Abstrict An impact crusher includes a center feed disk. The center feed
disk includes a peripheral edge portion, a first face, an opposing,
second face, a central bore extending through the first and second
faces, and first and second countersunk pockets provided about the
central bore in the first and second faces respectively. With this
arrangement, a fastener having a shaft portion and a head portion
can be inserted through the central bore to secure the center feed
disk to a drive mechanism, with the head portion residing in the
countersunk pocket. With this arrangement, once the first face portion
becomes worn, the center feed disk can be removed, inverted and
re-mounted such that the second face portion is exposed.
Claims What is claimed is:
1. An impact crusher comprising: an impeller table assembly including
an impeller table having an outer edge portion and an inner edge
portion that define an impeller surface, and a plurality of shoes
arranged about the impeller surface; at least one anvil spaced from
the outer edge portion of the impeller table; a center feed disk
including a peripheral edge portion, a first face, an opposing,
second face, a central bore extending through the first and second
faces, and first and second countersunk pockets provided about the
central bore in the first and second faces respectively; a fastener
mounting the center feed disk radially inward of the inner edge
portion of the impeller table with the first face being exposed,
said fastener including a head recessed in the first countersunk
pocket, and a shaft extending through the central bore wherein,
after the first face develops a wear region resulting from material
flow, said fastener can be removed, the center feed disk inverted,
and then the center feed disk re-mounted with the second face being
exposed, whereby an overall service life of the center feed disk
is increased.
2. The impact crusher according to claim 1 wherein the center
feed disk comprises a wear-resistant material.
3. The impact crusher according to claim 2 wherein the wear-resistant
material comprises a chromium-iron alloy, ceramic composite or cemented
carbide.
4. The impact crusher according to claim 3 wherein the chromium-iron
alloy includes approximately 23 30% Chromium.
5. The impact crusher according to claim 2 wherein the wear-resistant
material constitutes cemented carbide.
6. The impact crusher according to claim 5 wherein the wear-resistant
material constitutes cemented tungsten carbide.
7. The impact crusher according to claim 1 wherein each of the
first and second faces of the center feed disk are initially, substantially
smooth.
8. A center feed disk for an impact crusher comprising: a peripheral
edge portion; a first face defining a first impact surface; an opposing,
second face defining a second impact surface; a central bore extending
through the first and second faces; and first and second countersunk
pockets provided about the central bore in the first and second
faces respectively, wherein the center feed disk can be used in
an impact crusher with the first face initially exposed and then
the second face subsequently exposed.
9. The center feed disk according to claim 8 wherein the center
feed disk is formed from a wear-resistant material.
10. The center feed disk according to claim 9 wherein the wear-resistant
material constitutes a chromium-iron alloy.
11. The center feed disk according to claim 10 wherein the chromium-iron
alloy includes approximately 23 30% Chromium.
12. The center feed disk according to claim 9 wherein the wear-resistant
material constitutes carbide.
13. The center feed disk according to claim 12 wherein the wear-resistant
material constitutes cemented tungsten carbide.
14. The center feed disk according to claim 8 wherein each of
the first and second annular surfaces are substantially smooth.
Description BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to the art of impact crushers and,
more particularly, to a center feed disk for an impact crusher that,
after a first side surface has become worn, can be inverted to make
use of an opposing, second side surface for operating the impact
crusher.
2. Discussion of the Prior Art
There are a wide variety of impact crushers currently employed
to reduce the size of large earth materials to smaller sized aggregate.
Typically, a flow of large earth materials is dropped or fed onto
a rotating feed disk that, using centrifugal force, disperses the
large earth materials through the impact crusher onto crushing components.
Generally, the crushing components include impeller shoes and anvils
that are radially positioned about the feed disk. In any event,
impact crushers reduce large aggregate earthen materials to aggregate
sizes and shapes to meet the needs of, for example, the construction
industry as ingredients for cement and the like.
