if i wanted to build a jaw crusher...

[Scooby074]

I have a little info to add to your build. I worked as a mechanic for a company that sold them, however i usually worked on screens, so i dont have alot of knowledge of the crushers.
Heres a link to a PDF with some good cut away images of eccentrics and the lower jaw mechanism. It might help with your design.

http://www.miningandconstruction.sandvik.com/Sandvik/0120/Internet/Global/S003713.nsf/Alldocs/Products*5CCrushers*and*screens*5CJaw*crushers*2ACJ211/$file/Sandvik%20Jaw%20Crushers_EN.pdf

On a related note, i looked up the company that i think you work for Translated version of http://www.werklust.nl/ Is that correct? If so your machines have some very unique features. I especially like the swivel loader arms on the material handlers and loaders "Zwenkladers? " like the sl655. Good Designs.

 

[Renze]

Scooby, how did you figure the company i work for ? i cant remember i said it here.. on the other hand, Holland has only one manufacturer of heavy duty loaders, so finding that wouldnt be hard either...

Anyways, the Paus light duty swivel loaders, we are a dealer for them. We only build the bigger 10.5 to 17.5 ton models, the heavy duty ones.

The 12 ton hydrostatic Paus swivel loader didnt comply to the standards that a Werklust customer expects: Werklust loaders will spin all 4 tires on a dry concrete test track with a full bucket of ballast, the hydrostatic loaders dont give anywhere near that traction power. we stopped selling this 10/12 ton model and are developing our own 10 and 12 ton swivel loader models. Development started way before i began to work there 2 months ago, so i havent been involved in the design (yet). The prototype is under construction, and when its done, i will have to do the final production drawings.

This type of machine is very popular at pavement companies that pave with bricks: unlike other countries, Holland doesnt pave small roads and yards with concrete, crushed rock or asphalt, but with 10x20x7 cm paving stones because all our utility lines are mostly underneath the pavement.

Thanks for helping me out with the design: i see Sandvik uses double row spherical roller bearing.. SKF recommends them on their website for steel mills and other low rev, high load applications... i will dig into bearings later, first i need a housing design..

 

[Scooby074]

Werklust loaders will spin all 4 tires on a dry concrete test track with a full bucket of ballast,

Very impressive. I used to work on Volvo Construction Equipment, but i never had the guts to try that on dry concrete.

Holland doesnt pave small roads and yards with concrete, crushed rock or asphalt, but with 10x20x7 cm paving stones because all our utility lines are mostly underneath the pavement.

Thats an interesting idea.I can see how that would benefit the utility companys. It also would be beneficial to highway repair with the stones standard size, although i dont suspect your roads get as damaged as ours do over the winter.

Thanks for helping me out with the design: i see Sandvik uses double row spherical roller bearing.. .

No problem. I cant wait to see the pics of the completed unit! Sorry i didnt have any real hands on information to give you. I do remember assisting one of the guys with a bearing once... heavy and expensive

I tracked down your company via a discussion here on TBN where you mentioned one of the loaders you manufacture , i hope you didnt mind.

 

[Renze]

Very impressive. I used to work on Volvo Construction Equipment, but i never had the guts to try that on dry concrete.

We are building a product for our local Dutch market only: Dozers and graders are rare in Holland, all this work is done with the 10 to 15 ton class of universal loaders with bucket quick attach. Also a typical Dutch thing is using a wheel loader with a jib mast, a wheel loader can drive with a load, which a boom truck or AT crane cant. Working a jib with a loader with Z-kinematics is a real pain because it gives poor control of the implement tipping. Our parallel loaders give a strong tipping torque in the entire tipping range. Also, a Werklust has a lot of force when the bucket is fully tipped: If wheel traction doesnt help anymore, agricultural contractors can get their silage trailers unstuck by hooking a chain to the Werklust fully tipped out bucket, and just roll the bucket back.

The high tractive force also has to do with what a loader is used for in Holland: Silage pit rolling requires an efficient driveline: Off course, spinning 4 wheels on a concrete test track with ballast, isnt a real life situation, but on dirt, it can generate 100% of its traction for extended periods of time, without overheating the converter or transmission.

Thats an interesting idea.I can see how that would benefit the utility companys. It also would be beneficial to highway repair with the stones standard size, although i dont suspect your roads get as damaged as ours do over the winter.

paving stones are used only on small slow traffic roads (speed limit 60 km/h) However the county has paved asphalt over worn out existing country roads, because the manual labour is getting expensive, its hard work.

I wouldnt bet on it, that your roads suffer more during winter than ours: I dont know where you live in America, but at our family in Canada when it starts freezing it keeps freezing. In Holland we have many days that are thaw, with freezing nights. Its the freeze/thaw cycle that cracks up roads, every day the water sinks into the crack, at night the water freezes and the crack is pushed a little wider...

