WO2013028264A1

WO2013028264A1 - Rotary feeder

Info

Publication number: WO2013028264A1
Application number: PCT/US2012/045035
Authority: WO
Inventors: Laurence James MCMAHON
Original assignee: NAWA ENGINEERS AND CONSULTANTS PVT Ltd
Current assignee: NAWA ENGINEERS AND CONSULTANTS PVT Ltd
Priority date: 2011-08-24
Filing date: 2012-06-29
Publication date: 2013-02-28
Anticipated expiration: 2014-02-24

Abstract

The present invention is directed to an improved rotary feed distributor for use with a flat head or steep head cone crusher. The rotary feeder comprises a distributor box connected to a motor located underneath the distributor box and the motor that is, in turn, located above the top of the cone crusher head. The motor is attached to the crusher spider head by a rigidly attached adaptor plate, on steep head cone crushers, or via a rigidly attached adaptor housing assembly, which is part of an external support framework on flat head cone crushers.

Description

TITLE OF THE INVENTION

Rotary Feeder

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the field of rotary feeders used with rock crushing cone crushers and, specifically, to a rotary feed distributor used with a flat head or steep head cone crusher.

2. Description of Related Art

Conventional rock crushing requires the delivery and feed of rock materials to a crushing device, or a "crusher." Controlling the delivery of feed material to the crusher is important to optimize finished material production and crusher use.

Specifically, correcting feed material segregation prior to its introduction into the crusher is critical for efficient finished material production and maximizing the useful life of the crusher device.

Segregation of feed material arises in connection with the conveyor belts, vibro feeders and vibrating screen decks typically used in rock crushing for materials delivery to a crusher for production of smaller rocks having a predetermined size.

Rocks delivered via a conveyor belt or vibro feeder typically travel along the belt or pathway having a terminus located above the input of the crusher. Rocks delivered to the crusher via a conveyor belt or vibro feeder are subject to vibratory and gravitational forces en route, leading to segregation of rocks by size prior to their delivery to the crusher. That is, as the material moves along the conveyor belt, the vibrating action causes material stratification, such that smaller feed moves down through the stream of material to the bottom of the stream, and larger feed is thus biased towards the top of the stream. Accordingly, larger feed is in the front of the stream when the material discharges into the crusher and smaller feed is at the back of the stream. Typically, upon passing the belt or vibro feeder terminus, rocks fall under the force of gravity into the crusher. As the rocks fall into the crusher, they may be subject to additional gravitational forces that cause rocks of similar sizes to fall at the same rate and in the same general location, i.e., larger rocks fall with larger rocks and smaller rocks fall with smaller rocks. For example, feed delivered to the crushing chamber may be segregated such that larger feed is delivered to the far side of the crushing chamber while smaller feed is delivered to the near side of the crushing chamber. Segregated rocks delivered to the crusher via a conveyor belt or vibro feeder are also not typically discharged exactly in the center of the crusher and are not distributed evenly all around the crushing chamber.

Feeding of cone crushers directly off of vibrating screen decks typically results in feed comprising oversize rejects coming off a screen from the top deck only. Such feed material will still be graded from the largest piece to the smallest, with the smallest piece depending on the screen efficiency. Screens are not usually more efficient than about 90%, so there will be some materials delivered to the crusher that are smaller than aperture size. Sometimes feed from a vibrating screen deck to the cone crusher can comprise the rejected materials from two decks. In such a circumstance, the screen decks have different aperture openings that result in providing segregated feed to the crusher. Rejected materials from either a single deck or a two deck vibrating screen being fed to a cone crusher always have a range of feed gradation size.

