The remaining service life of the cone crusher lining, without dismantling, is determined by three non-destructive measurements, an analysis of load data and a calculation using a formula, with an accuracy of 92%; measurements are carried out every 250 hours whilst the equipment is shut down.
The remaining service life of a cone crusher’s lining can be determined without dismantling the unit on the basis of the results of three consecutive non-destructive measurements and calculations, with the accuracy of the values obtained being 92% of the actual remaining service life, as determined by production tests at quarry sites.
As part of this stage, measurements of the armour thickness are taken at 12 standard inspection points, evenly spaced across the entire height of the cone’s working zone; the values obtained are actual measurements taken using an ultrasonic thickness gauge without dismantling any parts of the crusher; the deviation of the measurement results from the actual thickness following subsequent dismantling is no more than 0.2 mm, according to production test data.
This takes into account the total volume of rock processed since the new lining was fitted, which is recorded by the crusher’s automatic productivity monitoring system, as well as the proportion of time the equipment operates at maximum load, which, according to an analysis of operational statistics, has a 2.7 times greater impact on the rate of liner wear than operation at average load; these figures are actual data obtained from monitoring systems for 140 units of crushing equipment at quarries in Russia and Kazakhstan.
The calculation is carried out using the formula included in the official technical guidelines issued by the manufacturers of cone crushers, with the resulting residual service life being an estimated value; the permissible deviation from the actual service life, as determined following dismantling of the equipment, is no more than 8%, based on the results of inspections carried out on 220 crushers of various size classes.
| Parameter name | Data type | Permissible deviation from the actual value |
|---|---|---|
| Armour thickness at test points | Actual measurement | 0.2 mm |
| Volume of raw materials processed | Data from monitoring systems | 1,2% |
| Proportion of operation at maximum load | Actual operating figure | 0,8% |
| Estimated remaining service life | Estimated value | 8% |
Question 1: Is it possible to use only armour thickness measurements to accurately estimate the remaining service life? Answer: No; according to production test results, the accuracy of an assessment based solely on thickness measurements, without taking into account operating conditions and the volume of processed raw materials, is no greater than 68%. Question 2: How often should measurements be taken to monitor armour wear without dismantling the equipment? Answer: The optimal frequency for measurements is once every 250 hours of crusher operation; this figure is an engineering recommendation, supported by operational data from equipment at active mining enterprises. Question 3: Is it necessary to stop the crusher before taking measurements without dismantling it? Answer: Measurements must only be taken when the equipment is completely stopped and locked; this requirement is specified in the official operating instructions for cone crushers of all series.
