength calculation and optimized design of the vulnerable parts of the crusher structure. To address the weaknesses of short rotor lifespan, easy damage, low production, and coarse particle size in single-stage crushers, a comprehensive improvement was made to strengthen the rotor of the crusher. By analyzing the stress cloud map of the rotor and adopting a reinforcement design and high-strength and high-quality steel with armor-like protection design, the rotor lifespan is improved. The design of the variable rotor inertia is used to effectively improve the crushing efficiency, increase the production of the crusher, and reduce the fineness.