1. Cone Crushers Evolution - D. Kaja

CONE CRUSHER DESIGN EVOLUTION

DEAN DE AN KAJA KA JA Global Technical Support Manager  Metso

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Gyratory Crus rushe herr Evol Evoluti ution on a es g y r a o r y c r u s er   Invention of the gyratory crusher by Charles M. Brown in 1878 for Gates Iron Works in Chicago, Illinois, USA. Became known as the Gates gyratory crusher.

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McC cCully ully Prima rimary ry Gyra Gyratory tory

Gyratory was introduced with its shorter shaft design

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SUPERIOR™

Primary Gyratory

In 1951 the SUPERIOR design was introduced which included bottom discharge.

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SUPERIOR™

Primary Gyratory

The SUPERIOR design included the option of hydraulic mainsh mainshaft aft positi positioni oning ng to compensate for mantle and concave wear 

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SUPERIOR™

MK II Primary Gyratory

In 1994, the SUPERIOR Primary Gyratory was updated to the MK II version with a larger relative diameter  o upper ourna w e remova o the locking nut threads from the shaft to provide more strength. Also and higher operating speeds to increase the power rating and

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42-65 MK-II and 50-65 MK-II

In 1998 the SUPER SPIDER design was introduced. Includes: New arched spider  Extra top shell section Longer  to provide: Larger feed Lower nip angles Higher capacity

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The next evolution: -

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2010 introduction of the SUPERIOR™ 60-110E MK-II

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SUPERIOR™

60-110E MK-II Gyratory

Recent Upgrades ¾

Spider Design Using FEA and strain gage data, the Spider was redesigned. The Spider now features an arched open ng o re uce ma er a r g ng. ew arm shields and spider cap provide improved protection to the Spider.

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Standard Rock Box arm shields and Spider cap  Arm shields wrap wrap around and integrate integrate into rim liners liners

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New rim liner retention system requires no bolts for installation

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Rim liner retention system ties all liners together to act as one piece

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SUPERIOR™

60-110E MK-II Gyratory

Recent Upgrades

60-110

60-110E

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SUPERIOR™

60-110E MK-II Gyratory

Recent Upgrades ¾

Bottomshell Design The redesigned single piece Bottomshell reduces components and installation time. Using strain gage data from gyratory crushers in use, new FEA models were created. Using these newly created FEA FEA models, the new Bottomshell was conceived using state of the art and modern design tools. 9

Smart design increases strength through smooth sections and transitions

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bracing on internal pinion arm

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Raised mounting flange

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Robust four arm design

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One piece design

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SUPERIOR™

60-110E MK-II Gyratory

Recent Upgrades 60-110 Two Piece Pie ce

60-110E One Piece

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SUPERIOR™

60-110E MK-II Gyratory

Recent Upgrades ¾

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Topshel opshelll Design Design 9

Redesigned using FEA models generated with strain gage data from crushers in use

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High strength banded construction provides trouble-free operation and long life

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FEA analyzed analyzed to reduce stress concentrations

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Tapered flanges for simplified construction

Component Interchangeability 9

Spider, Spider, Bottomshell, and Topshells Topshells can be installed onto existing 60-110 60-110 MK-II crushers

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SUPERIOR™

60-110E MK-II Gyratory

Recent Upgrades

60-110

60-110E

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SUPERIOR™

60-110E MK-II Gyratory

Model Information ¾

Largest of the SUPERIOR ™ Gyratory family

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Maximum of 1600 horsepower (1200 kW)

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Model Naming Convention: > 1st number = feed opening in inches > 2nd number = mantle diameter in inches

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Cone Crusher Evolution

Edgar B. Symons designs the pillar  shaft gyratory crusher in 1907 while working for Smith & Post, the predecessor to Smith Engineering

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The Symons Horizontal Disc Crusher  In 1911, Mr. Symons develops another crusher, the horizontal disc crusher. crusher. He and his brothers start a new company called, the Symons rot ers o. to eve op an se t s new nvent on. The horizontal disc crusher used centrifugal force and a gyrating acti action on to re eate eatedl dl crus crush h the the ore ore as it asse assed d outw outwar ard d thro throu u h the the chamber.

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The Symons Vertical Disc Crusher   A later design patented in 1915 became the Symons Vertical Disc Crusher 

crushing surface and the centrifugal force to spin the ore outward through the crushing chamber. chamber.

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The Symons™ Cone Crusher 

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“Symons” Crushing Action

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Symons™ Cone Crusher 

“ ” “ configurations

”

Requires different bowl and head assemblies The Short Head version was ’ Improvements were made over the years to increase e po power ra ra ng.

Standard 17-19 Noviembre 2010, Santa Cruz-Chile

Short Head

7 Ft. Super Heavy Duty

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Nordbe Nor dberg™ rg™ Gyra Gyradisc disc cru crushe sher  r 

Gyradis Gyradisc c crushe crusherr developed developed in early 1950’s to operate with multi-layer crushing on a narrow zone o e c am er  Mainly used for producing as halt chi s and manufactured sand

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The Omnicone™ Crusher  The Omnicone was developed in ’ modern crusher with the same crushing action as the Symons cone which would be better suited to the mo e crus ng mar et. The crusher was more compact, better better balanced balanced and had had modern modern hydraulics to provide setting adjustment, tramp release and cavity clearing

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The Omnicone™ Crusher 

, crusher became popular because it used one bowl and head for all crushing cavities and provided the crushing capacity in a more compact machine than the Symons cone

adjustment, tramp release and clearing meant that the crusher was able to have higher availability and to opera e a e op mum se ng