I tracked down your company via a discussion here on TBN where you mentioned one of the loaders you manufacture , i hope you didnt mind.

No i dont mind, its just that i want the freedom to express my personal opinion on things, when i get known as "the Werklust engineer" people will take my opinion for as i was speaking for the company. I mean, when i am asking around about a specific type of loader (which is mostly just personal interest) people could easily draw their own conclusions from it... The world is very small and rumors take off fast, especially over the internet.

Off course i am proud of having the one but best job in the world, but i'd like to keep that separate from my hobbies, like TBN and building machinery.

 

[Scooby074]

I wouldnt bet on it, that your roads suffer more during winter than ours: I dont know where you live in America, but at our family in Canada when it starts freezing it keeps freezing. In Holland we have many days that are thaw, with freezing nights. Its the freeze/thaw cycle that cracks up roads, every day the water sinks into the crack, at night the water freezes and the crack is pushed a little wider...

I live in Nova Scotia, Canada so im quite familiar with the freeze/thaw cycle and the damage it does to our roads.Concrete "paving" is the answer, but the provincial government has only done test sections (which are holding up quite well) and wont commit the money to make concrete the standard for new construction. They'd rather patch old asphalt than fix the problem withe concrete. Front end alignments are almost as common as oil changes on vehicles in the spring.

Thanks for the insight on how things are done differently in Holland. Its interesting to see how loaders are used as tool carriers over there. This concept is beginning to take hold here in Canada. Most companies in my experience run a limited number of attachments, basically just forks, blades (snow) and sweepers with the odd non-hydraulic jib and small surface miller thrown in. There is still lots of potential here.

 

[Zork]

Well this sounds like an interesting project!! I have more rocks than any one person should be allowed to have,, the biggest problem with them is they are totally useless, not big enough for anything and not small enough for anything,,,, now if I could crush them into a useful size at least I could use them on the driveways instead of paying to have them removed and paying to have stuff brought in. Whatever ideas anyone has I'm all ears! Unless it involves swinging a hammer to bust them up,, not into that idea.

Well now..... The sizes you mention here are just the right size many of us are looking for. The size you describe are just small enough to walk over and/or through, and just large enough to say we twisted our ankle on them and had to return to the living room to watch TV....LOL

 

[Crazy Canuck]

Sorry to bring up an older subject, but I am wondering how the jaw crusher has been progressing or if the project ever got off the ground. I am semi interested in this as I always have a need for an extra load of gravel and have an endless supply of rocks. I thought i could have a use for something like this and enjoy the challenge of designing and building a new project. I am basically looking to get information before investing a bunch of time of $$ into something like this.

 

[Renze]

No, no progress...

I did get an offer from someone who is interested in selling the drawings of his former business, of commercial sized crushers.

It requires a bunch of steel to do it well, i dont want to invest my money into a hand-fed flimsy thing. If too little is spent, it will be a "not good, cash gone" project. If i do it right, i'll blow my savings on 3 ton of machined steel, which is not worth it.

As some other members might remember, i have some projects to finish:

-finish my new muck spreader
-rebuilding the engine, and painting my 3011
-finish my tractor scraper/grader
-finishing the dirt buggy
-convert the JF straw chopper and Jeantil feeding bin, into a straw bale processor

 

[bearmtnmartin]

I saw this thread and it reminded me that there is a guy on heavy equipment forum that built one. It fit in his pickup. I think he uses it for concrete on building sites. I think he was posting about a JCB 1x skidsteer backhoe. I will try to find it later.

 

[slowzuki]

Hi Renze, just found your thread from outside doing google searches on jaw crushers. I sure wish I had one, I have endless rows of rocks in my fields and piled around the perimeters.

Looking into it further, an FAE type 3 pt hitch stone crusher would be a faster solution in my fields, not requiring collection.

 

[littlejohn2009]

I too grew up with a gravel operation. The use of a jaw was to crush the larger rock 12" plus, into about a 3-4". That product was fed into a roll crusher.

Using a jaw will require strong iron, as there is a significant impact. I remember when a particularly hard rock would enter the jaw there was a lot of banging. Jaw surfaces are also curved. As it was mentioned the rotating movement is in a manner to feed the rock into the jaw, but occasionally and hard rock, would fall in and be squeezed back out, propelling into the air.

The roll crusher is less stressful as the material is fed and into a small space between 2 rotating rollers, vs being banged together.

I would explore the roller idea before the jaw if I could as i think there will be less maintainaince .

In any case..good luck with your interesting project.

 

[charlz]

Old thread but I guess still a potential project. Not much technical info but maybe this will be of interest as it talks about the operation/testing of small crushers:

SDTDC Pubs, Portable Rock Crusher for Trails, 0423 1301

 

[littlejohn2009]

opps...I see that someone bumped it and I got caught.

