Insight into Every Detail, Prevention in Advance - Professional Judgment on The Timing of Cone Breakage And Replacement of Mobile Cones

In the fields of mining and aggregate processing, cone crushers are the core equipment for medium and fine crushing operations. The "heart" component - the moving cone, will gradually deteriorate in performance after long-term exposure to severe impacts and grinding. Timely replacement of the moving cone is the key to ensuring stable operation of the equipment, maintaining product particle size and production capacity, and controlling overall costs.

This article will provide you with professional and objective judgment based on the principles of device operation and industry practice.

1、 Core indicator: When the wear of the dynamic cone lining plate reaches its limit

The body of the moving cone is usually made of high-strength cast steel and has a long service life. What we usually refer to as "replacing the dynamic cone" mostly refers to replacing the dynamic cone lining plate (i.e. the dynamic cone rolling bowl wall).

When the following situations occur, it is strongly recommended to plan for replacing the dynamic cone liner plate:

The wear amount exceeds the maximum allowable value

Professional measurement method: Use the manufacturer's specialized measuring gauge or caliper to detect the depth of wear from the bottom to the top of the lining plate. When the wear depth at any point exceeds 60% -70% of the original thickness, or reaches the scrap limit specified by the equipment manufacturer in the technical manual, replacement must be carried out. Continuing to use will result in premature damage to core components such as the pressure cap and spindle.

Simple judgment method: observe the width of the discharge port. When the lining plate wears out, even if the adjustment ring has been rotated to the tightest position, the discharge port is still greater than the set value, resulting in the product particle size continuously exceeding the standard, which means that the lining plate has lost its effective crushing ability.

Uneven or abnormal wear occurs

Partial wear: One side of the lining plate is severely worn, while the other side is still in good condition. This is usually related to uneven feeding, low material level in the feeding bin, or inclined installation of the crusher. Unbalanced grinding can cause an imbalance in crushing force, exacerbate equipment vibration and component wear, and require immediate correction and replacement of lining plates.

Cracks or fractures: Visible cracks or even local fractures appear on the working surface or fixed ears of the lining plate. There is a significant risk of fragments falling into the crushing chamber and damaging the host equipment, and immediate shutdown and replacement are necessary.

**2、 Performance signal: "alarm" for device operating status

In addition to direct wear measurement, some abnormal performance during equipment operation is also an important signal for replacing the dynamic cone liner plate:

Significant decrease in production capacity: Under the same discharge port settings and discharge conditions, the main motor current significantly decreases, and the unit time output continues to decline. This indicates that the shape of the crushing chamber between the moving cone and the fixed cone liner has severely failed, resulting in low extrusion efficiency.

Product particle size out of control: Despite repeated adjustments to the discharge port, there is still an excessive amount of oversized or powdery aggregate produced, resulting in poor particle deformation and inability to meet grading requirements. This is a direct consequence of severe wear and tear on the lining profile.

Equipment vibration and abnormal noise increase: The crusher experiences abnormally severe vibration or continuous metal impact sound during operation. This may be due to loose lining plates (pressure cap or U-bolt issues) or partial detachment or breakage of the lining plates, and immediate shutdown inspection is required.

Abnormal increase in energy consumption: In order to maintain the original production capacity, the motor needs to pay a larger current, resulting in an increase in unit power consumption and a decrease in operating economy.

3、 Special case: When it is necessary to replace the entire cone assembly

In rare cases, it may be necessary to replace the entire cone assembly (including the cast steel body):

Major cracks or damage to the body: The dynamic cone body has cracks under long-term high stress cycles, which have been confirmed by non-destructive testing to be irreparable.

Cone fitting failure: The cone surface of the dynamic cone body that fits with the lining plate is severely worn or deformed, resulting in a loose fit of the lining plate after installation, which poses a safety hazard.

Equipment upgrade or modification: To improve efficiency or adapt to new processes, replace with a new model or specially designed dynamic cone assembly.

4、 Professional advice: Scientific decision-making, maximizing value

We suggest that users establish a preventive maintenance plan:

Regular inspection: Conduct external inspections for each shift, regularly (such as monthly) stop the machine, open the inspection door, measure the wear of the lining plate, and record it.

Paired replacement: To ensure the optimal shape of the crushing chamber, the best practice is to replace both the dynamic cone liner and the fixed cone liner at the same time. Changing only one side will result in a mismatch between the new and old lining plates, accelerating the wear of the new lining plates.

Traceability analysis: For abnormal wear, the root cause (such as feeding system, equipment levelness, lubrication system, etc.) should be thoroughly analyzed to avoid the problem from recurring.