The components of an impact crusher that are exposed to a material
flow are subject to wear. The wear is essentially caused by abrasion,
decomposition, fracture, impact, grinding and the like. In general,
the wear results from the velocity, acceleration and composition
of the material flow that is directed onto the components of the
impact crusher. Over time, the wear reaches a point which mandates
that one or more of the impact crusher components be replaced. One
component that is prone to wear is the feed disk. A typical feed
disk can process about 2500 tons of material before becoming worn
and in need of replacement. Thus, in an impact crusher that can
process 42 tons of material an hour, the average life of a feed
disk would be approximately 60 hours. Accordingly, every 60 hours
or so, the feed disk must be replaced. As only one surface of the
feed disk is usable, the costs associated with feed disk replacement
are high.
Based on at least these reasons, there exists a need in the art
for a feed disk that has a longer service life. More specifically,
there exists a need in the art for a feed disk that can be inverted
so that both surfaces of the disk can be used in operating the impact
crusher before the disk is discarded.
SUMMARY OF THE INVENTION
The present invention is directed to a center feed disk and an
impact crusher that are used to reduce the size of large earth materials
to smaller sized aggregate. The impact crusher includes an impeller
table assembly having a rotating impeller table. The impeller table
includes an outer edge portion, as well as an inner edge portion
that define an impeller surface. The impeller table assembly also
includes a plurality of shoes that are arranged about the impeller
surface. The shoes function to catch the large earth materials and
throw them, with tremendous centrifugal force, radially outwardly
against fixed anvils. Large earth materials are actually dropped
onto a rotating, center feed disk that receives and directs the
large earth materials toward the shoes and ultimately onto the anvils.
Upon impacting the fixed anvils, the large earth materials break
up, under their own momentum, into smaller aggregate material.
In accordance with the invention, the center feed disk includes
a peripheral edge portion, a first face and an opposing, second
face. A central bore extends through the first and second faces
and is surrounded by first and second countersunk pockets provided
in each of the first and second faces respectively. A fastener,
having a shaft portion and a head portion, is inserted through the
central bore to secure the center feed disk for rotation with the
impeller table. Preferably, the fastener is sized such that, when
fully engaged, the head portion is completely recessed within the
countersunk pocket. Once the first face of the center feed disk
exhibits sufficient wear, the center feed disk can be removed, inverted
and re-mounted to the impeller table such that the second face is
then used to receive and direct the large earth materials toward
the shoes to be crushed into aggregate. In this manner, an overall
service life of the center feed disk can be increased by as much
as two times.
In further accordance with the invention, the center feed disk
is formed from a wear-resistant material, such as a chromium iron
(ASTM A532/A532M-93a standards) alloy or a carbide, preferably cemented
tungsten carbide. Experience has shown that chromium, at levels
of 23 30%, produces advantageous wear-resistant qualities. In addition,
prior to inverting the center feed disk, smoothing and preferably
improving the balancing of the disk may be employed. Because the
disk rotates at high speeds, some as high as approximately 2000
rpm, an out-of-balance disk could cause substantial vibration. Thus,
prior to re-mounting, the wear regions are preferably filled with
a resin, such as liquid silicone, preferably a high density material
similar to LAB/metal.TM. or having greater density to provide a
uniform surface in the event of uneven wear, and preferably substantially
minimize, an out-of-balance condition. LAB/metal.TM. is marketed
by Alvin Products Inc., of Lawrence, Mass.