It is an interesting subject, but only for those where gravel is expensive. Here its cheap enough to buy..its delivery that costs.

 

[Redneck in training]

I remember seeing a rotary hammer rock crusher that was pulled behind a potato harvester. It pulverized the rocks to sand size pieces before they were discharged back to the field. Don't remember the design details.

Simlar crushers/pulverizers are used to pulverize coal in a power plants.
Coal mixed with flue gases (no oxygen there) enter axialy from sides and is crushed. Since the crusher also works as a blower pulverized coal is blown upward. The bigger pieces have to much energy to make a turn around a baffle installed in the duct and are bounced back to the mill. Small and light pieces (powder) make the turn and are blown to the burner.

 

[red rhino crushers]

There are models available from the UK, a small one that weighs around 740kg with an opening of roughly 16" x 6.5" that runs off either donor vehicle hydraulics (roughly 5-6TPH), a power pack or a 3PL system + a larger version with a jaw opening of roughly 20" x 10" weighing approx 1650kg - again as a stand alone unit run from a donor vehicles hydraulics or as a standard 3PL system (roughly 14-15TPH).

Both can handle rebar, stone, blocks, bricks, flint, kerbstone etc...

 

[red rhino crushers]

This guy has the 3000 series mounted to a quick hitch for a skid steer instead of the 3PL mounts, he did 120 tonnes in 7 hours!

YouTube - ‪Steve Downey - Building Services - Lincoln - Red Rhino - Bobcat‬‎

 

[atgreene]

I want to build one as well. I have access to flywheels and cranks from large one-lung gas engines and am trying to piece one together from those. The jaw plates I figure can be bought at any industrial/excavation supply place. By using existing plates they then can be replaced, saving manufacturing each time they wear out.

I used to run an old Pioneer, and the prospect of building one is apealing. Keep us up to date if you get a prototype built.

 

[Renze]

Been thinking of this since 2008, but I am planning to actually start the build next winter: this winter i am busy moving my workshop from my birth farm barn to the new place i rent next to my appartment. It would give me more time to work on my own projects, instead of servicing and repairing the stuff on the farm..

I read a lot of thesis and scriptions of science engineers around the world, from Germany, UK, to India. These students all tend to simplify the load to laboratory conditions, but it does get me up to date with the rock fracture mechanisms: point loaded rocks dont fail by comrpession, they fail because the pulverised material beneath the contact area acts somewhat like a fluid, it transfers the compressive force to the sides, causing the rock to split because its tensile stress is exceeded. Crushing a concrete ball with a 20n/mm compressive strength and 300mm diameter requires only 18 ton, because the tensile strength is 1/10th to 1/15th of the compressive strength. However in the real world we dont crush round balls, in Holland we hardly have natural rock so it will crush concrete slabs and kerbstones, which may contact the jaw on all 10 ribs if it is a square piece of concrete.

the point where i'm getting stuck is how ten vertical ribs of the crusher, would create a rock fracture perpendicular to the jaw ribs... Even if the rock doesnt break, the crusher with 10 ribs of 20mm wide, and a 30mm throw, would push 82mm of the rib into the rock, resulting in a 34 ton load in 20N/mm2 hard concrete (standard industry floors are 15 N/mm2)

Can anyone point me in the right direction ? I would rather use knowledge already there, than to overbuild and then find the real load by holding the bearings on by shearbolts, to get an idea of real world load conditions, so i can calculate how big the safety margin on the design strength actually is.
http://ethesis.nitrkl.ac.in/1483/1/...nalysis_of_Swing_Jaw_Plate_of_Jaw_Crusher.pdf

 

[CNC Dan]

Very nice job on the drawing! I have never seen one of these up close and am really interested in what the drive line would look like? How small would the crushed material be?

http://www.youtube.com/watch?v=DIwR7BZAnpg&feature=youtube_gdata_player

 

[Renze]

Maybe someone has access to a 15x24 or 13x20 inch jaw crusher and can measure the shaft diameter for me ? It would at least be a starting point for me. I would use the highest grade of shaft (CrMo4V) anyways, as 99% of the crushers use shafts of equivalent material.

Another thing i'm running into is bearings: i want to avoid roller bearings due to price and complication of design: Its not a mining operation, it just has to run a few days in the year.

SKF plain bushings dont cut it: they have high load capacities and sufficient slide speeds, but the online calculator deducts 80% of the capacity for operating near the slide speed limit, so there isnt much left. using wide bearings means bigger distance between shaft loadpoints, means more bend force means thicker shaft, means more bearing slide speed...

Old crushers used Babbitt bearings. What is the modern equivalent of a Babbitt bearing, RG7 bearing bronze, or RG12 ?