Improve Ascendable Efficiency Reliability Of The Quarry Equipment

To maintain the equipment during the quarrying process, there would be a requirement for spare parts. Nevertheless it has been identified that failures and breakdowns have numerous knock-on effects which include hindering productive work, increasing the operational cost and construction hazards. In order to minimize them and improve ascendable efficiency reliability of the Kilomega quarry crushers equipment, there is need to seek for what is wrong and seek ways of solving it. With this context in mind the authors focus only on externalities of typical failure surfaces of spare parts and possible damage control measures that do not impair your business operations. 

1. Conveyor Belt Failures

Common Issues:

Belt Misalignment: A torn or damaged edge may develop out of more wear than necessary through belts not turning in the right or right amount of direction.

Belt Slippage: The material flow rate is reduced due to slip that is demonstrated when the drive pulley is off the conveyor belt.

Too much wear: The belts can wear out over time through abrasive sharp material or just by pure weight.

Solutions:

Consistently Closer Check-Up and Corrections: Routine inspection of the alignments of conveyor belts is recommended. Of course there will always in some cases be a degree of misalignment that can be corrected to some extent by a tweak of the pulley and idlers.

Adequate Amount of Tension: Pull the belt up and narrow the strap sufficiently enough to effectively minimize slipping chances. Some form of tension control may be applied to maintain an optimum tension at all times, an automatic tensioner might apply.

Reinforced belts: The next time if the wear becomes excessive again it is preferable to replace the belts with an edge blanket that may be suitable with steel cords or heavy rubber belting for rigid conditions. 

2. Crusher Component Failures

Common Problems:

Jaws or Cones Worn-surfaced: Even a small exemplar knows that components like jaws or cone or other surfaces that are in contact with impact material are subjected to severe abrasion.

Blockades Quite Often: It happens quite a lot when oversized material is fed into the chamber causing a material blockage in the crusher chamber.

Bearing Damaged: Eventually, bearings can get damaged as a result of dirt, wear and tear or high load.

Solutions:

Material Resistance to Abrasion: It is advisable to use parts made out of high quality wear resistant materials such as manganese steel in prolonging the life span of vital components.

Periodical Measurements of Feed Size: Always ensure that the size of the material when put in the crusher is in within measurements that are tolerable in order to avoid creating a blockage.

Apply Lubrication: With the right amount of grease, it is possible to control the wear and tear of the elements and in this case, the bollards. Human error in applying grease can be mitigated with the use of automatic lubricating systems. 

3. Screening Equipment Failures

Common Issues:

Screen Tearing: Due to application of lateral forces edged rigid components are subject to damage and tearing and screener is not an exception when bulky or sharp items are processed.

Motor Overheating: A motor can overheat when it is over-stressed or when it is inadequately ventilated.

Weak or broken Fore stayed Bolts: Regular high frequency effects causes distortion in the joints, bolts and screws which ultimately results in loss of screening efficiency and nuisance.

Solutions:

Choose High-Durability Screen Materials: The surfaces for the screens should utilize tough or rubberized gathering surfaces to minimize the chances of tears.

Confirm that a Proper Motor Size is Used: The screen driving mechanism is required to be constructed for an average working effort. Carry out check and clean obstruction points of the ventilators.

Routine inspection and tightening of the fasteners: Last prevention of the wear and tear will occur by constant tightening of the fasteners which will subsequently enhance oscillation amplitude stability. Locknuts are, however, or joints which are vulcanized can be used as fasteners. 

4. Pump and Hydraulic System Failures

Common Issues:

Hydraulic Leaks: Leaks of this type are most likely to occur through hoses, seals, and fittings due to old age, fit deficiency, or excessive pressure.

Cavitation of the pump: Loss of a steady state flow from the pump due to trapped air which may result in damage to pump components.

Solutions:

Regularly examine seals and replace them whenever applicable: Awareness of seals and fittings with time allows a person to detect signs that these components are wearing out and are likely to fail soon. Such high quality seals which are strong should be used in quarry work as this is always a rough work environment.

Limit and control use of all fluids: This encompasses the general maintenance of the recommended amount of fluids including performing the recommended scheduled replacement of hydraulic oil by the manufacturer. During maintenance activities, make certain that fluid is not contaminated by the use of dirty implements.

Use appropriate filtration systems: Proper Kilomega Quarry crusher parts have to be purchased specifically designed for your hydraulic system and filter changes are a must every so often. 

5. Roller and Pulley Failures

Common Issues:

Bearing Seizure: Dust and debris include dust and trash as they may cause bearings to seize seizing too early, and even rollers fail.

Pulley Wear: The drive pulleys are in direct contact with the conveyor belt meaning constant wear and tear and subsequent loss of friction or grip.

Roller Misalignment: When positioners are out of alignment they are bound to force rubbing that leads to increased friction bearing on the belt and damage to the belt reducing efficiency.

Solutions:

Install Sealed Bearings: One should consider the type of bearings that should not get contaminated and therefore using those that come with covered metallic or plastic covers.

Use Rubber-Lagged Pulleys: Rubber-lagging on pulleys improving tractions. Some of the repairs that require time and attention are that worn pulleys must be changed to prevent further damage to the conveyor belt.

Adjust Roller Alignment: Rollers should be examined and aligned and checked whether they are placed properly into the right position. If there are, an alignment system can ensure that there will be less necessary maintenance and consequently, less on the wear and tear of belts. 

6. Vibration and Noise Issues

Common Problems:

Noise nuisance: The loaded noise could be of considerable value at the time of high and continuing load operations and may be indicative of an undesired unaligned or a worn-off loose part.

Vigor Vibration: At greenhouse farm and particularly on the quarry, the vibration is a common phenomenon during the extraction but may sometimes occur in extreme conditions due to other operational issues such as movement of loose parts or parts which are of unbalanced machines.

Solutions:

Identify Reason for Noise and Vibration: Employing rubber or any other material constraining control to vibration - damping plates or mounts to prevent noise and vibrations. And so they do not have to suffer such king of fate, they are able to torque any relevant slack associated components that maybe prevalent out there.

 Rotating Components Be Balanced: Everyone needs to be balanced. Non balanced parts are accompanied with non-balanced high level of worn out of the components and high level of vibrate.

Different period types of inspection: The most appropriate preventive measures can be taken in cases when damage is minimal so that the machine does not withstand at high risk and the operational conditions are handled smoothly. 

Conclusion: Improving the Reliability and Minimizing the Downtime of the Quarry Operations

 

In situations where the quarry’s objectives are to acquire specific spare parts, it becomes necessary to handle maintenance outages and operational downtimes wisely. When conducting periods of planned maintenance or ordering replacements, it is appropriate to apply low cost but good quality units which will last as long as planned maintenance can be carried out. In Kilomega, we provide almost all the required parts of wear and tear of a Kilomega Quarry Vibrating Screen Mesh and active management ideas as to how to optimize the processes in the quarry. We also focus on systems that are important in resolving the problems that are particular to the quarrying sector.