Additional objects, features and advantages of the present invention
will become more readily apparent from the following detailed description
of a preferred embodiment when taken in conjunction with the drawings
wherein like reference numerals refer to corresponding parts in
the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial, perspective view of a portion of a vertical
shaft impact crusher;
FIG. 2 is a perspective view of a center feed disk for the vertical
axis impact crusher constructed in accordance with the present invention;
FIG. 3 is a cross-sectional side view of the center feed disk of
FIG. 2 illustrating the exposure of a first face of the disk to
a material flow;
FIG. 4 is a cross-sectional side view of the center feed disk of
FIG. 3 illustrating wear caused by repeated sliding wear of the
material flow; and
FIG. 5 is a cross-sectional side view of the center feed disk of
FIG. 4 inverted to expose a second face of the disk to the material
flow, with the wear zone on the first face being shown filled with
a resin material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With initial reference to FIG. 1 an impact crusher, employed to
reduce a material flow of large earth materials to smaller sized
aggregate particles, is generally indicated at 2. Impact crusher
2 includes a housing 4 within which is arranged an impeller table
assembly 6. In accordance with a preferred form of the invention,
impeller table assembly 6 includes an outer edge portion 10 and
an inner 10 edge portion 12 that define an impeller surface 14.
Arranged about impeller surface 14 are a plurality of impeller mounting
brackets, one of which is indicated at 16 provided with a corresponding
replaceable shoes 19. In addition, a plurality of fixed anvils 24
are arranged radially about impeller table assembly 6. As will be
detailed more fully below, large earth materials are directed onto
anvils 24 with a tremendous impact force such that the large earth
materials disintegrate into smaller sized particles. Due to the
violent forces applied to the fixed anvils 24 over time they tend
to become worn and must be replaced. Therefore, each anvil 24 includes
a face portion 26 that leads to a tail portion 28. As shown, tail
portion 28 is formed so as to be slidingly received in an anvil
ring 30 that is disposed about an inner periphery of housing 4.
In general, the above-described structure is provided for the sake
of completeness and to enable a better understanding of the overall
invention. One key aspect of the present invention is particularly
directed to a center feed disk 40 located centrally witin impeller
table assembly 6. In operation, center feed disk 40 is rotated together
wit impeller table assembly 6. A flow of large earth materials is
dropped onto center feed disk 40 and a tremendous centrifugal force,
developed by rotating center feed disk 40 causes the flow of large
earth materials to be deflected radially outwardly toward impeller
shoes 16. Impeller shoes 16 catch the large earth materials and
throw them violently against fixed anvils 24. When the large earth
materials strike fixed anvils 24 the earth materials crack, under
the force of their own momentum, into relatively uniform, often
cubical pieces, that fall down onto a conveyor (not shown) or other
suitable output device. Due to the extreme forces involved, center
feed disk 40 must be formed from a wear-resistant material to provide
an acceptable service life. In accordance with one form of the invention,
the wear-resistant material is a metal alloy. A preferred metal
alloy is a high chrome iron alloy having approximately 23 30% chromium
(see ASTM A532/A532M - 93a (reapproved 1999).sup..epsilon.1). In
accordance with another form of the invention, center feed disk
40 is formed from carbide or other ceramic composite, preferably
cemented tungsten carbide. Regardless of the particular material,
center feed disk 40 must resist, as long as possible, the constant
wear from large earth materials being fed into impact crusher 2.
As best shown in FIG. 2 center feed disk 40 includes a peripheral
edge 42 a first face 44 and an opposing, second face 46. In addition,
center feed disk 40 is provided with a central bore 48 that extends
through first and second faces 44 and 46. In accordance with the
most preferred form of the invention, center feed disk 40 is provided
with a first countersunk pocket 52 formed on first face 44 about
central bore 48. In addition, a second countersunk pocket 53 is
formed in second face 46 also about central bore 48. With this
particular construction, after a significant amount of wear has
developed on first face 44 center feed disk 40 can be inverted
and re-mounted to impeller table assembly 6 to make use of second
face 46. That is, the material flow dropping onto and shifting along
center feed disk 40 causes notches, grooves, pits and other signs
of wear to develop over time on first face 44. This wear, if left
unchecked, could result in particles being deflected wildly about
housing 4 resulting in an overall reduction in efficiency of impact
crusher 2.