Chutes may be employed to direct the fall of rocks from the conveyor belt or vibro feeder into the crusher, but these chutes do not necessarily correct for the lack of even distribution of the rocks all around the crushing chamber. Also, materials passing through a chute to the cone crusher are subject to separation between the larger and smaller feed materials due to gravity. Conventional chutes are fixed and stationary and do not permit adaptive change in response to feed conditions. That is, because feed can often change in size, gradation, feed rate, moisture content, etc., fixed chutes provide only limited feed control. Further, in some plants, particularly portable or track mounted plants, the feed is often discharged directly from a conveyor belt, vibro feeder or vibrating screen into the crusher without passing through a chute, in order to save valuable head room above the crusher.

Entry of segregated feed into the crusher has several deleterious effects including inefficient processing of feed with reduced total throughput and longer times required to produce finished product sizes, product having inconsistent gradations, shapes and quantities, uneven crushing by the crusher resulting in premature wear and tear of the crusher, uneven wear on the mantle and concave causing significant differences in the closed-side-setting around the crushing chamber (which gets worse the longer the mantle and concave are used), increased

maintenance needs due to uneven wear, inefficient use of power, and increased risk of crusher overload due to rapid changes in the arc of crushing contact when acting on unevenly sized and distributed materials within the crushing chamber.

When segregated feed is introduced into a crusher, larger feed preferentially benefits from the crusher's work as the crushing chamber area receiving the larger feed crushes the material as it passes down the entirety of the crushing chamber from entry to exit. Since more work is done on the larger feed, more reduction of the larger feed takes place, and the crusher's settings (speed, stroke, crushing chamber profile, etc.) have a greater influence on the size gradation, shape, and quantities of the discharge material. Meanwhile, smaller feed is less processed by the crusher because it falls far down into the crushing chamber area receiving the smaller feed before it is acted upon by the crusher. Accordingly, less work is done on the smaller feed relative to the larger feed. This gives rise to discharge material having varying levels of finish with regard to size gradation and shape. Differences related to the processing of larger and smaller feed lowers the production rate of finished product.

Also, because more work is done in the crushing chamber area receiving larger feed, more wear takes place in this area. The differential wear, in turn, requires that the shaft be adjusted to maintain a desired closed side setting sooner to counteract the effects of uneven wear than it would have to be adjusted for a crushing chamber area where work is more evenly distributed. The closed side setting is the smallest space, at any instant, between the two wear resistant components in the crusher that do the actual crushing. Crushing chamber areas that are less worn over time gradually have a smaller closed side setting than more worn areas. This differential wear reduces the useful life of the crusher mantle and concave.

The effects of this differential wear are further exacerbated by the insufficient feed flow control and/or intermittent and/or inconsistent feed flow rate used with most crushers.

Entry of segregated feed into a crushing chamber also increases the danger of instantaneous overloads. Irregularly graded and inconsistent feed can cause sudden changes in the crushing arc of contact, which can then produce an enormous increase in crushing load for little change in horsepower draw. For example, an instantaneous reduction in the crushing arc of contact causes the lead angle of the resultant crushing force to be lower, and this can cause instantaneous crushing loads two to three times higher than normal for the same horsepower input. Instantaneous overload is a "silent killer" of many cone crushers. Overloading force does not show up on conventional power recording and hydraulic pressure measuring equipment as this equipment is not sensitive enough to pick up the massive, but instantaneous, pressure spikes associated with this type of overload.

Segregated feed also leads to inefficient use of power because it results in larger fluctuations of power draw. That is, the average power draw in a poorly fed crusher is higher than it would be in a well fed crusher because the fluctuations between the high peak and the low peak power draw are much smaller.

Various feeder mechanisms have been introduced in attempts to address the problems caused by the entry of segregated feed into crushers.

Some early feed distribution devices included plate-like devices directly mounted to the top of gyratory crusher heads to receive incoming feed. These devices were designed so that the motion of the gyratory crusher head would distribute feed material. See e.g., U.S. Patent Nos. 2,020,464, 2,656,120 and 3,614,023. U.S. Patent No. 4,106,707, to Kemnitz, discloses a feed distributor mounted above a gyratory crusher that purports to distribute feed uniformly around the entire circumference of the crushing chamber. The Kemnitz device employs a rotating cylinder having a rotating bottom plate of a larger diameter connected to it by ribs leaving a

circumferential opening between the cylinder and the plate such that, upon rotation driven by a separate external motor and drive belt, material is purportedly thrown off the plate around the entire circumference of the crushing chamber.