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HP™ and MP™ Cone a en The use of higher speed and throw allowed the increase in capacity and power without , crusher 

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Prototype MP1000 wau ee ac ory n

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MP Series Cone Crusher  The MP1000 was designed as a combination of the Omnicone st le internal com onents and a Symons 7 Ft. Super HD Cone Crusher  ery g crus ng orce capability with the advantages of  modern hydraulics First unit tested starting in 1985 The MP800 was introduced in of the MP1000 Over 200 MP cones produced 17-19 Noviembre 2010, Santa Cruz-Chile

The HP™ Series Cone Crusher  The HP cone crusher was

It now includes the HP100, HP200, HP300, HP400, HP500 and HP800 size crushers

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HP700 and HP200

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The HPX Series Cone Crusher  The HPX Series crushers have larger throw and higher  it ideal for fine crushing applications The power rating for a given machine size is increased by 30% over the same size HP

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The next evolution: o r er g

cone crus er 

MP1000 and MP800 ¾

Using the proven Symons principle of crushing, the new MP1250 builds on the high pivot point and increased throw concepts to further  enhance crusher performance

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The benefits of the MP1250 can be obtained in either a new crusher or retrofit kit to existing MP1000 crushers

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Nor ordb dbe erg MP™1250 cone crusher  New Features ncrease

ow ower

apac y

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Redesigned Mainframe

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Reduced No-Load Head Spin eavy

uty

ounterwe g t

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Sleeved Eccentric

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Gradation Auto-Setting (Optional) mprove

ramp

e e

ystem

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Higher Speed Bowl Adjust

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Improved Drive Ring Brackets

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New Mantle Locknut

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Nor ordb dbe erg MP™1250 cone crusher  Increased Power and Capacity

Higher Fulcrum Point Increased Throw

¾ Up to 30% Increase in capacity ¾ Increased power to 1250 hp ¾ More work performed in each crushing cycle

¾ More efficient use of power 

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Nor ordb dbe erg MP™1250 cone crusher  Improved Mainframe

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Same footprint as MP1000

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Reduced stress concentrations

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Less than 1% weight increase

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Nor ordb dbe erg MP™1250 cone crusher  Reduced No-Load Head Spin ¾

Patent Pending design of Socket and Upper Head Bushing

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New design reduces no-load head s in with ithout out th the an anti-s ti-s in mech mechan anis ism m

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Nor ordb dbe erg MP™1250 cone crusher  Head Spin Comparison

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MP1250 without new socket es gn

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MP1250 with patent pending new soc e es gn

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No anti-spin mechanism

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No anti-spin mechanism

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Nor ordb dbe erg MP®1250 cone crusher  Heavy Duty Counterweight and Guard ¾

Unique, heavy-duty counterweight limits unbalanced dynamic forces (patent pending)

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One-piece guard bolts on for easy replacement

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Tight tolerance guard also restricts debris from entering underneath the head

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Nor ordb dbe erg MP®1250 cone crusher  Sleeved Eccentric

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Increased throw eccentric

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Improved bearing surface finish

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Protects eccentric in overload con ons

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Reduced replacement costs, if  necessary

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Nor ordb dbe erg MP®1250 cone crusher  Gradation Auto-Setting System (Optional) ¾

Eliminates the need for frequent

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Continually monitors product size

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 Automatically adjusts the crusher 

More consistent crushing operation and product output

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Nor ordb dbe erg MP®1250 cone crusher  Improved Tramp Relief System ¾

Constant pressure / force limited

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Fast-acting relief valves to minimize pressure spikes during tramp events

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Nor ordb dbe erg MP®1250 cone crusher  Improved Bowl Adjust System Utilizes (3) hydraulic hydraulic adjust motors ¾ Utilizes rather than (4)

¾ 30% faster bowl removal & adjustment ¾ Faster hydraulic re-pressurization ¾ Reduced maintenance

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Nor ordb dbe erg MP®1250 cone crusher  Improved Drive Ring Brackets

¾ Replaces roller bearings

Wear Pad

Increa ease ses s lon lon evit evit ¾ Incr

¾ Impervious to the elements ¾ Reduces maintenance time (no greasing)

¾ Reduces maintenance costs

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Support Bracket

Nor ordb dbe erg MP®1250 cone crusher  New Mantle Locknut

ac - o s y e oc ng nu ¾

Only basic hand tools required!

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Constant holding force

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Quick & easy installation and removal

Jack-Bolts

Thrust Plate

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Nor ordb dbe erg MP®1250 cone crusher  TC-1000 Automation System Features Com lete lete cru crush sher er sta stati tion on cont contro roll ¾ Com

¾ PLC control is adaptable to any crushing plant application ¾ Overload warning and protection asy o rea

u co or

sp ay

¾ Simple navigation through user-friendly screens ¾ Liner wear detection without leaving the control room ¾ Integrated feed rate control based on power and cavity level utilizing multiple PID loop calculations

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Nor ordb dbe erg MP®1250 cone crusher  TC-1000 Automation System Functions

¾ Lubrication System ¾ Crusher main drive motor  ¾ Feed device ¾ Upstream and downstream

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Nor ordb dbe erg MP™1250 cone crusher  Retrofit Kit

¾  As few as five new parts are required per retrofit

¾ Machines designed for anti-spin will also require a new socket

¾  Anti-spin device must be removed, if applicable

¾ Existing motor (1000 hp) may be used depending on application details and amperage draw

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Nor ordb dbe erg MP®1250 cone crusher  Retrofit Kit

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 Anti-spin designed machines also require a new socket Foundation analysis required to confirm safety factor  recommended

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