As best represented in FIG. 3 center feed disk 40 is initially
installed into impact crusher 2 with first face 44 being exposed
to the flow of large earth materials. More specifically, center
feed disk 40 is placed centrally within impeller table assembly
6 and secured to impeller surface 14 through a fastener 60. Fastener
60 is provided with a head 64 that is received within countersunk
pocket 52 and a shaft 66 that extends through central bore 48 to
secure center feed disk 40 for rotating with impeller table assembly
6. At this point, center feed disk 40 is rotated, together with
impeller table assembly 6 causing the large earth materials to
be guided radially outwardly onto impeller shoes 16 which hurl the
large earth materials onto anvils 26 in the manner described above.
As indicated above, over time, wear begins to develop on first
face 44 such as indicated by an annular notch 74 in FIG. 4. The
presence of annular notch 74 can cause earth materials to be directed
at angles that would not result in optimum impacts on either impeller
shoes 16 or anvils 26 thus lowering the overall efficiency of impact
crusher 2. To address this problem in accordance with the invention,
once a substantial degree of wear has developed on first face 44
fastener 60 is removed, center feed disk 40 is indexed or inverted,
and then feed disk 40 is remounted to impeller table assembly 6
with second face 46 exposed to the material flow. With this overall
arrangement, the service life of center feed disk 40 can be increased
by as much as two times, thereby reducing the overall cost of operating
impact crusher 2.
In accordance with the most preferred form of the invention, prior
to inverting and remounting of center feed disk 40 annular notch
74 as well as other imperfections (not shown) on first face 44
is filled with a resin, or preferably a high density material such
as LAB/metal.TM., to smooth and improve the balance and level center
feed disk 40. Because center feed disk 40 rotates at speeds upwards
of 2000 RPM, the various imperfections, and particularly annular
notch 74 in first face 44 can cause significant vibrations to impact
crusher 2. Therefore, in order to smooth the surface of and improve
the balance center feed disk 40 a resin material 78 is applied
to first face 44 and allowed to harden to resurface first face 44.
The resin material may contain a filler material such as aluminum,
iron, lead, tungsten or tungsten carbide to further improve the
balance of the disk.
Prior to remounting center feed disk 40 to impact crusher 2 with
second face 46 exposed to the material, a spacer or shim 84 can
be placed upon first face 44 as indicated in FIG. 5. In accordance
with the most preferred embodiment, spacer 84 is made of steel.
More specifically, it is important to ensure that the exposed face
44 46 is maintained at a specified level above impeller surface
14. That is, if first or second face 44 46 falls below the level
of impeller surface 14 material can enter or collect at inner edge
12. Ultimately, this could wear away inner edge 12 and perhaps reach
a drive mechanism of impact crusher 2. Thus, prior to remounting
center feed disk 40 spacer 84 can be positioned to ensure that
second face 46 is at the specified design height in related to the
impeller surface 14. The remounting of center feed disk 40 is enhanced
by incorporating symmetrical countersunk pockets 52 and 53 in faces
44 and 46 respectively. In any event, the overall service life of
center feed disk 40 can be increased be inverting and remounting
center feed disk 40 after wear has developed on first face 44. This
ability reduces the costs, inconveniences, and lost work associated
with disk replacement.
In one particular embodiment of the invention, a cemented tungsten
carbide center feed disk 40 was utilized for crushing 120000 tons
of earth materials before being removed and inverted. When inverted,
a steel spacer 84 was employed. In any event, it should be readily
apparent that the combination of the materials used to make center
feed disk 40 and the ability to invert center feed disk 40 in accordance
with the invention results in a dramatic increase in the useful
life of center feed disk 40. Correspondingly, the costs associated
with operating impact crusher 2 and its related downtime are significantly
reduced such that an extremely advantageous and commercially viable
arrangement is established.
All documents, publications and patents referred to herein are
hereby incorporated by reference.
Although described with reference to a preferred embodiment of
the present invention, it should be readily apparent to one of ordinary
skill in the art that various changes and/or modifications can be
made to the invention without departing from the spirit thereof.
For instance, it should be understood that the use of the terms
first and second surfaces is for the sake of clarity and is not
intended to limit the scope of the present invention. In general,
the invention is only intended to be limited to the scope of the
following claims. |