Other devices, such as the one disclosed in U.S. Patent No. 3,506,203 to Rossi involves a rotating feed distributor driven by a separate external motor and drive belt that aims to minimize feed impact and ricochet upon entrance of rock into the crusher and to minimize the power required to turn the distributor itself. The Rossi device has a rotating chute having a downwardly inclined path that is located centrally above the crushing chamber. Similarly, U.S. Patent No. 3,785,578 also to Kemnitz, purportedly an improvement to the Rossi device, provides for a similar feed device that provides a single unitary assembly that purportedly permits easy removal from and

unencumbered access to the top of the crusher.

U.S. Patent Nos. 3,212,720, 3,358,939 and 3,384,215 to Gasparac et al.

disclose a centrifugal feed device driven by a separate external motor and drive belt that may be set at a distribution rate independent of the crusher head rate of movement. U.S. Patent Nos. 3,604,635 and 3,604,636, also to Gasparac et al, disclose a rotary feed distributor driven by a separate external motor and drive belt for use with gyratory crushers.

U.S. Patent No. 7,040,562 to Sawant et al, discloses a rotating feed distributor that is mounted on top of a crusher with external support and uses belts and a motor located external to the feed distributor box.

Despite the many previous efforts made to address the problems associated with the entry of segregated feed into crushers, the various conventional feeders are suboptimal and require additional and unnecessary parts that needlessly complicate the rotary feeder device itself. Specifically, conventional rotary feeders independently driven by separate belt(s) and/or drive chains connected to a motor located separate and apart from the feeder include vulnerable parts susceptible to dust, dirt, and breakage that may interfere with and/or interrupt rotary feeder operation. Use of separate belt(s) and/or drive chains also results in suboptimal transfer of energy between the motor and the rotary feeder as energy is transferred to the belt and/or chain before it is delivered to the rotary device. Conventional independently driven rotary feeders also require external supports in the form of a frame and/or legs to position the feeder above the crusher. Conventional independently driven rotary feeders also occupy a significant amount of space, or "headroom" above the crusher. The amount of headroom occupied by conventional independently driven rotary feeders is undesirable as it typically involves an overall suboptimal height and may also encompass additional space-consuming external supports and/or a separate motor and belt and/or chain system. Such increased headroom is particularly undesirable in connection with portable and/or track mounted plants.

The present invention addresses problems not addressed by conventional rotary feeders by providing for an improved rotary feeder that provides for desegregation of feed material prior to its entry into the crusher and also,

advantageously, improves upon the overall design of an independently driven rotary feed mechanism to provide a more efficient, robust, reliable, easier to maintain system that also beneficially comprises lower headroom and fewer parts.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to an improved rotary feed distributor for use with a flat head or steep head cone crusher. The rotary feeder comprises a distributor box connected to a motor located underneath the distributor box and the motor is, in turn, located above the top of the crusher head. The motor is attached to the crusher spider head by a rigidly attached adaptor plate, on steep head cone crushers, or via a rigidly attached adaptor housing assembly, which is part of an external support framework on flat head cone crushers. The present invention is primarily intended for use with tertiary and quaternary stage crushers, but it can also be used on secondary stage crushers to process feed sizes up 250 Mm.

In addition to improved desegregation of feed material prior to its entry into the cone crusher, the present invention offers numerous advantages over conventional rotary feeders including requiring fewer working parts, including eliminating vee belts and chain drives, reducing maintenance and work interruption, lowering rotary feeder headroom, providing infinitely variable speed within the speed range set, use of a hydraulic motor, and, optionally, not requiring external support structures to support the rotary feeder above the crusher when used on steep head cone crushers.

