Rock Crusher Maintenance
Know When It Is Going To Go Down
Just as is the case with approximately anything, the most likely time that rock crushers break down is when you will need to get the most out of them. As it is, you never realize how foremost something is until you do not have it, or when it is most required. In order to skirt high heal costs and output loss, allowable periodical maintenance of rock crushers is required. The most logical thing to do in order to maximize the crusher life is to found and execute a plan that will increase the life of the crusher thereby reducing heal cost and increasing the output. This can be done straight through laying down a rock crusher maintenance program that is adhered to. Following are five steps to help accomplish the goal.
1. Know and succeed the Rock Crusher Constraints
Every motor has a few reservations and this applies to a rock crusher as well. There are basically three limitations that are particularly foremost to be kept in mind while operating a crusher i.e. The horsepower, volume, and the crushing force. It is an overload if any one of these limitations is exceeded during operation. The operator needs to take into observation the type of rock being crushed and environmental conditions as this too may change the rock crusher's limits on the fly. By forcing the crusher to go beyond limits and stressing out dissimilar aspects of the machine, the lifespan is decreased and the time that it has in the middle of repairs and failure is shortened. All this leads to more heal expenditure, more man-hours, reduced output and in few cases permanent failure of the machine.
2. Forewarn yourself with the Maintenance Needs of your Rock Crusher
As with all the mechanical machines, maintenance is needed and must be followed. Rock Crushers are no different. There are three types of maintenance that one must succeed to properly assert the crusher. They are - Preventive maintenance, Predictive maintenance and Reactive maintenance.
- Preventive Maintenance
This type of crusher maintenance plan need to be on a program and followed to keep up the crusher life. Following the manufacturer's maintenance by hand should be the rule in this case. This includes seeing after the components like crusher liners and other wearing components for their good health.
By not changing the liners in the crusher as they become less and less efficient, you will not only be losing money because of poor/out of spec stock but also on labor as well since the operator will still be there for the same estimate of time, but doing much less crushing. Also, the out of spec or oversized material may re-circulate in a finished circuit to added increase the load on the already deficient crusher.
- Predictive Maintenance
This refers to monitoring the condition of the rock crusher while it is in use. This is done by using predictive maintenance tools, such as lubricating oil thermometers, lube oil pressure gauges, lubricating oil filter condition indicator device, lube oil analysis, crusher drive motor ammeter and daily operator crusher log sheets. These are used to conclude the normal operating specs of the crusher. This will allow seeing when things are not running properly and allow allowable and corrective action to occur.
- Reactive Maintenance
This maintenance occurs when the crusher is not operating properly and it is decided it is time to fix. In other words, waiting until it is broken in order to assert it. This should be seen as the last resort and be avoided.
3. Root Cause Analysis
Identify and apply corrective measures to the root cause because of which the rock crusher is facing issues. This can be very cost effective in the long run as it will minimize the recurrence of the problem. Root cause analysis not only helps in curbing the current qoute but also in forecasting the inherent of an incident. Thus corrective measures can be implemented well in advance.
There are many dissimilar techniques and tools for conducting root cause analysis like convention data, checking the operator's skills and knowledge, inspection of the motor and end product, motor placement, soldiery of nature, maintenance processes etc. Once the root cause is identified, found the corrective measure plan which will best suit to accomplish your goals. The tracking of corrective measures can be documented in the form of dash-boards for the staff.
4. found and Implement an employee Training Plan
Many problems that would occur with a rock crusher can be prevented if employees are trained properly. Employees can be trained on one-to-one basis or straight through a group session. Group sessions are more advisable if a new technique or process has to be imparted to employees. employee training program should be designed in such a manner that it keeps in mind each employee's needs and current skill status.
Proper training of employees increases their morale, inevitable in operating the crusher, their efficiency to work and decreases employee turnover. Which in turn lead to great working motor and an increase in behalf over the long run.Employee training is not a one time job rather it should be done periodically so that each someone is well adequate with the accurate and updated knowledge of operating and maintenance of the rock crusher.
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