山特维克破碎机ASRPlus

1. 山特维克公司及物料搬运技术简介山特维克公司是一家总部位于瑞典的高科技集团公司。

山特维克矿山工程机械是全球除卡特彼勒以外的第二大矿山设备供应商。

包括露天矿山、地下矿山和工程机械等三个主要的业务领域。

同时，山特维克是全球最大的散料移动设备供应商之一，代表了当今最为先进的设计自造水平。

在全球重要的矿山、堆场、港口和电厂等都有他们提供的设备。

近年来在结合了德国Aubema、芬兰Roxon和巴西的MGS等知名公司后公司的规模和综合实力得到了迅速提升。

在过去五年内向全球销售了多达121台移动散料搬运设备。

近年山特维克矿山领域业绩中较为有特点的有：向巴西淡水河谷销售的两台大型全移动破碎机；泰国Mea Moh煤矿的半连续工艺包括4台半移动站、两台万吨排土机和14公里胶带运输机在内的系统总包工程；全球最大的紧凑型斗轮挖掘机；全自动化无人驾驶的大型悬臂斗轮取料机等。

并且在中国山特维克公司近年来向中国用户提供了几乎所有的大型排土机、同时也是中国主要半移动破碎站的主要供应商。

图一，全球最大紧凑型斗轮挖掘机和与其配套的大型转载机图二 巴西淡水河谷定购的山特维克专利产品全移动破碎站图三泰国Mae Moh煤矿使用的山特维克大型排土机产能达到22000t/h2.2 山特维克全移动破碎站斯蒂芬先生着重介绍了近年针对平朔东露天等大型矿山开发的专利产品山特维克PF300全移动破碎站。

该破碎站总结了现有移动破碎站的优缺点，充分考虑了与大能力上游电铲和下游转载设备的配合使用，是为平朔东露天等大型煤矿定制研发的产品，该破碎站主要特点为：2.2.1．四履带底盘结构2.2.1.1 4履带的均衡底盘布置彻底解决了双履带底盘过小、无法承受电铲，特别是大型电铲（如PH4100等）卸料冲击载荷的造成破碎站摆动和底盘局部受力过大问题。

