The JLM Ingeniería impact crushers, MI model, are machines designed to reduce material size through the kinetic impact action of the rotating rotor against the material, causing the fragmentation of the fed material.
These machines account for more than 65% of the crushing equipment installed in the mining industry (quarries and gravel pits) and are also used in other sectors such as construction, recycling, and cement manufacturing.
Operating principle
The operation of the JLM Ingeniería horizontal shaft impact crusher involves the circular motion of the rotor, which consists of a shaft covered by steel paddles shaped like a drum, onto which replaceable wear plates called blow bars are attached.
The rotor is housed within a reinforced steel casing lined with wear-resistant steel, equipped with replaceable and adjustable impact plates.
Rocks enter the crusher through the feed opening and fall onto the rotor, which propels them against the impact plates, causing their fragmentation. This breaking process is repeated until the fragmented rock is small enough to pass through the gap between the impact plates and the blow bars.
Types of impact crushers
The impact crusher is considered the backbone of the grinding sequence in many industrial processes.
Its use depends on the maximum input size and its placement in different stages of the production process, resulting in the following types:
- PRIMARY Impact Crusher. It is fed with large-sized material and operates at low speed with an oblique feed. The final product typically has a particle size between 0 and 250 mm.
- SECONDARY Impact Crusher. The input material dimensions are around 350 mm, producing final products ranging from 0 to 80 mm.
- TERTIARY Impact Crusher. This is the last stage in the grinding process. Its feed can be oblique or vertical, and the final product size ranges between 0 and 20 mm.
At JLM Ingeniería, our product catalog includes the MI model secondary impact crusher. The material dimensions at the feed opening range from 250 to 400 mm, achieving production rates between 80 and 400 tons per hour, depending on the specific model.
Components
The JLM Ingeniería impact crusher consists of the following elements:
- Rotor. A rotor with blow bars, whose dimensions vary depending on the model.
- Blow Bars. Made of manganese Steel and crome (Mn13, Mn18).
- Impact Plates. Located inside the housing, these interact with the material projected by the rotor, creating a secondary impact and further reducing material size. They are easy to install and remove and can be adjusted to control the product size.
- Housing. Made of high-strength structural steel, designed to withstand the impact forces generated by the rotor and prevent deformation. It offers easy access for maintenance and cleaning.
Control parameters for the JLM Ingeniería horizontal shaft impact crusher
The control and maintenance of the JLM Ingeniería MI model crusher, like any impact crusher, is essential to ensure optimal performance, prolong the lifespan of its components, and minimize downtime.
These essential maintenance practices can be divided into:
Daily Inspections
These regular inspections are critical for detecting potential issues before they escalate into significant failures. For the MI model:
- Inspect the wear of the blow bars: Check for uneven wear, cracks, or fractures in the bars. Ensure they are firmly secured to the rotor.
- Condition of the impact plates: Verify wear levels. Confirm that the distances between the plates and the rotor meet specifications (proper adjustment to ensure the desired output size).
- Lubrication: Inspect rotor bearings and check lubrication levels.
- Check for abnormal vibrations: Abnormal vibrations may indicate uneven wear, rotor misalignment, or material build-up in the chamber.
- Cleaning: Avoid the accumulation of dust, crushed material, or debris inside the housing to prevent blockages and unnecessary heat.
Periodic Maintenance
These tasks should be performed weekly, monthly, or quarterly, depending on the equipment’s usage level.
- Rotor wear: Inspect the edges of the rotor and the mounting slots. Repair or replace worn or damaged components.
- Readjust the impact plates: Confirm and adjust the position of the impact plates to maintain efficient crushing. Check that bolts and fastening systems are tight.
- Inspect bearings: Clean and re-lubricate the bearings. Inspect bearing clearance; excessive clearance may indicate internal wear.
- Condition of belts and pulleys: Check the tension and alignment of the drive belts. Replace worn belts to avoid energy losses.
- Inspect the hydraulic adjustment system (if applicable): Check hydraulic fluid levels and inspect for leaks in hoses or cylinders. Ensure the plate adjustment system operates smoothly.
Long-term Maintenance
This type of maintenance is performed after a significant number of operating hours or during scheduled shutdowns:
- Complete replacement of blow bars and impact plates: Replace blow bars and plates when wear is extreme or performance standards are no longer met. Always use original parts recommended by JLM Ingeniería to ensure optimal performance.
- Rotor inspection: Check rotor balance using appropriate tools. Make adjustments or replacements if it is not balanced.
- Housing inspection: Inspect the housing for cracks, deformations, or hardened material build-up. Replace damaged parts.
- Comprehensive inspection of the transmission system: Check the condition of the electric motor, couplings, and protection system.
Industrial applications
The industrial applications of the JLM Ingeniería impact crusher, MI model, include:
- Mining Industry: Processing hard minerals such as coal, phosphates, and bauxite.
- Recycling Industry: Size reduction of debris, bricks, and concrete.
- Construction Industry: Production of manufactured sands. Crushing rocks such as granite, basalt, and limestone.
- Cement Industry: Secondary crushing of limestone and clay. Preparation of materials for grinding with ball mills.
Specific advantages of the JLM Ingeniería impact crusher
- High energy efficiency.
- Versatility due to its ability to process materials with various properties.
- High crushing efficiency, achieving uniform product sizes with the possibility of controlling the output size through simple adjustments to the impact plates.
- Compact and robust design that allows integration into existing production lines and is designed to handle abrasive and hard materials.
- Simplified maintenance with easy access to replaceable components, minimizing downtime to the fullest extent.
