A mobile crusher is a versatile piece of equipment designed for crushing and recycling various materials directly at the site of operation, eliminating the need for transporting heavy materials to a fixed crushing plant. It combines the functionalities of a crusher and a mobile platform, allowing it to move freely across different terrains. Here’s a detailed look into how a mobile crusher works:
Key Components of a Mobile Crusher
- Chassis: The base frame that supports the entire crusher system, designed to be sturdy and stable while being mobile.
- Crusher: The main component where the crushing of materials occurs. Depending on the design, this could be a jaw crusher, cone crusher, impact crusher, or hammer crusher.
- Engine: Provides the necessary power to drive the crusher and other auxiliary systems.
- Feed Hopper: A large container at the top of the crusher where raw materials are loaded.
- Conveyor Belts: Transport crushed material to different stages of the process or to stockpiles.
- Control System: Includes manual and automated controls for operating the crusher and monitoring its performance.
Components and Working Principle
- Primary Crushing Unit: Mobile crushers are typically composed of a primary crushing unit and a secondary crusher with a screen plant at the discharge end. The primary crushing unit usually consists of a crusher or a feeder, where initial crushing happens. In some cases, primary crushing can take place underground, but most often, the crusher is installed on the surface.
- Crushing Chamber: Inside the primary crusher, there is typically a chamber where the raw material is initially processed. This chamber contains a fixed jaw and a moving jaw, or a cone and its mantle, depending on the type of crusher. The material is fed into the chamber from the top and crushed between the jaws or cones.
- Hydraulic Systems: Mobile crushers use hydraulic systems to perform various functions. Hydraulic cylinders adjust the crusher’s setting, control the feed and discharge, and prevent damage to the crusher from uncrushable materials. Some crushers also feature an optional integrated magnetic separator to remove metal contaminants from crushed materials.
- Transportation and Mobility: Mobility is a key feature of mobile crushers. They are designed to be easily transported from site to site and set up quickly. This mobility allows them to be used in various locations within a quarry or on construction sites, making them versatile and efficient tools for material processing.
Mobile crusher operation
- Loading and Feeding: Raw materials are loaded into the crusher’s hopper or directly onto the vibrating feeder that feeds the crusher. The feeder controls the rate at which the raw material enters the crusher, ensuring a consistent feed.
- Crushing Process: As the raw material moves from the feeder into the crusher, it encounters the crushing mechanism, where compression, impact, or attrition forces are applied depending on the design of the crusher. This process breaks the material into smaller pieces suitable for further processing.
- Screening and Discharge: After primary crushing, the crushed material may pass through a secondary crusher for further reduction, or it may proceed directly to screening. Screens are used to separate the material by size before it is discharged from the crusher. This ensures that only the desired product size passes through for further processing or sale.
Mobile crushers are essential for modern construction, mining, and recycling operations, offering flexibility, efficiency, and cost savings. By understanding their components and operation, users can maximize their productivity and minimize downtime, ensuring smooth and effective material processing on-site.