图四. 四履带底盘系统稳定支撑料仓受料端和破碎机2.2.1.2采用4履带驱动支撑底盘系统，实现真正的稳定全移动性能。

KEY FEATURESNew generation world-class Automation & Connectivity System (ACS)Automatically adapts the crusher to varying feed condi-tions ensuring maximum 24/7 performanceHydroset™ system Provides safety and settingadjustment functionsMainframe is built as a unibody without moving parts For optimal strength and less components requiring maintenanceTop serviceability Lifting from above minimizesrisks, and allows for quicker andsafer maintenanceAdjustable eccentric throw To exactly balance capacity tothe process thus harmonizingthe crushing stagesConstant liner profile Maintains the feed opening andperformance during the entireservice life of the linersWide range of crushing chambers suited for all types of applications Choose from extra coarse crushing chambers with the largest intake to extremely fine crushing chambersMechanical dump valve for tramp iron protection Reduces pressure peaks and mechanical stress on the crusher, greatly improving reliabilityFull lubrication monitoring and control Real-time monitoring of the crusher lubrication system for increased uptime and reliabilitySandvik CH840i is a technologically advanced, high capacity mid-range cone crusher for secondary and tertiary crushing, designed for crushing applications in mines or large sized quarries.Each crusher has a hydraulically supported main shaft which is supported at both ends. With a robust design, adjustable eccentric throw, a constant intake opening, high performance can be achieved by proper selection of a Sandvik OEM crushing chamber. The CH840i brings you a revolution in intelligent crushing. Connected via the My Sandvik portal,it offer 24/7 access to data generated by your connected Sandvik crusher fleet. Now you can make decisions based on facts, and clearly see areas where you can improve uptime and productivity. My Sandvik also gives you access to manuals and ane-commerce platform for easily and efficiently buying and reordering wear and spare parts. It lets you track and trace parts online to make maintenance planning simpler.The CH840i comes with the new generation Automation and Connectivity System (ACS) as standard. The system continuously monitors and optimizes crusher performance and controls the complete lubrication system, increasing uptimeand reliability. It can automatically adjust crusher settings to compensate for crushing chamber wear, ensuring consistent product size. Hydroset™ and the advanced dump valve automatically provide overload protection to let tramp iron or other uncrushable material pass through.Bolted rather than welded top and bottom shell liners reduce maintenance time and are much safer. It’s 90% faster to change liners compared to welding. The improved over-pressure system with dedicated air channel inlets keeps dust out to increase reliability. The standard off-line filter unit keeps lubrication oil cleaner with 24/7 fine filtration, reducing wear on your internal crusher components and extending oil life by up to 5 times.GENERAL DESIGN CRITERIA Crusher type Cone crusher, hydraulically adjusted Application Minerals processingCrushing stage Secondary, tertiary, quaternary Max. feed size 250 mm CSS range 10-48 mm Nominal capacity*103-427 mtphAmbient temperature -20°C to +40°C(Contact Sandvik if outside range)Altitude of site≤ 2,000 m(Contact Sandvik if outside range)* Capacity and possible CSS is dependent on the crushing chamber, the eccentric throw, the crusher’s setting and the feed material’s bulk density, crushability, size analysis, moisture content, etc.GENERAL CRUSHER DATA Weight 20,278 kgMain frameTwo-part unibody structure without moving parts.Cast steel.Top shell Two-arm design Bottom shell Five-arm designTwo inspection hatches Feed hopper Rubber / steel lined steel hopper Two inspection doors Feed level sensor Vegapuls 67Main shaftSupported at both ends Top spider bearing and eccentric bearing Eccentric bushings (Throws – mm)• 28, 32, 36• 36, 40, 44• 44, 48, 52Eccentric speed327 rpm (50 Hz, SPC-belt)332 rpm (60 Hz, SPC-belt)331 rpm (60 Hz, 8V-belt)Max. motor power 330 kW DriveV-Belt or DirectSafety coupling Omega (for Direct drive option)Pinion shaft speed1,470 rpm (50 Hz, SPC-belt)1,494 rpm (60 Hz, SPC-belt) 1,491 rpm (60 Hz 8V-belt)SubframeWith rubber dampersMaintenance tool boxExtractor for eccentric bushing Extractor for bottom shell bushing Extractor for step bearingAdditional lifting and maintenance tools includedGENERAL INFORMATIONMOTOR CHARACTERISTICSManufacturer WEG Model W22/HGFType