The diminished head room required by the present invention is particularly advantageous for use with wheel mounted or track mounted portable plants. For example, the present invention can reduce the headroom required by conventional feeders, such as the Innotech Solution RFD 300 and 500 models, by Innotech

Solutions, LLC, by between about 4 inches to about 8 inches depending on the size of feed being processed and the distributor box used.

The present invention comprises a distributor box, a motor, and an adaptor plate that connects the motor to the cone crusher spider head. The present invention may, optionally, incorporate an external support structure as part of an adaptor housing assembly to secure the rotary feeder above the cone crusher head.

For example, in one embodiment, the present invention may include external support structures as part of the adaptor housing assembly used with flat head cone crushers. In an alternative embodiment of the present invention, external support structures can be completely eliminated from rotary feeders used with steep head cone crushers.

The present invention is primarily intended for use with both tertiary and quaternary stage crushers, as these are the two crushing stages where the majority of end products are made, and the crushing loads are a lot higher. In quaternary stage crushers, the need for a rotary feeder is extremely high. However, the invention can also be used on secondary stage crushers with feed sizes up 250 Mm. Additionally, the rotary feeder can be used for other applications, such as distributing material into a stock pile or storage bin, to minimize the segregation in a pile, and/or anywhere that minimizing materials segregation is advantageous.

As a general matter, the present invention counteracts feed segregation during rock crushing by passing feed through a rotating distributor box, continuously rotating the distributor box by a motor attached thereto, and applying centrifugal force to discharge the feed evenly around the entirety of the cone crusher crushing chamber. Feed entering the distributor box, whether larger or smaller in size, is discharged together into the same crushing chamber location. Because the feeder rotates continuously over the full 360° rotation, feed material is spread evenly around the whole 360° of the crushing chamber.

A major factor in the feeder's capacity will be the rotating speed. The present invention provides for infinitely variable speed within a designed speed range. This makes the invention ideal for integration into automated feed control systems that integrate the feed level in the crusher with the rate of feed delivery, the horsepower being drawn, the resultant crushing loads measured through the crusher hydraulic system, the size gradation of the feed and the desired crusher discharge size gradation, etc. For any particular set of circumstances there will be an ideal rotary feeder speed. To be able to easily vary the speed is an advantage that the current mechanically driven feeders do not have.

A preferred embodiment of this invention comprises a hydraulic drive motor that can have infinite speed variations within the speed range it is designed for, such that the speed control can be integrated with the rate of the feeder feeding the crusher, and the level of feed in the crushing chamber, to provide the optimum feed rate for the required crushing performance. Where the speed of the feeder matches the rate of feed that is being fed to it, any tendency for the feed to build up in the distributor box and overflow is prevented. In another preferred embodiment of the present invention, the hydraulic motor speed is integrated with the rate of the feeder feeding the crusher.

The distributor box is located directly below a feed source such as a conveyor belt, vibro feeder, chute, etc. The distributor box is also located above the main shaft spider housing. The distributor box may be a welded construction of Mild Steel (M.S.) plate. The distributor box fits inside the conventional feed hopper fitted to crushers. The distributor box dimensions will change depending on feed size. The distributor box is open at the top to allow feed to enter and has an outlet opening on its side. The distributor box is reinforced around the top edge with an angle iron. The distributor box is closed at the bottom with a plate and a reinforcing plate is welded in the center on the outside of the bottom plate. There is a baffle plate fitted on the inside of the distributor box, which is so placed as to assist the box to be balanced, once the rock-boxes are full of material.

In operation, the distributor box will have a bed of stone built up inside everywhere that moving material travels. This stone bed, also referred to as a "dead bed" or "rock box," prevents unnecessary wear on the body of the distributor box. The internal portions of the box covered by this stone bed may be treated with an anti- rust surface protector. The discharge opening of the distributor box may be fitted with a wear bar welded to the edges of the discharge opening. As the distributor box is rotated, material discharges out of the discharge opening and into the crushing chamber on a full 360° rotation.

