Learn From Me The Latest Crusher Shaft Head Wear Repair Technology

Learn from me the latest crusher shaft head wear repair technology

Why do companies choose this path if the shaft head is worn and cannot be disassembled or welded?

There is a company that owns a crusher that weighs 100 tons. When the hammer plate is added, the total weight is astonishing. Once the shaft head wears out and then shuts down, it will cause huge losses. The traditional repair method requires first disassembly, then transportation, then welding, and finally reassembly. It takes at least a week to complete a set of such processes. After the company learned about our company's online repair technology, its technical team conducted in-depth exchanges with it and found that it did not require major disassembly and could fix the problem directly at the equipment site. This gave them hope of quickly resuming production.

What companies fear most is that after repairs are of poor quality, they will be damaged again soon after. Our engineers introduced the performance of Sole carbon nanopolymer material in detail, showing that after repair, it can be restored to the original fit size, and the service life can even exceed that of new parts. This promise impressed the company, and they decided to give it a try.

The first step is to dismantle and clean the shaft head to reveal its true appearance.

When on-site construction began, workers took the lead in dismantling all parts on the shaft, including bearings, seals, retaining rings, etc., in order to fully expose the worn shaft head. Then use cleaning agent to thoroughly clean away the oil dirt and dust on the surface of the shaft head to ensure that subsequent processing can directly touch the metal surface.

This step is very critical. If the oil stain is not cleaned up, the adhesion of subsequent materials will be greatly reduced. Workers use scrapers and cotton cloth to wipe repeatedly until there is no greasy feeling when touched by hand. The entire cleaning process took about two hours and laid the foundation for subsequent construction.

Oxyacetylene flame degreasing without leaving any oil traces

Subsequently, an oxygen-acetylene flame is used to degrease the shaft head. The worker adjusts the flame to a suitable temperature and heats the surface evenly to completely carbonize the remaining oil stains. During the operation, the heat must be strictly controlled. It is not allowed to burn too violently to cause oxidation of the metal surface, nor is the temperature insufficient to achieve the degreasing effect.

Where the flames pass by, you can see the oil traces turning into black carbide, but there are no sparks. This shows that the oil removal effect is thorough and the temperature is properly controlled. This step takes about forty minutes to ensure that the surface is clean and oil-free, thereby creating the best conditions for material adhesion.

Only when the polishing machine is rough and the original color of the metal is visible can it be qualified.

After the oil removal work is completed, the workers use a polisher to carry out fine polishing operations on the repaired surface. The goal of polishing is to make the surface rough, without loose particles, and to reveal the original color of the metal. After the grinding wheel is installed on the grinder, grind it evenly along the circumferential direction of the shaft head , repair the wear and riveting of the bearing position of the eccentric shaft of the jaw crusher , and control the rotation speed within a reasonable range.

The polished surface shows a silvery-white metal-specific luster, and you can feel the slight roughness when you touch it with your hands. The workers use their naked eyes to check whether there are missing oxide scales or loose objects. They learn the latest crusher shaft head wear repair technology from me, and will not stop until it is confirmed to be qualified. This link is extremely important and critical. A rough surface can enhance the mechanical bite between the material and the metal, thereby ensuring the strength of the repair.

Calculate the blending material to be applied uniformly without pores

Technical engineers calculate the amount of Sole carbon nanopolymer material required based on the actual measured wear amount. Then strictly follow the product instructions and mix the mixture thoroughly with the help of a stirrer until the color is uniform and there is no agglomeration. The blended material has appropriate fluidity and plasticity for easy coating.

The operator uses a scraper to apply the material in an even state on the repaired surface, focusing on filling parts such as wear and depressions. During the coating period, extreme attention must be paid to draining the air . The wear and riveting repair of the eccentric shaft bearing of the jaw crusher must not leave any bubbles or pores. After one brushing is completed, the material should be inspected again. The areas with depressions should be repainted to ensure that the entire contact surface is covered by the material. After the coating work is completed, wait for the material to solidify on its own.

Curing and verification of dimensions and reassembly of bearing repair completed

The material curing time is determined based on the ambient temperature. In summer , the time will go faster, but in winter, it will be slower. When the material is cured, workers will hold an inner micrometer to measure the numerical volume of the repaired part to confirm whether it has returned to the originally designed dimensions. If you notice that the size is too large or too small, use a scraper and sandpaper to remove the excess material until the size is accurate.

After verifying it and confirming that it was correct, the workers began to reinstall the bearing, using special tools during assembly to avoid damage to the repair surface due to knocking. After the bearing was installed in the corresponding position, grease was added, and then rotated for testing to ensure that the operation was flexible and there was no jamming. The entire repair process took less than two days, and the company's equipment was put into production again. Compared with traditional methods, it saved more than five days of downtime.

Try to guess, how much loss did this repair help the company save due to production suspension? You are welcome to share your personal views in the comment area, like it and forward it, so that more peers can see this solution with practical value.