The Horizontal Shaft Impactor (HSI) revolutionized the crushing process. Patented in by Dr. Erhard Andreas of Muenster, Germany, the “Andreas Impact Crusher System” design utilized old torpedo tubes and steel from decommissioned tanks. Since then, there have been many unique features of the design patented but they all operate basically the same.
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While there are several varieties of HSI, their similarities are more numerous than their differences. All varieties feature externally fed horizontal rotors with breaker bars, which propel material into a series of apron-mounted breaker plates that crush or pulverize many different types of materials to specified degrees of fineness.
Reduction ratios of up to 30:1 are achievable in a single stage with HSI crushers. The simple design offers low capital and operating cost, while low headroom requirements make it easy to install. Product sizes may be varied by changing rotor speed and the clearances between rotor breaker bars (also called blow bars or hammers) and apron breaker plates. HSI applications have gone beyond soft and nonabrasive materials such as limestone, phosphate, gypsum and weathered shales, to harder minerals thanks to the introduction of alloy steel rotor breaker bars. Typical alloy steels contain manganese and/or high or medium chromium content. There are many different crushing chamber designs on the market, and proper selection will depend on the knowledge of the application for proper feed, crushing chamber configuration, metallurgy of the crushing chamber components, gap setting and rotational speed. Finally, computer controls can automatically adjust HSI settings on the fly to adjust for wear or changing specs.
Operation
HSIs have a lined crushing chamber with rotating breaker bar rotor on a horizontal axis. The size reduction takes place quickly along short fracture lines, producing a more cubical product to meet aggregate specifications. This fast impact fracture is different from the slow compression breaking in cone or jaw crushers that produce more slabby or flat material (5-to-1 length-to-height ratio).
Feed enters the primary crushing chamber and meets the rotor breaker bars, which impel the feed against the first apron lined with breaker plates. Impact with the rotor, the breaker plate and inter-particulate collision all contribute to comminution. Material is reduced in the primary chamber and passes by the front apron breaker plate gap, entering the secondary and, in some configurations, tertiary chambers, for final reduction. A high percentage of the initial size reduction comes from the first impact with the rotor breaker bar. Aprons are shaft suspended at the front and from a spindle in the rear, allowing for continuous gap adjustment as wear progresses. Unlike hammer mills, the open discharge impactor has no screens or grates holding material inside the crusher. Material is efficiently processed at high rates for low costs.
The rotor breaker bars operate best at specific speed ranges for maximum results. As the total processing capacity and rotors get larger, the number of breaker bar rows increases. On smaller sizes, there are only two rows; on larger rotors, there are four or more rows of rotor breaker bars. The optimum configuration has material delivered to each row of rotor breaker bars in a continuous bed over the width of the rotor for optimum performance and consistent wear part utilization. Some rotor interiors are open, and some are closed depending on feed conditions. For example, concrete recycling requires a closed rotor so rebar doesn’t get entangled.
Application
The HSI is used for all types of material with compressive strength less than about 20,000 pounds per square inch. It’s widely used for sand and rock for roads, railways, reservoirs, electrical grid isolation, building materials and many industrial applications such as metal reclamation and recycling.
Wear part metallurgy is critical to proper applications and performance. It’s a good idea to keep a log of these items to determine the best wear part selection and maintenance schedule: feed and discharge information, throughput rates, change out records and measurements of worn parts. Proper selection of wear part metallurgy will result in optimum production rates; longer maintenance cycles and fewer changeouts, which reduce labour costs and downtime, and increase the life of wear parts.
Materials with high moisture content can be successfully handled by using heaters and air cannons to reduce and dislodge material adhering to the crushing components and chamber.
The spacing between rotor breaker bars and breaker plate aprons can be adjusted to produce different products within one crusher. It is possible to crush soft raw material limestone or high-grade harder limestone for cement or asphalt applications with one crusher by externally adjusting the breaker bar and plate settings. Gap adjustment between the rotor breaker bars and breaker plates by manual or computer controlled systems adjusts the crushing gap so that product particle size distribution remains constant.
Maintenance
HSIs have multi-turn breaker bars for extended life before changeout. Design simplicity offers safe and easy access for breaker bar replacement and access to all areas of the crushing chamber. Front-opening models eliminate the need for a crane in some cases, while rear-opening models can allow unique installation applications.
A crusher is a machine designed to reduce large rocks into smaller rocks, gravel, sand, or rock dust, which is consists of thousands of parts. These thousands of parts are called crusher parts. According to its frequency replacement and function, the crusher parts are divided into crusher spare parts and crusher wear parts.
Crusher Parts Types
Main Crusher Parts Function
Crusher Parts Price
How To Choose The Right Crusher Parts And Suppliers?
Who is the crusher parts manufacturer?
Different types of crusher, there are different crusher parts types.
