Crusher shaft repair Crusher shaft repair, the fastest and most effective repair method, so you don’t have to wait for repairs, the fastest and most effective repair method, so you don’t have to wait for repairs
Traditional repair methods have too many drawbacks and enterprises cannot afford to wait.
In a cement plant, the main shaft bearing of the crusher was severely worn. The eccentric shaft bearing of the jaw crusher was worn and repaired by riveting . The amount of wear on one side reached 1.5 to 2 mm. After the equipment stopped, maintenance personnel discovered that the bearing position with a shaft diameter of 320 mm and a width of 315 mm could no longer fit properly. The most urgent thing for enterprises is to repair the worn riveting and welding of the eccentric shaft bearing of the jaw crusher to resume production. However, traditional repair methods either take too long or have the problem of thermal stress damage to the material. After surfacing, machining and riveting repair of the worn and riveted bearing of the eccentric shaft of the jaw crusher may also cause the shaft to bend or break. Thermal spraying also cannot eliminate the thermal impact.
The brush plating coating is too thin and easy to peel off
Brush plating can repair the worn dimensions. However, due to the limitation of coating thickness, the thickness of a single repair is limited. When encountering a large amount of wear, multiple constructions are required. Moreover, the bonding force between the brush coating and the base material is limited. In heavy-load and high-impact working conditions such as crushers, the coating is prone to peeling off. More importantly, all the metal repair methods mentioned above are "hard-to-hard" fit, and there is no way to eliminate the gap between the bearing and the shaft. When subjected to comprehensive mechanical forces during operation, wear will occur again.
Polymer composite materials have obvious advantages in on-site repair
The company finally selected Fushilan 2211F polymer composite material to carry out on-site online repair. This material is not a metal, but a polymer, which can effectively buffer and resist the impact force during mechanical operation. After repair, the bearing position and the bearing can achieve 100% surface fit, and there will be no gap, thus solving the hidden danger of re-wear. The entire repair process does not require disassembly of the spindle or large-scale machining equipment, which greatly shortens downtime.
Surface preparation before repair is key
The first step is to use an oxygen-acetylene flame to roast the surface to be repaired until there are no sparks flying around, so as to ensure that grease and impurities can be completely removed. Next, a polishing machine is used to polish the worn area, so that the original color of the metal can be revealed, so that the composite material can be fully bonded to the base material. Finally, a dry test of the mold is necessary to check the tightness of the fit between the mold and the shaft, so as to ensure that there will be no deviation during installation.
Quickly install the mold after applying material
Wipe the surface to be repaired with absolute ethanol to ensure that the surface is clean, dry and strong. Apply the release agent on the inner surface of the mold and the fastening bolts, preferably twice, to prevent the material from adhering to the mold. Use all your strength to blend Fu Shi Blue 2211F polymer composite material and apply it evenly to the surface to be repaired. Quickly install the mold and tighten the bolts, ensuring the material is squeezed into place and filling any wear pits.
After curing, the mold can be disassembled to install the bearing.
After waiting for the 2211F material to completely solidify, the mold can be disassembled and the excess material can be removed using a scraper or sandpaper. At this time, the repaired surface has returned to its original size. Just install the bearing and remove the sleeve directly. The entire repair process took less than a day from preparation to completion. Compared with traditional surfacing welding followed by machining, which takes several days or even a week, it greatly shortens the downtime period and helps companies quickly resume production.
After the shaft of this crusher was repaired, it was running in a stable state and the problem of jumping and stopping did not occur again. If you have encountered a similar bearing wear situation, would you choose the traditional repair method or this polymer material online repair method? Welcome to share your experience in the comment area, and get more useful information on equipment maintenance by liking and following.
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