The shape of the distributor box is preferably four-sided, such as square or rectangular, so that piles of rock, or "rock boxes," form in the corners. Rock boxes help direct flowing rock material into the center of the discharge opening.

Rectangular shaped boxes may be used with larger cone crushers so that the rock discharge would be outside the spider hub area.

Rock raw materials discharged by gravity into piles have what is termed an "angle of repose" or "rill angle" which is the angle measured to the horizontal, that corresponds to the angle where the material will start to flow by gravity. Depending upon the material and the condition of the materials in the pile, the rill angle varies between approximately 25° and about 45°. In the case of the rotary feeder, because of the rotation, the rill angle is somewhat less than the natural angle and may be a maximum rill angle of between about 30° to about 35° depending on the size and type of the feed material.

The floor shape of the distributor box may vary. In a preferred embodiment, the distributor floor shape is flat and lies in a level horizontal plane above the cone crusher crushing chamber. In an alternative embodiment, the distributor floor shape is further defined by one or more plates fitted inside the distributor box which form a hollow compartment. The one or more plates used to form a hollow compartment within the distributor box may be referred to as a baffle plate or baffle plates. The hollow compartment reduces the amount of "dead bed" or "rock box" materials that are retained within the box at all times so that any unbalancing forces acting on the hydraulic drive motor are reduced.

The overall size and the outlet opening of the distributor box are dimensioned and positioned according to the feed sizes being handled and the rate of the feed to be distributed. In one embodiment, distributor boxes are sized to accommodate maximum feed sizes of about 125/150 Mm, about 75/90 Mm, and about 40/50 Mm. In an alternative embodiment, the distributor box is sized to accommodate maximum feed sizes of about 250 Mm for small secondary stage crushers or large tertiary stage crushers.

The distribution box outlet opening has to be a certain size to allow easy discharge of the larger rocks without the larger rocks bridging across the opening. As a general matter, in static chute discharges, the minimum opening dimension should be at least three times that of the biggest piece in the discharging material when handling material less than 150 Mm maximum feed size. The smallest discharge dimension is the normal distance from the closest rill line of the "dead bed" material in the distributor box to the top edge of the discharge opening. In the case of the distributor box for 125 Mm maximum feed size, this dimension is 375 Mm if the rill line angle is 30° to the horizontal. Because the material is not discharging from the distributor box by gravity only, but by centrifugal force also, it is believed that the 3: 1 general rule can be lowered, so that a box for 125 Mm maximum feed, could also be used for up to 150 Mm feed.

As described in greater detail below, there are various sized distributor boxes for the different maximum feed sizes, including 250 Mm, 125/150 Mm, 75/90 Mm, and 40/50 Mm maximum feed sizes. The present invention contemplates the ready exchange of distributor box sizes to accommodate a change in feed sizes.

The present invention does not contemplate a minimum feed size. Any graded feed that could benefit from segregation control can be used with the present invention. Maximum feed size can be determined by how easily the feed can be handled. For example, if the feed size is too big, then moving the feed into and out of the distributor box can be problematic. Because larger feed, i.e., greater than 150 Mm in size, requires a larger distribution box, there is a point at which it is not practical to mount the rotary feeder above the crusher due to the overwhelming size and weight of the distributor box. Furthermore, increasing the size of the feed and distributor box past a certain point will lead to more problematic out of balance loading. Importantly, however, the distributor boxes of the present invention can be adapted to handle larger feed sizes if the unbalancing forces generated by larger feed sizes are taken into account and steps are taken to counteract these unbalancing forces. For example, feed of up to about 250 Mm can be distributed using the distributor boxes of the present invention if 1) the centerline of the distributor box is offset from the centerline of rotation so as to reduce the unbalancing forces acting on the hydraulic drive motor, and/or 2) the amount of "dead bed" or "rock box" materials retained within the distributor box is reduced in order to reduce the weight of unbalancing forces operating on the hydraulic drive motor, and/or 3) other steps are taken to correct for the unbalancing forces imparted by the processing of larger feed. One way to reduce the amount of "dead bed" or "rock box" materials retained within the distributor box is to form a hollow compartment or space within the distributor box itself using one or more plates. Such a plate or plates may be referred to as a baffle plate or baffle plates. It is also noted that it may not be necessary for all larger feed size applications to offset the centerline of the distributor box from the centerline of rotation so as to reduce the unbalancing forces acting on the hydraulic drive motor, but that as feed size increases, including this feature can further counteract the unbalancing forces created when processing larger feed sizes.

