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A heavy and rigid cast-iron frame supports the two-roll assemblies, each of which comprises a shaft, a roll centre, and a shell of wear-resisting metal, such as high-carbon steel, or manganese steel. Each roll is independently driven by a flywheel type, flat-belt pulley, or V-belt sheave. One of the two pairs of bearings is arranged to slide horizontally on the side frames.
Although crushing rolls fitted with corrugated shells have been used in some special applications for secondary crushing, they are essentially a fine-reduction crusher, and as such are always fitted with smooth-face shells. The maximum one-way dimension of feed size is established by that point at which the rolls will nip the feed. This, in turn, depends upon the coefficient of friction of the material, the diameter of the rolls, and the spacing between roll faces.
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Several factors enter into the determination of the maximum practicable surface speed of crushing rolls. Theseare
So long as flat belts were the established driving medium, it was customary to equip the fixed roll with a large pulley, and the movable or spring roll with a smaller one generally one-half the diameter of the large one. The large pulley was designed to carry the full amount of power needed to drive both rolls, which of course relegated the smaller one to the status of an idling pulley its sole purpose was to bring the spring roll up to speed, and to maintain that speed during idling periods.
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The diagram in Figure 3 shows the method used in calculating maximum feed size for any diameter of rolls the accompanying table gives a listing of feed sizes for standard diameters. These figures are based upon zero roll spacing therefore the distance between faces i.e., the discharge spacing to be used should be added to them to obtain the maximum feed size for any combination of roll diameter and setting. The calculations are predicated on a coefficient of friction of 0.3, which is safe for most materials, provided that the surface speed of the rolls is not too high.
The theoretical capacity of crushing rolls is arrived at simply by calculating the volume of the ribbon whose cross section is the area of the discharge opening, and whose length is the peripheral speed of the roll faces per unit of time. The formula, for material weighing 100 lb per ft3, is
There was a logical purpose behind this arrangement. Because of the variables involved, it would be the exception, rather than the rule, if both roll faces ran at exactly the same speed under no-load conditions, and if this slip between faces continued when the rolls were loaded, wear on the shell faces would be greatly accelerated. The large-and- small pulley set-up permits the material to gear the shell faces together so that the speeds are the same, and any compensation that might be required in surface speeds is taken care of by belt slippage on the small pulley.
These movable bearings are spring-loaded to provide a safety relief for excessive pressures, such as are caused by tramp iron, etc. They are drawn up against locating shims which establish the spacing between roll faces discharge setting, and are held in that position by the springs, which are pre-set to the working pressure for which the particular machine is designed. This working pressure may vary fromas low as90kiloper linear centimetre of roll face, for light-duty rolls, to as high as 5.3 tonne per centimetre of roll face for extra-heavy-duty rolls.
When the multiple V-belt drive came into its own, and line-shaft transmission was replaced by individual motor drives, an improved driving arrangement for crushing rolls was developed. V-belt sheaves of equal size were installed on both rolls, and the load was divided between two motors. With this system, any speed compensation which may be required is taken care of automatically by increased slip of whichever motor happens to be driving the roll with highest no-load peripheral speed.