Three-phase, squirrel cage Weight 1,850–2,650 Kg Rated power330 kW Frequency 50/60 Hz Poles4Vibration resistanceMotor is supplied with special winding that is reinforced in order to support the vibration levels Insulation class F Protection classIP55MECHANICAL DUMP VALVE System descriptionMechanical spring loaded hydraulic valveSYSTEM CHARACTERISTICS Type Dust seal air pressure Air input Blower Air quality Filtered Air flow <70 m³/h Air pressure<10 kPa Weight (blower, hoses)25 kg Motor power 0.75 kWMotor speed 2,800 rpm (50Hz) 3,350 rpm (60Hz)Phases 3Insulation class F Protection classIP55CRUSHER DRIVE SYSTEMCRUSHER DUST EXCLUSIONCRUSHER TRAMP IRON PROTECTIONUPPER FEED HOPPERNo. of rubber liners 16Max. weight 8 kgMaterialSandvik WT6000 rubber Fastening methodBoltedCONE LINER No. of rubber liners 20Max. weight 9-10 kg / 4-5 kgMaterialManganese steel or Sandvik WT6000 rubber (option)Fastening method BoltedTOP SHELL SPIDER CAP Max. weight 198 kg MaterialCarbon steelFastening methodBolted seal with O-ringTOP SHELL ARM SHIELDS No. of shields 2Max. weight 84 kgMaterialManganese steel Fastening methodBoltedBOTTOM SHELL BODY LINERS No. of liners 10Max. weight 16-24 kg / 5-7 kgMaterialWear-resistant hardened steel or Sandvik WT6000 rubber (option)Fastening methodBoltedBOTTOM SHELL ARM LINERS No. of liners 5Max. weight 80–83 kg MaterialManganese steel Fastening method Bolted (welding*)CRUSHER WEAR PROTECTIONCRUSHING CHAMBERS Mantle alternatives A, B, FlexiFeed B Concave alternatives EC, C, MC, M, F Alloys for mantles and concaves M1, M2, M7, M9Mantle and concave backing materialPlastic free, metallic contactLifting tools for mantles and concavesAvailable as option *No main frame weldingMONITORING FUNCTIONS Main/secondary lubrication circuit dataOil temperature Oil flowOil pressureOil tank temperature Oil levelDifferential pressure across filter Pinion shaft lubrication circuit dataOil pressureDifferential pressure across filterOver-pressure air system Filter monitoring functions Offline filter statusOPERATIONAL FUNCTIONSOil heatersMain lubrication oil pump Pinion lubrication oil pump Over-pressure fan Air/oil coolers Offline filter functionsELECTRICAL HARDWARE Lubrication controlConnection modules tank Cable kit CABINET DIMENSIONS Lubrication control cabinet (LxHxD)1200x800x250 mmHYDROSET SYSTEM System designSingle reversible pump Oil tank reservoir capacity 85 liters Pump design Gear pump Pump capacity10.4 l/min @50 Hz 12.6 l/min @60 HzOil filter Filter type Spin-on Filtration grade 10 µm Filter materialGlass fiber No. of filters 1Pump motor Type Three-phase, squirrel cage Power 3 kW @50 Hz 3.6 kW @60 Hz Speed 1,500 rpm @50 Hz 1,800 rpm @60 Hz Poles4Insulation class F Protection classIP55GENERAL DATAOil tank reservoir capacitySupplies oil to the main lubrica-tion system, Pinion lubrication systems and to the Hydroset system.No. of doors3No. of inspection hatches 2 located on top of unit Cabinet materialMetalTank unit dimensions (LxWxH)1,980x1,130x2,000 mm Dry weight865 kgMAIN CRUSHER LUBRICATION SYSTEM System designClosed circuit, single pump, gravity return Oil tank reservoir capacity 400 liters Pump design Gear pump Standby pump N/APump capacity112 l/min @50 Hz 135 l/min @60 HzOil filters Filter type Filter element insert Filtration grade 25 µm Filter material Glass fiber No. of filters1TANK UNITLUBRICATION CONTROL (ACS)SETTING REGULATIONSOFTWARE PACKAGE (OPTIONAL)PINIONSHAFT LUBRICATION SYSTEM System designClosed circuit, single pump, gravity return Oil tank reservoir capacity52 liters Pump design Gear pump Pump capacity0.9 l/min @50 Hz 1.1 l/min @60 HzOil filter Filter type Spin-on Filtration grade10 µm Filter material Glass fiber No. of filters 1Pump motor Type Three-phase, squirrel cage Power 0.12 kW @50 Hz / @60 Hz Speed1,500 rpm @50 Hz 1,800 rpm @60 Hz Insulation class F Protection classIP55OPERATOR’S PANEL Dimensions (LxHxD)316X251X72.5 mm Weight3.5 kgOperational temperature -25°C to +70°C Protection class IP65Power supply10–30 VDCMONITORING FUNCTIONS(AVAILABLE WITH METRIC AND IMPERIAL UNITS)Energy consumption Hydroset hydraulic pressure Main shaft positionCalculated CSS (based on main shaft position)Lubrication oil temperatureTemperature close to the spider bearing Liner wear Historical data logAutomatic liner wear compensation (Only available for CH-models)AUTOMATION & CONNECTIVITY SYSTEM (ACS) REGULATION FUNCTIONS (CRUSHING MODES)CSS (Auto CSS)Keep CSS constant Peak Pressure (Auto Load)Keep load constant Multi-CSS (Multi – CSS)Alternate between two CSS settings10 customized