In a preferred alternative embodiment, the present invention includes a distributor box capable of processing larger feed of up to about 250 Mm in size. This distributor box is a 900 Mm square distributor box comprising M.S. plate

construction, a 900 Mm square inside in plan, an inside depth of 820 Mm, a discharge opening of 690 Mm (height) and 750 Mm (wide), is open at the top, and is

encompassed at the top end by a 75 Mm by 75 Mm by 6 Mm angle iron stiffener. This distributor box can be fixed to the hydraulic drive motor through a boss having about a 300 Mm diameter and about a 38 Mm thickness. Additionally, plates are fitted inside this distributor box to form a hollow compartment at its lower right hand side. The one or more plates fitted inside the distributor box may be referred to as baffle plates. This hollow compartment serves to reduce the amount of "dead bed" material that is retained within the box at all times so that the unbalancing forces acting on the hydraulic drive motor are reduced. Also, the centerline of the box is offset from the centerline of rotation to further reduce the unbalancing forces acting on the hydraulic drive motor. As a general matter, absent additional steps taken to counteract the

unbalancing forces generated by processing larger feed sizes, the present invention contemplates a maximum feed size of approximately 150 Mm. As noted above, however, if additional steps are taken to counteract the unbalancing forces generated by processing larger feed sizes, i.e., feed larger than 150 Mm, the present invention further contemplates a maximum feed size of up to about 250 Mm. There is no optimal feed size range, but the smaller the size range from maximum to minimum size pieces in a given feed, the better the results that may be achieved.

For a tertiary crusher in a plant producing minus ¾ inch products, typical feed size ranges may comprise, for example, about 15% of about 3 inches to about 2 inches, about 20%> of about 2 inches to about 1½ inches, about 30%> of about 1½ inches to about 1 inch, about 25% of about 1 inch to about ¾ inch, and about 10% of about ¾ inch to about ³/g inch. For a quaternary stage crusher in a plant producing minus ³/g inch products typical feed size ranges may comprise, for example, about 30% of about 1 inch to about ¾ inch, about 30% of about ¾ inch to about ½ inch, about 30%) of about ½ inch to about ³/₈ inch, about 5%> of about ³/₈ inch to about ¼ inch, and about 5% of minus ¼ inch.

The distribution box is directly driven by a motor, most preferably, a hydraulic motor. The hydraulic motor is well sealed against dust and water penetration.

Advantageously, no vee belts or chain belts are required to operate the present invention.

In a preferred embodiment, the hydraulic motor is a wheel drive motor that is adapted to be vertically mounted. In a preferred embodiment, the horsepower ("HP") requirements are 3 HP for the maximum tonnage of 600 t.p.h. at a maximum speed of 30 rotations per minute ("RPM"), with a maximum pressure of approximately 3000 pounds per square inch at just above 0 RPM. In one embodiment the motor may be, for example, a Poclain motor MS02-1110 or other similar such motor.

In a preferred embodiment, the upper end of the hydraulic motor is rigidly attached to the distributor box. Specifically, the motor is bolted to the reinforcing plate on the outside surface of the bottom plate of the distributor box. A spigot on the motor end plate fits neatly into the c'bore in the reinforcing plate, and is fastened with SAE grade 8 bolts.

