Non standard customization process and core advantages analysis of wear-resistant accessories for mining crushing equipment

Mining crushing equipment is often subjected to extreme conditions of high load, strong impact, and multi-media corrosion for a long time. A single standard wear-resistant accessory is often difficult to adapt to the personalized needs of different minerals (such as iron ore, phosphate ore, coal mine), crushing processes (coarse crushing, medium crushing, fine crushing), and equipment models. Non standard customization has become the core solution for solving pain points such as rapid equipment wear, frequent maintenance, and limited production capacity through a dynamic process of "working condition adaptation technology reconstruction full chain service".

Non standard customization full process: dynamic closed-loop from demand to value-added

The non-standard customization of wear-resistant accessories for mines is not simply a matter of "size modification", but a dynamic optimization process based on working condition data and technological innovation, covering five key aspects:

1. Accurate diagnosis of working conditions: customized "source anchor point"

At this stage, precise positioning is achieved through "data collection simulation analysis requirement decomposition", breaking the limitations of traditional "experience judgment":

Multidimensional data collection: The technical team goes deep into the mining area, monitors the crushing load and material trajectory through 3D scanning equipment cavity structure, IoT, and combines core parameters provided by customers such as mineral hardness (such as 3-5 Mohs hardness for phosphate ore and 5-6.5 hardness for iron ore), daily processing capacity, equipment shutdown records, etc., to form a "working condition diagnosis report".

Simulation verification: Use CFD fluid dynamics simulation to simulate the impact trajectory of materials, and predict the failure risk of standard components through wear simulation testing. For example, for the sand making machine cavity, high wear areas can be determined through simulation, providing data support for subsequent material selection and structural design.

Structured disassembly of requirements: Transforming customer vague requirements into clear technical indicators, such as "reducing wear of ball mill chute", which can be disassembled into: wear resistance life ≥ 6 months, impact strength ≥ 20J/cm ², and adaptability to existing equipment installation size error ± 2mm.

2. Customized design of solutions: dynamic balance between performance and cost

Based on the diagnostic results, implement a "one machine, one strategy" design from the three dimensions of materials, structure, and process:

Material Science Proportioning: Optimize the composition according to the type of wear, such as increasing the content of alloy elements such as chromium, molybdenum, tungsten, etc. for high hardness ore impact, so that the hardness of the weld layer can reach HRC60 or above; For corrosive slurry environments, adding nickel element to form a passivation protective film enhances corrosion resistance. In a customized case of a phosphate mine in Hubei, the wear-resistant life of the feeding hopper was extended from 3 months to 9 months by using self-developed K95 red porcelain material.

Structural dynamic optimization: Design irregular structures based on equipment operating trajectories, such as using thickened modular liners for vertical impact zones and streamlined staggered layouts for conveyor chutes, which not only dissipate impact kinetic energy but also reduce material running resistance. Customized "biomimetic sawtooth+unloading groove" structure for the crusher toothed plate of easy to jam materials, reducing the jamming rate by more than 90%.

Process path matching: Based on the size and accuracy requirements of the accessories, special processes are combined. Small shaped accessories are processed using five axis linkage to ensure contour accuracy, while large wear-resistant plates are controlled by multi pass and multi-layer welding processes to control deformation. Key parts are enhanced with electrical discharge strengthening treatment to improve surface wear resistance.

3. Sample trial production and verification: Mass production of "risk filters"

At this stage, dynamic adjustments are made through the process of "small trial, medium trial, and iteration" to ensure the feasibility of implementing the plan

Rapid sample production: Using 3D printing rapid prototyping technology to produce accessory prototypes, or through modular pre assembly to achieve core structure verification, the sample delivery cycle is shortened from the traditional 15 days to within 7 days.

Full condition simulation testing: Set up a simulated crushing environment in the laboratory to conduct hardness testing (Brinell/Rockwell hardness tester), wear testing (MLS-225 abrasive wear tester), and impact testing on the samples. For example, the Wodun wear-resistant plate needs to undergo a 72 hour continuous wear test simulating heavy mining conditions to ensure that the wear amount is ≤ 0.5mm/100 hours before entering mass production.

Iterative optimization of the plan: If the sample does not meet expectations (such as insufficient hardness or installation interference), immediately coordinate with the design and process teams to make adjustments. After testing the tooth plate samples of a certain coal mine, it was found that there was an impact fracture problem. By increasing the proportion of manganese element (from 12% to 14%) and optimizing the heat treatment process, the impact resistance performance was improved by three times.

4. Flexible production and quality control: "accuracy guarantee" for batch delivery

Adopting a mixed production mode of "standardized modules+customized processing", balancing efficiency and accuracy:

Flexible manufacturing response: 70% of universal basic components are standardized for mass production, and 30% of customized components are quickly switched for production through intelligent production lines. For example, a five axis machining center can achieve automatic tool path adaptation for different specifications of lining plates, shortening the delivery cycle by 40% compared to the industry average.

Full process quality monitoring: 12 inspection nodes are set up from raw material entry (spectral analysis to detect components), processing (first piece coordinate measurement) to finished product delivery (non-destructive testing for internal defects). A certain enterprise in Shandong has compressed the single piece quality inspection time from 8 seconds to 0.5 seconds through an intelligent visual inspection system, and reduced the scrap rate from 2.1% to 0.3%.

Extreme working condition adaptation processing: For equipment in high-altitude mining areas, customized accessories need to undergo -40 ℃ low-temperature impact testing; For high-altitude mining areas, optimize material grain size to ensure performance stability at altitudes above 5000 meters.

5. Delivery and value-added services: dynamic protection throughout the entire lifecycle

Customized services are extended to the entire lifecycle of devices, achieving a closed loop of "delivery operation iteration":

Scenario based delivery support: Provide on-site installation guidance, such as Jingcheng Special Ceramics adopting modular porcelain bonding technology in the phosphate mine project to ensure seamless fit between the lining plate and the equipment cavity, increasing installation efficiency by 50%. Coordinate logistics to achieve "48 hour delivery of spare parts" for remote mining areas.

Intelligent operation and maintenance monitoring: Install wear sensors for customized accessories, transmit data in real-time through 5G modules, achieve a fault warning accuracy of 92%, and avoid unplanned downtime in advance.

Continuous iterative optimization: Regular follow-up visits are conducted to collect usage data. For example, after 6 months of use, the hammer head of a certain iron ore crusher is optimized based on the wear trajectory to improve the cutting edge angle of the hammer head, resulting in an additional 20% increase in wear life for subsequent batches.