What should you do if the crawler-mounted impact crusher station has low productivity and earns little profit?

The tracked mobile impact crushing station has gained wide popularity in recent years due to its simple operation, convenient relocation, high cost-effectiveness, high production capacity, and excellent product particle shape. Additionally, it comes equipped with an integrated environmental protection and dust suppression system that meets China's stringent national environmental standards. Typically, these stations are commonly used for the primary processing of solid waste resources such as construction debris. Traditionally, tracked mobile impact crushers were often paired with tracked mobile screening stations. However, some companies have now developed innovative integrated tracked mobile crushing and screening machines. These versatile units not only deliver efficient production but also significantly reduce users' equipment purchase costs, making them an excellent alternative for the initial processing of construction waste and other solid waste resources.

No matter what kind of machine it is, you're bound to encounter various issues during operation. So, how should we proceed to enhance the impact crusher's productivity and bring greater economic benefits to those of you currently using impact crushers?

1. Reasonably reduce material moisture

If the material contains a high moisture content, it tends to stick easily within the crushing chamber and is also prone to clogging during the feeding process, thereby reducing the production capacity of the impact crusher. Therefore, for materials with higher moisture levels, you can take preventive measures such as pre-drying or drying them in advance to appropriately lower their humidity, ultimately boosting the productivity of the impact crusher.

2. Choose an impact crusher equipped with a pre-screening material belt

If the material contains a large amount of fine powder before crushing, it will reduce the capacity of the impact crusher. This is because these fine powders tend to stick easily, disrupting both transportation and material discharge. However, if the impact crusher is equipped with a pre-screening conveyor belt, it can effectively separate and process the powdered material, ensuring that the material entering the crushing chamber better meets the design requirements of the crusher—and ultimately boosting its overall productivity.

3. Reasonably increase the main motor power

Within the range of the rated motor power, the higher the main motor power, the greater the production efficiency and capacity of the impact crusher. Therefore, during production, you can increase the main motor power—within permissible limits—to boost the capacity of the impact crusher.

4. Appropriately increase the rotor's rotational speed

The rotor speed of the tracked mobile impact crushing station is one of the critical operating parameters of the impact crusher, playing a decisive role in determining the crusher's production capacity, product particle size, and reduction ratio. Experiments have shown that as the rotor speed increases, both the crusher's throughput and reduction ratio significantly improve, resulting in finer product particles. However, along with the increase in rotor speed, power consumption also rises, leading to faster wear of the hammer plates and higher production costs. Therefore, in actual production, it’s essential not to blindly pursue excessively high rotor speeds—instead, speed adjustments should be made judiciously to strike a balance between efficiency and cost-effectiveness.

5. The angle of the impact plate must be appropriate.

Currently, the market offers both linear and arc-shaped impact plates. The angles of the impact plates at each stage significantly influence the effective crushing force generated when material strikes the plates, while also greatly affecting the impact and shear forces that contribute to material fragmentation.

The zigzag-shaped impact plate has a simple structure, but it doesn’t guarantee that the crushed material will undergo more effective impact crushing. Therefore, when purchasing and adjusting the impact crusher, be sure to carefully observe the angle of the impact plate, aiming to ensure that the material collides with the plate perpendicularly whenever possible—this will help maximize the crusher’s production capacity.

The curved-shaped impact plate commonly features an involute design. This structural configuration ensures that at every point along the plate, the material is struck perpendicularly, resulting in higher crushing efficiency and increased production capacity.

6. Properly adjust the impact crusher and ensure uniform feeding

Ensure the feed to the impact crusher is uniform, preventing oversized materials and non-crushable objects from entering the crushing chamber. If abnormal vibrations or unusual noises are detected in the impact crusher, stop the machine immediately for inspection. Once the cause has been identified and the issue resolved, restart the crusher only after confirming everything is functioning properly.

The clearance between the impact plate and the hammer has a significant impact on the product particle size. Before starting the machine, the gap between the impact plate and the hammer should be adjusted to within the specified range.

7. Replace wear-resistant parts promptly

For worn wear-resistant parts—especially components like plate hammers and impact plates that come into direct contact with materials—they should be replaced promptly. When replacing plate hammers, be sure to weigh and carefully select the new ones to ensure proper static balance of the rotor.

As the saying goes: "It takes a thousand days to raise an army, but only a single moment to put it into battle." If you want to enhance your counterattack and breakthrough capabilities—and, by extension, boost your earnings—regular inspections, maintenance, and upkeep of your counterattack equipment are equally essential.

1. Daily Precautions, Inspections, and Maintenance

The machine operates smoothly; however, if the vibration level suddenly increases, the machine should be stopped immediately to identify and eliminate the cause.

Under normal circumstances, the temperature rise of the bearing should not exceed 35°C, and the maximum temperature should not surpass 70°C. If the temperature exceeds 70°C, the machine should be stopped immediately to identify and eliminate the cause.

When the wear on the hammer reaches the limit mark, it should be turned over for use or replaced promptly.

After assembling or replacing the hammer plates, rotor balance must be maintained.

When the rack liner plate wears out, it should be replaced promptly to prevent wear on the machine casing.

2. Check the equipment before powering on

1. Strictly inspect whether the foundation bolts of the motor, body bolts, bearing housing bolts, and bolts at the guard plates—among other fixed components—are loose.

2. Check the fasteners of the impact plate for any looseness or fractures.

3. Inspect the internal components of the equipment, such as whether the plate hammers are severely worn, since they significantly influence the discharge particle size. Additionally, check the condition of other easily worn parts, including their degree of wear and the presence of any cracks or defects.

4. Confirm the upstream and downstream processes, and only start up after the belt conveyor and baghouse dust collector are operating normally.