The hydrolyzing in and out oil lines may be fitted to the motor before mounting the motor on the adaptor plate or into an adaptor housing assembly. The oil lines may be located underneath the spider arm shield for protection. This shield is a wear resistant cover and may have recesses underneath it to allow the oil lines to run fully protected right up to entry into the hydraulic motor. The standard spider arm shield can be modified to have an extension piece on it to ensure protection for the full length of the oil lines. Alternatively, an additional protection plate may be fitted to the top of the spider arm and the oil lines may be fitted underneath the additional protection plate.

The hydraulic motor is powered by an external power pack. The external power pack may comprise a small oil reservoir, filter, variable displacement pump, and control and relief valves. The power pack may be adapted for incorporation into the existing lube/hydraulic power pack assembly unit for the crusher, but may require a different circuit and/or different oil.

The hydraulic motor, with the external power pack, can operate over a wide range of temperatures without requiring oil cooling or heating, or both. However, depending on climate conditions, heating and cooling facilities for the oil are also provided for climate conditions that require such facilities. The variable displacement pump can work in a closed loop with the hydraulic motor, with an inlet and outlet line for the motor between the pump and the motor.

Conventional cone crushers typically have a spider cap on the crusher head to seal off the spider bearing arrangement. In one embodiment, the present invention removes this spider cap and replaces it with an adaptor plate to allow fitting the motor to the top of the spider hub and crusher head. The adaptor plate of the present invention may be adapted to suit each particular make and size of crusher. In a preferred embodiment, the adaptor plate will be cast steel to BS3100: 1991, Grade Al, or equivalent, and fully annealed. Optionally, the adaptor plate may include one or more slots or openings to permit passage of the oil lines to and from the motor.

The adaptor plate may be a neat fit on the spigot of the spider hub, and use the existing tapped holes previously used to retain the spider cap to retain the adaptor plate. SAE Grade 5 retaining bolts can be torqued to approximately 75% of yield to attach the adaptor plate to the crusher head. The tightening procedures follow the system of first tightening any 2 bolts diametrically opposite each other, in turn, and then doing likewise with all the other bolts, working around all the bolts in order, in either a clockwise or counter-clockwise direction. Tightening of all the bolts with half torque is required, and then with full torque. The adaptor plate should be secured down on the flange to ensure dust entry prevention and to ensure that the adaptor is sufficiently rigid to resist the rocking motion that an out of balance distributor may impart.

In another embodiment, an adaptor housing assembly is used, for example, with a flat head cone crusher, in order to support the rotary feeder securely above the cone crusher. The adaptor housing assembly may include one or more slots or openings to permit passage of the oil lines to and from the motor.

When used with steep head cone crushers, the present invention

advantageously provides for a rotary feeder using an adaptor plate that does not require additional external supports to be securely located over the cone crusher.

Examples of steep head cone crushers suitable for use with the present invention include, but are not limited to cone crushers manufactured by Sandvik, Jaques, NAWA, Metso G Cone, Kawasaki, Kobe, etc.

When used with flat head cone crushers, the present invention may optionally involve external support structures to secure the rotary feeder above the cone crusher. Examples of flat head cone crushers suitable for use with the present invention include, but are not limited to cone crushers manufactured by Metso, Excel, NAWA, Cedar Rapids, JCI, etc. External support structures may include frames, legs, beams, bars, etc.

In one preferred embodiment, the rotary feeder comprises a rigidly attached distributor box, motor, and adaptor plate assembly that is rigidly attached to the top of a steep head cone crusher.

In another preferred embodiment, the rotary feeder comprises a rigidly attached distributor box, motor, and adaptor housing assembly that is rigidly attached to the supporting frame above the flat head cone crusher, and supported by external supports.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The accompanying Figures, which are incorporated in and constitute a part of this specification, illustrate various exemplary embodiments.

Figure 1 Figure 1 provides a front elevation view of a rotary feeder according to the present invention.

Figure 2 Figure 2 provides a front elevation view of a rotary feeder shown together with a steep head cone crusher according to the present invention.

