EnglishViews: 0 Author: Site Editor Publish Time: 2026-07-03 Origin: Site
The wear rate of crushing walls is directly linked to working conditions and operation methods. Standardized startup, feeding and shutdown operations can mitigate abnormal component damage and avoid stress concentration and overload impact.
Before equipment startup, operators shall focus on checking the assembly status of the crushing wall. Confirm that the crushing wall is closely fitted to the mantle base, fastening nuts, thrust washers and other fixing parts are free of loosening and offset, and lining filler is fully cured without hollowing or cracking.
Check that no residual ore, metal impurities or maintenance tools remain inside the crushing cavity. Hard foreign objects striking the crushing wall directly after startup may cause surface damage or microcracks. Meanwhile, verify that parameters of the hydraulic and lubrication systems fall within calibrated ranges, and the main shaft rotates smoothly without jamming.
Feeding shall be continuous, uniform and stable. Instant concentrated feeding and unilateral biased feeding are prohibited. Eccentric feeding subjects one side of the crushing wall to sustained high compressive load, accelerating local wear and stress accumulation, which gradually develops into cracks.
Control feed particle size strictly. Oversized materials exceeding the equipment’s design specifications are not allowed into the crushing cavity, as large lumps may cause local overload on the crushing wall, resulting in edge chipping and block falling.
Front-end impurity removal shall be implemented. Magnetic separators and metal detectors shall be adopted to screen out metal impurities such as steel plates, drill bits and shovel teeth from materials to reduce iron passing incidents. Instant heavy impact stress generated by iron passing is one of the key causes of sudden crushing wall fracture.
In case of overload alarms, abnormal cavity noise or excessive vibration during production, stop feeding immediately and avoid continuous operation with faults.
After startup, run the equipment under no-load condition for a period until stable operation and consistent parameters are achieved, then increase feeding volume gradually. Direct full-load feeding upon startup is forbidden.
Before production shutdown, stop feeding first, and wait until all materials inside the cavity are crushed and discharged before shutting down the main unit. Shutdown with accumulated materials in the cavity is not allowed.
Restarting equipment with stockpiled materials imposes intense impact on the crushing wall, which easily triggers lining cracking and equipment jamming. Frequent startup and shutdown with residual materials aggravate fatigue damage to crushing walls and shorten service cycles.
Daily maintenance centers on routine inspection, hidden danger troubleshooting and working condition adjustment. Timely elimination of minor hidden dangers prevents small defects from escalating into component failures, forming the foundation for stable crushing wall operation.
Before and after each shift and during production intervals, inspect the crushing wall through observation and maintenance hatches. Focus on surface abrasion, microcracks, edge chipping and local block loss, as well as gaps, displacement and other abnormalities at lining fitting positions.
Pay close attention to the upper impact zone and middle compression zone where the crushing wall bears concentrated force. Mark and track all microcracks; shut down the equipment immediately if crack expansion is observed.
Monitor main motor current, equipment vibration amplitude, hydraulic system pressure and other core parameters during production. Adjust feeding speed and particle size promptly if parameters fluctuate abnormally.
Prolonged operation with high current and severe vibration indicates excessive load on the crushing wall, which accelerates fatigue wear and induces cracking. Avoid long-term overload operation and organize production in line with rated working conditions.
Clear fine materials and accumulated damp deposits adhering to the cavity regularly. Long-term material adhesion alters the actual crushing gap, leading to uneven stress distribution and asymmetric wear of the crushing wall.
Remove residual impurities at feed chutes and cavity corners to ensure even material falling tracks and reduce local impact abrasion.
Carry out cyclic disassembly and maintenance according to equipment operating hours, focusing on assembly hidden dangers, component fatigue damage and matching structural wear to eliminate crushing wall failures from assembly links.
Dismantle and inspect the crushing wall fastening structure after fixed operating cycles, retighten locking nuts, and replace aged and deformed thrust washers and sealing accessories.
Vibration generated during long-term operation loosens fasteners, causing slight displacement and enlarged fitting gaps of the crushing wall. Frictional impact during operation will gradually trigger cracks and accelerated wear.
Inspect the fitting surface of the mantle base simultaneously, clear residual filler, rust and burrs. Repair worn and uneven deformation on mating surfaces to guarantee uniform fitting between the crushing wall and mantle without partial suspension or concentrated pressure.
Measure the wall thickness wear margin of the crushing wall regularly, record wear data and track wear patterns. Replace components timely when wall thickness wears down to the lower limit specified by the equipment; operation beyond thickness limits is prohibited.
A severely worn thin crushing wall suffers sharp decline in structural strength and bearing capacity, prone to fracture and block spalling under normal crushing conditions. After installing new crushing walls, pour special filler following technical requirements and reserve sufficient curing time; startup before filler curing is forbidden.
During each overhaul, trace root causes if abnormal wear or cracking of the crushing wall is detected. For partial eccentric wear, adjust distributing devices and correct material feeding tracks. For frequent cracking, check main shaft swing, abnormal hydraulic pressure and high material hardness, and rectify equipment and working condition hidden dangers to avoid repeated identical failures.
For high-hardness ore, large feed particle size and continuous high-load production, adjust maintenance frequency and operation standards to adapt to high-intensity production scenarios. High-hardness materials speed up crushing wall abrasion; shorten inspection intervals, increase wall thickness measurement frequency and stock spare parts in advance to prevent unplanned shutdown from sudden component failure.
Damp and silty materials bring stronger abrasive performance and easily cause cavity blockage. Increase cavity cleaning frequency to clear accumulated materials and mitigate long-term abrasion of crushing walls.
Under low-temperature winter conditions, extend no-load preheating time before startup. Low temperatures reduce material toughness of crushing walls, raising risks of brittle cracking under impact.
All maintenance work on crushing walls must follow lockout-tagout procedures. Cut off total power supply and place warning signs; live-line maintenance and inspection on statically incomplete equipment are forbidden.
Do not reach into the cavity for inspection or impurity cleaning during equipment operation to prevent mechanical injuries and avoid component damage from foreign object impact.
Repaired crushing walls are only for temporary transition use, and shall not serve as long-term substitutes for new spare parts. Complete replacement as soon as possible to reduce operational risks.
Do not modify core parameters such as crushing gap and hydraulic pressure without authorization. Arbitrary parameter adjustment changes the bearing load of crushing walls and triggers abnormal wear and cracking.