programs can be storedOTHER FUNCTIONS & CABINET DIMENSIONS Push button box for manual setting of CSS Setting regulation cabinet (LxHxD)1200x600x250 mm Connection box crusher (LxHxD)600x350x155 mm Network repeater box (LxHxD)(Recommended for distances over 100m)300x300x210 mmSAFETY FUNCTIONSProtects the crusher from overload by automatically regulating the crusher based on preset operational limits and the real-time input from the crusherAlarm severity levels: Direct Stop, Sequential Stop, Feeder stop, Notices and EventsSignal permitting operation of the crusher drive motor Alarm logELECTRICAL HARDWARE Setting regulation control Power measurement unit Customer interface gateway Connection box crusher Cable kitPump motor Type Three-phase, squirrel cage Power 4 kW @50 Hz 4.8 kW @60 Hz Speed1,500 rpm @50 Hz 1,800 rpm @60 Hz Insulation class F Protection class IP55Oil heaters No. of heaters 2 (Optional 3)Type Immersion heater Rating1.65 kWInstallation typeImmersion heater tube Phases3Communication gateway interfaceControlNet DeviceNet Ethernet/IP Modbus TCP Profibus ProfinetWINiOperating system compatibility:Windows 10, Windows 8, Windows 7, Windows Vista, Windows XP, Windows 2000Simultaneously control up to 9 different crushers with ACS from a PC via Ethernet networkControl the ACS remotely using the same graphical user interface ACS ReporterExport data from theAutomation & Connectivity System to a PC for analysis and storageOFFLINE FILTER UNIT FOR MAIN LUBRICATION MANUALSPurposeRemoves particles and water from the main lubrication system in a continuous slow offline filtration process Model 27/54Oil capacity20 litersDimensions (LxWxH)650x450x1,055mm Weight 100 kg Pump designGear wheelOil filter Filter type Filter Insert Filtration grade 3 µm Filter material Cellulose Filter housing material Cast iron No. of filters 2Pump motorType Three-phase, squirrel cage Capacity 200 @50 Hz 240 @60 Hz Speed915 rpm @50 Hz 1,120 rpm @60 Hz Protection classIP55Operator’s manual Any language Installation manualAny language Installation manual appendix Any language Maintenance manual Any language Spare parts catalogueEnglish onlyKg Lb Top shell assembly 6,35814,017Bottom shell assembly 5,77212,725Main shaft assembly4,2019,262Pinion shaft housing assembly 244538Hydroset cylinder assembly 1,0802,381Feed hopper assembly 1,4403,175Eccentric assembly 7951,753Dust collar assembly239527Hoses and protection assembly 51112Crusher weight 20,27844,706Subframe1,3843,051Electric motor (max.)2,6505,842Tolat weight(incl. subframe and drive)25,26855,707OIL COOLING SYSTEMS(FOR MAIN CRUSHER LUBRICATION)STANDARD AIR/OIL COOLERS No. of units1Dry weight (incl. stand)240 kg Material Aluminum Oil volume 12.8 liters Max. air flow2.8 kg/s @50 Hz3.3 kg/s @60 HzHOT CLIMATE AIR/OIL COOLERS No. of units1Dry weight (incl. stand)390 kg Material Aluminum Oil volume 19.0 liters Max. air flow7,8 kg/s @50 Hz 9,3 kg/s @60 HzAIR COOLER FAN MOTOR Type Three-phase, squirrel cage Power 2.2 kW @50 Hz 3.6 kW @60 Hz Speed1,500 rpm @50 Hz 1,800 rpm @60 HzAIR COOLER FAN MOTOR Type Three-phase, squirrel cage Power 5,5 kW @50 Hz 6,3 kW @60 Hz Speed1,500 rpm @50 Hz 1,800 rpm @60 HzCH840i CONNECTED – NOMINAL CAPACITY* (MTPH)ConcaveEC C MC M F Max. feed size (mm)F85**14111681--F901721411279773F10025020515912192Max. motor power (kW)330330*********Eccentric throw (mm)28-5228-5228-5228-5228-52CSS (mm)810131619222529323538414448---162-193174-272186-290198-309214-334226-352238-371250-366261-335273-324289---177-210190-297203-317216-337233-364246-384259-356272-349285-312298----187-254201-313214-334228-356246-384260-406274-427287-421301-385315-374333--155-213167-261180-280192-299204-299220-282233-254245----103-132109-170119-185128-200137-214147-215156-214169-200178-----MantleA/B/FFA/B/FFA/B/FFA/BA/B* based on material with bulk density of 1,600 kg/m 3** Additional feed size requirement applicable for FF mantle only (FlexiFeed)PERFORMANCEWEIGHT (KG)T S 5-1227:03/E N G /M E T R I C © S a n d v i k M i n i n g a n d R o c k T e c h n o l o g y 2019 S A N D V I K i s a r e g i s t e r e d t r a d e m a r k o w n e d b y S a n d v i k I n t e l l e c t u a l P r o p e r t y A B i n S w e d e n a n d o t h e r c o u n t r i e s.Sandvik Mining and Rock Technology reserves the right to make changes to the information on this data sheet without prior notification to users. Please contact a Sandvik representative for clarification on specifications and options.ROCKTECHNOLOGY.SANDVIK* Always refer to the installation manualsDIMENSIONS*4159 mm (Max)2160 mm3393 m m。

SANDVIK 圆锥破碎机电气及ASRi自动控制系统技术分析李建新引言：SANDVIK 圆锥破碎机是目前新疆有色集团“亚克斯4000吨选矿厂”，选用的自动化程度较高的矿石破碎设备，特别是电气控制部分，采用了“软起装置”及智能型ASRi自动控制系统，使设备运转的安全性，灵活性和适应性大大增强。

然而由于ASRi控制系统的引入，从另一个方面来讲，对我们工程技术人员，在设备安装、使用、维修与维护方面的思路和方法,也相应提出来了新的要求。

也就是说：要保证此类设备的正常运转并发挥其优良的性能，我们不但要熟练传统电气控制技术，还要进一步了解掌握ASRi控制系统的工作原理及应用技术。

为了使有关工程技术人员能够尽快掌握ASRi控制系统应用的基本知识基本技能，本文从以下几个方面，对SANDVIK圆锥破碎机电控系统基本结构及工作原理进行了简要的阐述和分析，以供参考。

因笔者水平有限，不足之处请指正。

一、整机电控系统的基本构成及作用：以315kw SANDVIK圆锥破碎机为例，其电控系统主要是由启动回路、控制回路、ASRi 自动调节控制系统构成的。

1 启动回路是由MCD3315软起装置与一个旁路接触器组成的。

当破碎机接入电网，且其他条件（油压、油温）满足机械运转条件要求时，软起装置即可在设定时间内(软起面板设置），将破碎机电机以减压启动方式启动起来。

并且通过软起装置内部继电器接点，联通旁路接触器线圈，使旁路接触器闭合，实现电动机减压启动与常压工作状态平稳转换。

破碎机转入正常运行后，MCD3315软起装置可按照预先设置的各种参数（过电流、过电压、缺相等......详见MCD软起动设置说明）对启动运行回路的电气元件、线路、电动机执行监控与保护功能。

2、控制回路：是按照破碎机、润滑、温度、正压风机等辅助系统设备的“启动”“、运行”、“停止”、“检测”及“安全保护联锁”功能等要求，设置的普通机电保护连锁回路，它是独立的，不受ASRI系统的控制，是设备安全运行的前提。

山特维克破碎机的应用及相关指标试验研究前言选矿厂阶磨阶选工艺流程改造系统达到设计指标后，由于球磨机原矿台时处理量大幅度提高，对原矿量需求比改造前大幅度增加。

给细破机带来了非常大的压力，使细破机处于超负荷运转状态，加之现有细破机设备性能已老化，故障率较高，对破碎产量和球磨机原矿处理量造成了较大的影响。

为降低细破机负荷，确保原矿量，矿业公司于2006年2月从国外进口了2台处理能力大的H8800山特维克液压圆锥破碎机来更新现有的Ф2200细破机，分别安装在选矿厂破碎车间细破作业原1#、6#系统。

经过一年多的生产调试、改进、适应，具备了对该设备及相关指标试验考查的条件，为了评价新破碎机的使用效果，试验组根据试验计划于2007年11月完成了对该设备及相关指标试验考查。

一、设备性能特点1、挤满给矿方式，处理能力大，作业率高。

2、自动化程度高，排矿口自动调节。

3、具有过载过铁保护装置。

4、结构简单牢固，安装方便。

5、检修、维护简单方便，机内所有部件都能从上部吊出方便检修。

6、采用正压空气防尘和润滑油风冷，不需要水封水和冷却水。

二、配套设备改进情况1、给料皮带改进原破碎机给料皮带采用1.1米平皮带给料，出现了运行时皮带跑矿，皮带薄，强度不够，给矿量不足的问题。

为解决此问题，根据我厂长期的生产实践经验，决定将原平皮带改为槽型皮带，皮带加宽到1.4米，对托辊和支架也同时进行了改造，达到了生产要求。

2、下矿料漏子改进改造前后示意图改造前（图一）由于设计时漏子过低，造成了给矿不均匀，物料直接冲击老虎帽的前端，加大了前面的磨损，后端不断积矿使下矿始终偏向破碎腔的一边，功率损耗严重，破碎压力系统波动大，设备振动剧烈，损坏设备的零部件，破碎壁损坏较大。

已造成多次事故。

改造后（图二）将下矿漏子前移，下矿点在前端。

下矿时，物料先冲击漏子的前部挡板，后返至圆漏子，使物料正好垂直下到老虎帽上，避免了物料下矿不均的现象，大大改善了破碎机的给矿和工作情况，系统压力工作平稳，平均作业功率可达350kW以上，破矿粒度更均匀，台时处理量也从800吨/小时提高到900吨/小时。

颚式破碎机山特维克有着一百多年设计、制造颚式破碎机的历史，熟知用户的期望和需求，向用户提供完备的山特维克颚式破碎机系列产品，其中也包括了专门用于移动破碎机组的规格。

山特维克的颚式破碎机与其它颚式破碎机相比，具有更高的强度，而重量却有所减轻。

产量高、综合成本低等优势使山特维克颚式成为用户的最佳选择。

坚固的结构山特维克颚式破碎机为单肘板复摆颚式破碎机，以设计和制造方面对细节的重视为特色。

我们在融合传统技术精华的同时运用了最新的科技成果。

型铸件*，具有很高的刚度/重量比。

大弧度过渡圆角和焊缝设置在低应力区，大大降低了应力集中。

焊接结构与螺栓连接相比其优势在于，各个方向具有均等的强度，对冲击负荷具有很好的耐久性，这将主机架出现故障的风险降到了最低。

下图为一侧板用有限元分析（FEA）软件输出的应力分布预测图。

优化的性能* CJ200系列定颚为筋板焊接结构。

适应各种应用WT ：CC ：ST ：CC ：HD ：所有颚板都可翻转使用，而“WT”型颚板动定颚还可互换。

山特维克设计了高性能、低运行成本的磨耗件。

高质量的材料和富于经验的设计是磨耗件高质量的保证。

破碎机设计了多种形式的颚板，可针对不同的应用进行选择。

山特维克颚式破碎机具有更高的可靠性，大幅提高了无故障运行时间，这些皆源于精细的设计。

破碎机的四个滚柱轴承采用油脂润滑，充满润滑脂的迷宫式密封圈，有效防止粉尘侵入。

作为标准配置设备安装了集中润滑分配器，各个润滑点均由油管集中连接于此，这使轴承的润滑更加安全便捷。

自动润滑系统 可以连接到现有的控制系统远程警报指示，从而更好地保护滚柱轴承。

排矿口设置有传统的垫片调整方式、液压辅助调整方式和楔形块液压调整方式。

用压条和支撑条这种快捷的安装方式将颚板固定在破碎机上。

一些保护性部件的使用，有效地避免主要部件的损坏，降低了设备寿命周期的总成本并提高了作业率。

比如在颚板与动颚和定颚间增加了可更换的垫板，在排料口处设置的可更换的支撑条均保护动颚和定颚体免于磨损；轴承座上采用了重型护板，避免轴承座的磨损等等。

Sandvik反击式破碎机
下图所示为瑞典山特维克(Sandvik)公司生产的P和S系列反击式破碎机，它
Sandvik反击式破碎机
a-P型；b-S型
用于水布桠水电站。

浙江某机械厂生产了PFC和PFX这两种反击式破碎机。

这种破碎机上图所示，其结构特点是，P型用于粗、中碎，有两级反击板，S型用于中、细碎，有三级反击板。

其后腔反击装置悬挂点与反击板悬挂点在一起，这样增加后腔反击装置的重力矩。

过铁时反击装置又能迅速抬起，异物排出后又能迅速返回原处。

这种破碎机P型和S型都是采用四个“香蕉形”板锤，可翻转使用，在磨损周期内与物料的接触角保持不变，排料粒度均整。

P型和S型反击式破碎机简要技术参数列于下表所示。

资料整理：双金机械。