Stone crusher plant is the core production equipment in mining, quarry, construction waste recycling, and other industries, whether its operation is standardized, safe, and efficient, directly affecting the production efficiency, equipment life, and personnel safety. It is crucial to master the correct operation process and points. This article will provide you with a clear, practical guide to the operation of the crushing plant to help you maximize the use of your stone crushing plant.
Step 1: Inspect and Prepare Before Starting
Equipment body inspection:
- Looking: Are there any large foreign objects or a serious accumulation of material clogging the feed opening, discharge opening, and crushing chamber? Are there any cracks, breaks, or excessive wear (e.g., flat teeth) visible to the naked eye on the jaw plate/hammer head/impact plate/liner?
- Tapping: Tap with a hand hammer or use a spanner to check whether the big bolts of the main machine, motor, bearing seat, pulley, and other key parts are tight. Is there any sense of looseness?
Lubrication system check:
- Look at the oil level: Open the oil window or dipstick of each bearing and gearbox to check whether the lubricant/grease level is between the marked lines. Is the oil clear, with or without emulsification, blackening, or impurities?
- Check the oil circuit: Is there any breakage or leakage in the oil pipe of the automatic lubrication system?
Transmission system check:
- Look at the belt/chain: Is the tension of the conveyor belt appropriate (downward pressure with elasticity)? Is there any serious wear, cracks, or oil? Is the protective cover intact and well covered?
Hydraulic system check:
- Oil level/pressure: Is the oil level in the hydraulic tank normal? Is the pressure gauge zeroed before a cold start? Is there any leakage from the oil pipe joints?
Electrical system check:
- Look at the appearance: Is there any damage to the cables? Is there any burnt or loose terminal in the control cabinet?
- Test function: press the emergency stop button to confirm that it can cut off the power (need to be reset after release).
Feed/discharge system check:
- Look at the belt: Check whether the feeder and conveyor belt are intact and remove the accumulated material.
- Clearing the discharge channel: Is the discharge outlet and stacking area clear and free of obstacles?
Finally, make sure all guards, emergency stop buttons, and safety door locks are intact. At the same time, clean up the debris around the equipment to ensure that the operating channel is clear.
Step 2: Start-up Operation
Choose the stone crusher plant with a PLC integrated control system that can be started with one key, which is convenient and efficient, but you need to pay attention to the step-by-step process when starting.
Start the crusher host first:
- Start the crusher mainframe with no load first, make sure there is no material in the crushing chamber (check with naked eyes or listen to the sound of no material). Let the mainframe run at least 1-2 minutes with no load to reach a stable speed.
Then start the feeder:
- Start the upstream equipment first: start the vibrating feeder and the upstream conveying belt.
- Slowly and evenly feed the material: the initial feeding quantity is controlled at 30%-50% of the designed capacity, and observe the change of the current of the host. When the current is stable and lower than the rated current, then slowly and evenly increase the feeding amount to the normal range.
Note: Feeding must be continuous and even! It is strictly prohibited to put a large amount of material instantly! It is strictly prohibited to enter the super-large pieces (more than 80% of the size of the feed opening) or unbreakable materials (metal, wood)!
Step 3: Monitoring During Operation
Continuously listen to the sound of the crusher mainframe, motor, and bearing operation. If there is any abnormal metal friction, knocking, whistling, or violent vibration sound, immediately check or stop the machine!
Test meter readings:
Bearing Temperature: Main and motor bearing temperatures are checked hourly. If the temperature exceeds the value specified in the equipment manual (usually <70°C) or if the temperature rises too quickly, stop the machine immediately to check the lubrication and bearings!
Observe material condition:
Whether the feeding material is even and continuous, with or without oversized lumps or foreign materials.
Whether the discharge particle size meets the requirements. (If the aggregate suddenly becomes coarse, the liner/hammer head may be worn out or dislodged)
Monitor the operating environment:
Observe the equipment and the surrounding area for any abnormal smoke, sparks, or leakage.
During operation, the batching speed can be adjusted remotely according to the production progress to ensure production continuity. Of course, this requires the selection of a feeder equipped with an intelligent remote control system, such as the Andamine crusher plant.
Step 4: Shutdown Safely
The following steps need to be followed to ensure a safe shutdown of the equipment and to safeguard the safety of personnel and the good condition of the equipment:
- Stop the feeder: First, stop the vibratory feeder or upstream conveyor belt completely. Ensure that no new material enters the crushing system!
- Empty the crushing chamber: Let the crusher mainframe and discharge belt continue to operate. Wait for the sound of material crushing and emptying in the crushing chamber to become smaller and single. At the same time, observe the main motor ammeter and wait for the current to drop and stabilise near the no-load current value.
- Stop the crusher: After confirming that the crushing chamber is emptied (the current reaches the no-load value), press the stop button of the crusher machine.
- Stop the discharging system: After the main machine stops, stop the discharging belt conveyor under the crusher.
- Stop the auxiliary system: stop the dust removal equipment, etc.
- Cut off power supply: Finally, switch off the main power switch of the equipment.
Step 5: Work After Shutdown
In order to prolong the service life of your stone crusher plant and reduce the maintenance cost, it is necessary to carry out simple inspection and cleaning after shutdown.
- Check the crushing chamber: Wait until the equipment is completely stopped and the power is cut off before opening the inspection door to make sure there is no residual material or abnormality inside.
- Clean up the site: Clean up the material, dust, and oil on the surface of the equipment and the surrounding area. Clean up the spilled materials near the feeding and discharging ports.
- Simple Maintenance: Perform lubrication maintenance (filling lubricant/grease) for the shift according to the protocol. Tighten loose bolts found during inspection (to be done in a safe condition).
- Inspection of parts: Record the wear and tear of wearing parts (e.g., jaws, liners).
- Operation record: Record in detail the operation time, processing capacity, abnormal conditions during operation, reasons for stopping the machine, contents of inspection and maintenance, and status of wearing parts.
Following the above process can help you reduce unexpected downtime, extend equipment lifespan, lower maintenance costs, and ensure efficient production. If you have any other questions, please feel free to contact us at any time.