Tongli Impact crusher Introduction

An impact crusher is a type of crusher that uses impact energy to reduce the size of materials. Unlike other types of crushers that rely on compression, an impact crusher works by feeding the material into a rotating rotor, which is equipped with a series of hammers. As the rotor spins, the hammers strike the material, causing it to break into smaller pieces. The broken pieces are then thrown against a fixed plate or another rotor, where they are further crushed by impact and shear forces. The final product size can be adjusted by changing the speed of the rotor, the gap between the plate or rotor, and the type and shape of the hammers. Impact crushers are widely used in various industries, such as mining, quarrying, cement, limestone, gypsum, brick, concrete, gravel, and more. They can handle different types of materials, such as hard rock, soft rock, abrasive rock, non-abrasive rock, wet and sticky materials, etc. They can also be used as primary, secondary, or tertiary crushers, depending on the application and the desired product size. Impact crushers have some advantages over other types of crushers, such as high crushing efficiency, low operating costs, easy maintenance, and good product shape.

Tongli Impact crusher structure

The components of an impact crusher work harmoniously to achieve efficient material reduction through powerful impact forces. From the rotor’s dynamic impact to the blow bars’ crushing action and the purposeful design of the crushing chamber, each component plays a vital role in shaping the crusher’s overall performance. Proper selection, maintenance, and interaction of these components ensure optimal crushing outcomes, making impact crushers valuable tools in material processing.

Rotor:The rotor is the central component of an impact crusher. It consists of a heavy-duty shaft and a set of hammers or blow bars attached to it. The motor drives the rotor to rotate, and the hammers strike the incoming material, imparting kinetic energy and initiating the crushing process. The mass and design of the rotor ensure effective impact forces for efficient material reduction, making it a crucial component for the crusher’s performance.

Blow Bars: Blow bars, also known as impact hammers, are the striking tools that directly interact with the material. They have various shapes and compositions, designed to withstand the impact forces and abrasion during crushing. When the material enters the crusher, the blow bars deliver high-energy impacts, breaking it down into smaller sizes. The selection and condition of the blow bars directly affect the crusher’s efficiency and the quality of the end product.

Impact Plates/Breaker Plates: Impact plates, also called breaker plates or aprons, are located within the crushing chamber. They provide a surface against which the crushed material rebounds after being hit by the blow bars. Impact plates ensure efficient transfer of impact energy to the material, breaking it down further. Well-designed impact plates optimize material flow and distribution, enhancing the crusher’s productivity and particle size control.

Crushing Chamber: The crushing chamber houses the rotor, blow bars, and impact plates. Its shape and dimensions affect the trajectory and velocity of the material, impacting the crushing efficiency. The chamber’s design directs the material towards the blow bars, facilitating effective impact and particle reduction. A properly configured crushing chamber ensures optimal material flow, impact forces, and energy utilization for efficient material crushing.

Frame and Housing: The frame and housing provide structural support and protection for the internal components. They maintain the crusher’s integrity during operation, ensuring stability and safety. The housing encloses the rotor and impact plates, preventing material from escaping and reducing the risk of hazards. Additionally, the frame and housing facilitate access for maintenance and replacement of components, contributing to the crusher’s longevity and ease of operation.

Adjusting Device and Discharge Opening: An adjusting device, often in the form of hydraulic systems, regulates the crusher’s discharge opening. This adjustable gap controls the size of the crushed material and influences the final product’s particle size distribution. The ability to modify the discharge opening allows operators to produce different-sized materials for various applications. It enhances the crusher’s versatility and adaptability to specific processing needs.

Tongli hammer crusher design principle

Versatility in Material Processing: Impact crushers excel in processing a wide variety of materials, from soft and medium-hard rocks to abrasive and high-hardness ores. Their ability to handle diverse materials makes them suitable for various industries, including mining, construction, and recycling. This adaptability allows impact crushers to address a wide range of material processing needs.

Efficient Particle Size Reduction: Impact crushers achieve efficient particle size reduction through high-velocity impacts between the blow bars and the incoming material. This high-energy collision breaks down the material into smaller particles, producing well-defined and uniform end products. The controlled impact forces result in finer particle sizes with minimal oversize material, making impact crushers ideal for producing high-quality aggregates and consistent product sizes.

Cubical Shaping of End Products: Impact crushers are known for producing cubical and well-shaped end products. The controlled impact forces and the interaction between the blow bars and the material ensure that the crushed particles have consistent shapes. This advantage is particularly valuable in applications where particle shape influences the performance of concrete, asphalt, and other construction materials.

High Production Capacities: Impact crushers can achieve high production capacities due to their ability to handle a continuous flow of material. The rapid impact forces efficiently break down materials, resulting in high throughput rates. This advantage is especially beneficial for large-scale operations that require substantial material processing within a short period.

Ease of Maintenance and Serviceability: Impact crushers are designed with simplicity in mind, making maintenance and servicing relatively straightforward. Accessible components and well-designed access points facilitate routine inspections, wear part replacements, and general maintenance tasks. This ease of maintenance minimizes downtime and contributes to the crusher’s overall uptime and reliability.

Selective Crushing and Adjustable Discharge: Impact crushers offer selective crushing capabilities, allowing operators to adjust the discharge size according to specific requirements. By altering the distance between the blow bars and the impact plates, operators can control the product size distribution. This adjustability enables the production of various end-product sizes, enhancing the versatility and adaptability of impact crushers for different applications.

Specifications of tongli Impact crusher

Note: * Capacity based on material compressive strength 300MPa

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Zhejiang Tongli Heavy Machinery Manufacturing Co., Ltd (Formerly known as Tongxiang Coal&Mining Machinery Factory) established in year 1958 is a member of the Chinese National Building Material Machinery Association. Tongli is on the vendor list of designated production enterprise of the Ministry of Coal Industry. ISO9001、ISO14001、ISO45001 certified, accredited as High-tech & new technology enterprise of Zhejiang Province. With 65+ years of experience, Tongli has earned first class R&D and manufacturing capabilities, dedicated to provide satisfactory manufacturing equipments for global customers.   

Industry Knowledge extension

How can I troubleshoot common problems of impact crusher?

Check for blockages in the crushing chamber or discharge chute. Inspect the blow bars for wear or damage. Check the oil level and quality. Check for loose or damaged belts or pulleys. Consult with a qualified technician or equipment supplier if you are unable to resolve the issue.

What are some common applications of impact crushers?

Impact crushers are used in various industries, including mining, construction, and recycling. They are ideal for processing soft to medium-hard rocks and ores, as well as abrasive and high-hardness materials such as granite, basalt, and limestone.