A jaw crusher uses compressive force for breaking of particle. This mechanical pressure is achieved by the two jaws of the crusher of which one is fixed while the other reciprocates. A jaw or toggle crusher consists of a set of vertical jaws, one jaw is kept stationary and is called a fixed jaw while the other jaw called a swing jaw, moves back and forth relative to it, by a cam or pitman mechanism, acting like a class II lever or a nutcracker. The volume or cavity between the two jaws is called the crushing chamber. The movement of the swing jaw can be quite small since complete crushing is not performed in one stroke. The inertia required to crush the material is provided by a flywheel that moves a shaft creating an eccentric motion that causes the closing of the gap.
Based on its frequency replacement and function, the jaw crusher parts are divided into jaw crusher spare parts and jaw crusher wear parts.
Jaw crusher wear parts include:
Jaw crusher main spare parts include:
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A Cone Crusher is a compression type of machine that reduces material by squeezing or compressing the feed material between a moving piece of steel and a stationary piece of steel. Final sizing and reduction are determined by the closed side setting or the gap between the two crushing members at the lowest point. As the wedge or eccentric rotates to cause the compression within the chamber, the material gets smaller as it moves down through the wear liner as the opening in the cavity gets tighter. The crushed material is discharged at the bottom of the machine after they pass through the cavity.
Based on its frequency replacement and function, the cone crusher parts are divided into cone crusher spare parts and cone crusher wear parts. Details check the right standard cone crusher structure picture.
Common cone crusher wear parts include:
Common cone crusher spare parts include:
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A gyratory crusher includes a solid cone set on a revolving shaft and placed within a hollow body, which has conical or vertical sloping sides. Material is crushed when the crushing surfaces approach each other and the crushed products fall through the discharging opening. The gyratory crusher is similar in basic concept to a jaw crusher, consisting of a concave surface and a conical head; both surfaces are typically lined with manganese steel surfaces. The inner cone has a slight circular movement, but does not rotate; the movement is generated by an eccentric arrangement. As with the jaw crusher, material travels downward between the two surfaces being progressively crushed until it is small enough to fall out through the gap between the two surfaces.
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Based on its frequency replacement and function, the gyratory crusher parts are divided into gyratory crusher spare parts and gyratory crusher wear parts. Details check the right standard gyratory crusher structure picture.
Common gyratory crusher wear parts include:
Common gyratory crusher spare parts include:
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Impact crushers involve the use of impact rather than pressure to crush material. The material is contained within a cage, with openings on the bottom, end, or side of the desired size to allow pulverized material to escape. There are two types of impact crushers: horizontal shaft impactor and vertical shaft impactor.
VSI crushers use a different approach involving a high-speed rotor with wear resistant tips and a crushing chamber designed to ‘throw’ the rock against. The VSI crushers utilize velocity rather than surface force as the predominant force to break the rock. In its natural state, rock has a jagged and uneven surface.
Common VSI wear parts include:
Common VSI spare parts include:
The HSI crushers break rock by impacting the rock with hammers that are fixed upon the outer edge of a spinning rotor. HSI machines are sold in Stationary, trailer mounted and crawler mounted configurations. HSI’s are used in recycling, hard rock, and soft materials. In earlier years the practical use of HSI crushers is limited to soft materials and non-abrasive materials, such as limestone, phosphate, gypsum, weathered shales, however, improvements in metallurgy have changed the application of these machines.
Common VSI wear parts include:
Common VSI spare parts include:
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A gyratory crusher is made of six main assembly parts. Base, mainframe and concave liners, Drive assembly, mantle, spider arm assembly, and oil system.
If you need original OEM crusher parts, you can check with your crusher brand manufacturer or local part department agency. If you need aftermarket replacement crusher parts, the price can be the following.
For some spare parts, such as hose, bolt, nuts, pins, seal, adapter, motor, and other spare parts, the price is based on per pcs or set. Those aftermarket replacement spare parts price around 40%-60% of the original parts.
For casting wear parts, such as jaw plate, cone liner, blow bars, mantles, and other casting wear parts, the price is based on the casting material. For example, a set of jaw plate, weight:kg, material: Mn18Cr2.
The price USD = Pattern fee(USD600, USD0.6 per kg for wood pattern) +Casting fee (USD, USD1.6 per kg for Mn18Cr2)
All crusher plant have their part manuals. When you purchase the crusher, you can get the operation manual and part manual. Check in the manual book to find which part number crusher parts your inquiry.
If you need aftermarket crusher parts, you also can ask a professional engineer to measure the drawings or send a sample product to our suppliers.
If end-users need the original OEM parts, just check with the original parts departments or local agency. If end-users need the aftermarket replacement parts and want to find the right aftermarket parts suppliers, the following things must be prepared:
The part numbers can find in the operation manual book. Some part numbers also cast in the part unwork surface.
The drawings can purchase from drawings businessmen or ask a professional engineer to measure CAD drawings.
For most of casting wear parts, check the quality by sizes report, material report, Mechanical behavior report, and flaw detection report.
There are some standard materials for common crusher wear parts.
For jaw crusher:
For cone crusher:
For gyratory crusher:
For HSI crusher:
For VSI crusher:
There are thousands of crusher parts manufacturers in the world. The following companies are some quality manufacturers or suppliers.
China is the biggest industry product manufactures in the world, there are some quality crusher parts manufactures: