Presentation

On
Track Mounted Crusher
Development

Presentation
By
E.V.Ravindran

Feb-2016
 Introduction
 It is proposed to Design and Develop Track
Mounted Crushers driven by Diesel Engine.

 This Paper Aims in determining the apt Product

Configuration in terms of Drive System , Size
Special Features etc.
 Due consideration is given on Market
Requirement,
 Technology Development , Operational Economy
and Comparison with Existing Equipment in the
field.
 Structure

This Presentation is Structured as Follows.

 Understanding Track Mounted Crushers
and its Types.
 Stationary Crushing Plants vs. Mobile
Crushing Plants.
 Existing Models in the Field and their
Features
 Analysis of Features
 Outline of New Model features.
 Market Positioning Strategy.
 Understanding Track Mounted Crushers

Track Mounted Crushers are The Crushers Mounted on Hydraulic

Driven Twin Crawler Units as Shown Above
Generally The unit Consists of the following Systems.
 Basic Crusher Unit.(Jaw , Cone or Impact Crusher)
 Equipment Chassis
 Crawler Unit
 Prime Mover (Mostly Diesel Engine)
 Hydraulic System/Power pack for Drive
 Crusher Lubrication , Hydroset unit Etc.
 Feeding , Conveying and Sieving System.
 Diesel Tank , Hydraulic Tank.
 Control Panel.
 Working Platform and Walk ways.
 Lighting Arrangements
 Stationary Crushing Plants vs. Mobile Crushing
Plants.
1.Construction Features

Stationary Plants Mobile Plants

1. Permanent Civil Structures Mounted on Crawler Chassis

2. Heavy Investments Moderate investment

3 Needs Power Source Can be operated with diesel.

4 Flexible Plant Layout Restricted layout in Equipment

5 Needs More time for Operation

Can be put in to operation in Short Time
Commencement
 COMPARISION OF VARIOUS CRUSHER DRIVES
CRUSHER DRIVE Drive through Diesel Engine - Fluid Coupling
Advantages Disadvatages
Less space Coupling needs hydraulic pump & system
Ease of ON\OFF Control Constant speed depends on oil pressure and leakage.
Replacement of V-Belts is easy Failure due to oil contamination
Simply fitted in the engine flywheel Supply source is restricted

CRUSHER DRIVE Drive through Diesel Engine- Hydraulic Pump - Hydraulic motor (Closed circuit)
Advantages Disadvatages

Easy to fit & saves space
Avoids heavy pulleys & belts
We can vary the crusher speed with flow control
Pump fited directly to engine as piggy pack with other pumps.
Life of pump & motor is low needs replacement every year.
Very sensitive to oil contamination.
Performance is affected by leakages
High cost and needs long lead for procrument of unit & spares
Only trained persons can operate and service these units.

CRUSHER DRIVE Drive through Electric Motor

Advantages Disadvatages
Can be used from main power supply also if available It requires more space & weight.
No complicated hydraulic parts required & good wiring is sufficient. High level electrical safety to be ensured
DGMS approval required.
Requires costly startres like softstart,VFD to restrict alternator size.
 Crusher Drive-Fluid Coupling
( Fig 1)

The PTO is a variable fill fluid coupling enclosed into a casing

Connected to the Diesel engine by means of SAE housing. The
PTO has been designed to meet the market requirements for a
Unit combining the technical features of a conventional Power Take
Off with the performances of a fluid coupling.
The PTO has an integral feeding pump driven by the Diesel
Engine. A remote electrically operated ON-OFF solenoid valve
Allows the fluid coupling circuit to be fed when it is turned ON,
While a rapid oil drain through calibrated orifices located on the
Periphery of the fluid coupling occurs when it is turned OFF.
A forced bearing lubrication is always assured continuously.
The PTO range is suitable for powers up to 1000 kW.
The engine flywheel is connected to the PTO input by a Torsional flexible
coupling. The output shaft can be connected to the driven machine by an
elastic coupling, a cardan shaft or a Pulley.
 Crusher Drive-Closed Loop Hydraulic pump
motor
( Fig 2)
Hydraulic Motor

The Crusher is driven by a Closed Loop Hydraulic Motor either through a

belt drive as shown or Directly Coupled to Crusher Shaft.
Here we can see that the motor has several minute servo valve system very
near to
Crushing Zone.
This will result in
 Dust particles getting into Hydraulic System
 oil contamination
 Irregular Function of Load Sensing valves.
 Variations in Motor speed
 Over Heating of Motor
 Reduction in Motor Bearing Life.
 Analysis of Features
Sl Market
Drive Type Drive Details Application Limitations Remarks
N0 Segment
Crusher Directly Driven By Diesel The
(Fig-1) Engine through engaging Fluid Performance
Coupling and Speed
Depends on
Diesel Engine--Hydraulic Pump- GOOD MOBILITY.
Fluid
Track Twin Hydraulic Motors For Many Models of Metso,
Large Mines Coupling and
LRC. Large Mines Terex and Sandvick are
DIESEL- Who Wants to often Needs
who use these in the market
DIRECT- Start The Servicing.
1 where no
ELECTRIC Crushing High
power is Retrofit work for
DRIVE instantly and at Operating
All Drives Driven By Electric available. conversion into
any place. Cost and we
Others Motors through Engine electrical is going on in
can never use
Alternator some mines.
the available
power

Driven By Electric Motor This is not Size of the

Crusher powered by Power pack popular in market Equipment
alternator as this is a could be very
Medium Sized
Driven By Hydraulic Motor- technically large if normal THIS PRODUCT CAN
mines who
DIESEL- Hydraulic Pump-Electric Motor upcoming starters are BE PLACED IN THE
Track have Contract
2 ELECTRIC powered by Power pack Product. used for motor MARKET BY
Crushing and
DRIVE alternator It can replace The starting. PROPEL
High Mobility
present Hydraulic Use of Soft
of Projects.
All Drives Driven By Electric Version of Track start or VFD
Others Crushers. Preferred
Motors through Gen Set.
 Analysis of Features
Sl Market
Drive Type Drive Details Application Limitations Remarks
N0 Segment
Few Model are
The
used in this type
Crusher Both Crusher and Traction are performance
for optimal
alternatively Driven by separate depends on
space design of
Hydraulic Motors through Piggy Hydraulic
equipment and to
DIESEL- Pack Hydraulic Pumps driven by System and Very Rarely
use standard
ELECTRIC- Track Diesel Engine oil Used.
3 power pack for
HYDRAULI contamination Ex.
lubrication. Also
C DRIVE . KLEEMAN.
Standard
High
Electrical Driven
All Drives Driven By Electric Operating
Others conveying
Motors through Gen Set. Cost.
systems can be
used.

Crusher Low life of

Large Mines Hydraulic Presently No
All Drives Including Crusher Who Wants to Motor/ Pumps of models are Retrofit work for
DIESEL- Drive are operated by Hydraulic Start The of Crusher as working in the conversion into
4 HYDRAULI Track Motors through Hydraulic Crushing a closed loop field. Issues electrical is going on in
C DRIVE Pumps, Driven By Single instantly and at pump is used. related to some mines.
Diesel Engine. any place. High Skill Hydraulics
Operators are High.
Others Required.
 FEATURES OF PROPOSED TRACK CRUSHER

Diesel Engine Driven Generator with Control panel Soft Start /VFD Starter.
The control Panel Can be Connected to Either Main Power Supply or Generator.
Main Power
Source The Entire electrical System Mounted on the Equipment has to be properly insulated
and prevented from mechanical damages. Needs DGMS Approval.

Crusher Drive Driven by Electric Motor through V-Belts.

Traction Drive Driven by Electric motor.

Pump(Hydraulic This is a open circuit Hydraulic System which will be operating only during traction.
Power Pack) This Hydraulic System will be completely sealed from dust.
Hydroset and
Lubrication power From Control Panel
pack drive.
Conveyors and
From Control Panel
other drives
 Market Positioning
Strategy

The Proposed Model Has to be positioned Against the lacuna Of the existing
Direct Diesel / Hydraulic Drive of the Main Crusher.

The Lead Points are.

 As there is no Hydraulic Oil and Pump used for Crusher Drive during
operation major Hydraulic oil is not exposed to Dust.
 During traction a devoted Hydraulic power pack with electric motor is
used.
 Heavy maintenance cost is reduced during operation.
 Down Time due to Hydraulic Setting is reduced.
 Easy to change over to main power source possible when available. The
cost of operation is minimised.
 Carrying spare parts with the mobile equipment is reduced.