EnglishViews: 0 Author: Site Editor Publish Time: 2025-12-29 Origin: Site
Evaluation method for synchronous replacement of related supporting components when replacing the conical broken lining plate
When replacing the wear-resistant lining plate (rolling bowl wall and crushing wall) of the cone crusher, whether to replace the key matching parts synchronously is an important decision that affects the subsequent operation accuracy, stability, and expected service life of the new lining plate of the equipment. Blind replacement will increase unnecessary spare parts and downtime costs; If the replacement is not carried out, it may cause rapid damage to the new lining plate or even lead to host failure due to local coordination failure. Scientific evaluation should be based on quantifiable testing standards, a systematic understanding of component functionality, and the concept of preventive maintenance.
1、 Core evaluation logic: shifting from "single component replacement" to "coordinated system recovery"
The lining plate does not work independently, it forms an interrelated "mating system" with bowl shaped bearings (bowl shaped tiles), spindle bushings, locking nuts/adjusting ring threads, etc. The core function of this system is to ensure the stable operation of the dynamic cone component on a predetermined trajectory. The fundamental goal of replacing the lining plate is to restore the working efficiency of the entire crushing chamber, rather than just providing a new wear-resistant surface. Therefore, the focus of the evaluation is to determine whether the existing components can still provide the required positioning accuracy, support stiffness, and locking reliability for the new lining plate.
2、 Inspection standards and replacement criteria for key components
1. Bowl shaped bearings (bowl shaped tiles)
Function: Support the entire dynamic cone component (spindle, dynamic cone, crushing wall), withstand huge vertical pressure and certain impact force, and ensure smooth rotation of the dynamic cone.
Inspection method and replacement basis:
Wear depth measurement: Use a depth gauge to measure the wear pits in the working area of the bowl shaped tile sphere. If the maximum wear depth exceeds the allowable value of the equipment manufacturer (usually 10-15% of the original thickness, or specifically 3-5mm), its geometric shape has changed and cannot provide stable support for the moving cone, and it must be replaced.
Contact trace inspection: Check the contact mark between the bowl shaped tile and the lower spherical surface of the moving cone body. The ideal contact should be a uniform and continuous surface contact. If severe eccentric wear, local peeling, or penetrating cracks occur, it indicates uneven stress or material fatigue and needs to be replaced.
Oil tank and lubricating oil circuit: Check whether the oil tank is worn, deformed or blocked. Damaged oil grooves can affect the formation of lubricating film, leading to increased abnormal wear.
2. Main shaft bushing (eccentric bushing/straight bushing)
Function: Installed inside the eccentric sleeve, it cooperates with the spindle to convert the rotational motion of the eccentric sleeve into the swinging motion of the moving cone, which is the key friction pair that determines the accuracy of the moving cone motion.
Inspection method and replacement basis:
Gap measurement: This is the most critical quantitative indicator. Measure the fit clearance between the spindle and the bushing using a feeler gauge or an inside/outside micrometer. Compare this value with the maximum allowable clearance value provided by the equipment manufacturer (usually 2-3 times the clearance of the new machine). If the measured gap exceeds the maximum allowable value, it will cause the dynamic cone swing trajectory to be unstable, resulting in a sharp increase in impact load, seriously affecting the service life of the lining plate and product particle size, and must be replaced.
Internal surface inspection: Check for severe scratches, adhesive wear (burrs), or discoloration (bluing) on the inner wall of the liner. These are irreversible damages that accelerate spindle wear, and it is recommended to replace them even if the clearance is temporarily qualified.
3. Lock nut and adjusting ring thread
Function: The locking nut is used to fix the rolling bowl wall (fixed cone lining plate) and the adjustment ring; Adjust the ring thread to regulate and secure the discharge port. They are directly related to the overall rigidity of the fixed cone component.
Inspection method and replacement basis:
Thread condition inspection: After thoroughly cleaning the threads, visually inspect and touch them with your hand. If there is thread crushing, deformation, fracture, or wear exceeding 30% of the tooth width, its locking force and anti loosening ability have been severely reduced. Under crushing vibration, the lining plate may become loose, causing accidents and requiring replacement.
Coordination between nut and adjustment ring: Check if the contact end face between the locking nut and the adjustment ring is flat. If there is uneven wear or deformation, even tightening cannot provide uniform preload force.
History: If the thread condition was found to be poor during the last lining plate replacement but was not addressed, priority should be given to replacement this time.
3、 Systematic decision-making process and recommendations
It is recommended to follow the following process for decision-making, which can be made into a checklist:
Pre disassembly inspection and recording: Before disassembling the old lining plate, record any abnormal sounds, vibration data (if any), and changes in product granularity during equipment operation, which may indicate issues with specific components.
Synchronization check during disassembly process:
After lifting the cone, immediately inspect the wear marks and condition of the bowl shaped tile.
After disassembling the locking nut, carefully inspect the thread condition.
Measure the clearance between the spindle bushings.
Standard based decision-making: Compare the above inspection results with the allowable limit values in the equipment technical manual. Any indicator that exceeds the standard constitutes a clear basis for replacement.
Consider the correlation between impact and economy:
Relevance: For example, if the clearance between the main shaft bushing is too large, it is likely that the main shaft mating surface has also worn out and needs to be checked together. When replacing bowl shaped tiles, it is usually recommended to check or replace the corresponding dynamic cone body spherical protective cover (if replaceable) at the same time.
Cost trade-off: Calculate the risk cost of reducing the lifespan of new lining plates by more than 30% or causing unplanned downtime due to poor condition of a certain component. The cost of this risk is usually much higher than the value of the supporting components themselves.
Execution and recording: After deciding to replace, ensure that the new parts meet the specifications of the original equipment. After installation, record in detail all component information, measurement data, and decision reasons for this replacement, providing historical basis for the next maintenance cycle.
4、 Conclusion
The evaluation of supporting components during the replacement of conical broken lining plates is a preventive maintenance work based on data and standards. The core principle is to restore and ensure the basic mechanical environment on which the new lining board relies for normal operation.
In short, when the wear or damage of the matching parts has affected the motion accuracy of the moving cone, the locking stability of the fixed cone, or the rigidity of the entire support system, synchronous replacement must be carried out. Following strict inspection standards and systematic decision-making processes, although it may increase the cost of spare parts for a single maintenance, it can effectively ensure that the new lining board achieves the expected service life, avoid losing big for small things, and improve the continuous operation time and production economy of the equipment as a whole.