Figures 3A-3D provide perspective views of the rotary feeder of the present invention mounted on top of a steep head cone crusher in various stages of rotation.

Figures 4A-B provide a side elevation view of a distributor box according to the present invention. Figure 4A shows a closed side of the distributor box. Figure 4B shows the distributor box side containing an opening.

Figure 5 provides a side elevation view of an adaptor plate according to the present invention.

Figure 6 provides a front elevation view of a rotary feeder according to the present invention as configured for use with a vibro feeder, feed chute, and steep head cone crusher.

Figures 7A-7D provide perspective views of the rotary feeder of the present invention mounted on top of a steep head cone crusher in various stages of rotation as further configured for use with a vibro feeder and feed chute.

Figure 8 provides a front elevation view of a rotary feeder according to the present invention as configured for use with a conveyor belt, feed chute, and steep head cone crusher.

Figures 9A-9B provide close up and exploded views of the attachment of the motor to the distributor box's reinforcement plate and the adaptor plate.

Figure 10 provides a front elevation view of a rotary feeder according to the present invention as configured for use with a flat head cone crusher.

Figure 11 provides a front elevation view of a rotary feeder shown together with a flat head cone crusher according to the present invention.

Figure 12 provides a front elevation view of a rotary feeder according to the present invention as configured for use with a conveyor belt, feed chute, and flat head cone crusher. Figure 13 Figure 13 provides a front elevation view of a rotary feeder according to the present invention as configured for use with a vibro feeder, feed chute, and flat head cone crusher.

Figure 14 Figures 14 provide a side elevation view of a distributor box which includes a hollow compartment according to the present invention. Figure 14A shows a closed side of the distributor box. Figure 14B shows the distributor box side containing an opening.

DETAILED DESCRIPTION OF THE INVENTION

Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure.

Figure 1 provides a front elevation view of a rotary feeder 10 according to the present invention. As shown, distributor box 20 is mounted on top of motor 40 via reinforcement plate 28. Distributor box 20 is shown located beneath fixed chute 200. Motor 40 is, in turn, attached to the head of a steep head cone crusher 80 by adaptor plate 60. Distributor box 20 is made of 10 Mm and 6 Mm Mild Steel (M.S.) plate and 50 Mm x 50 Mm x 4 Mm angle iron, and has a 38 Mm thick reinforcing plate 28 welded to the outside of the 10 Mm bottom plate. The reinforcing plate is machined to locate the spigot on the hydraulic motor 40 and to provide a flat and accurate face for the motor 40 to bolt to. Distributor box 20 has an overall height of 634 Mm, including the reinforcing plate, a 600 Mm square outside dimension, with 50 Mm x 50 Mm x 4 Mm steel angle iron 22 around the top to assist rigidity of distributor box 20, and has a 445 Mm high by 380 Mm wide discharge opening 24 when handling a maximum feed size of 150 Mm.

As shown, distributor box 20 sits within the feed hopper 90 of steep head cone crusher 80, but also rises above feed hopper 90. Feed hopper 90 is the standard feed hopper normally fitted to steep head cone crushers. Distributor box 20 is depicted with a bed of rock materials 26 contained therein. The bed of rock materials 26 are presented with a rill angle deflecting away from distributor box opening 24.

Reinforcement plate 28 is made of 38 Mm thick by 250 Mm diameter M.S.

plate, and is welded to the 10 Mm bottom plate of distributor box 20. The outside 250 Mm diameter face of the reinforcement plate is skim machined flat, and also has a nominal 93 Mm diameter by 8.5 Mm deep counterbore machined in the outside face to locate the motor 40.

Motor 40 is a hydraulic wheel motor. Motor 40 is attached to reinforcement plate 28 by 5 M14 Hexagonal Head, SAE Grade 5 Screws, torqued to 75% of yield. Motor 40 is attached to adaptor plate 60 by 10 M12 Hexagonal Head, SAE Grade 5 screws, torqued to 75% of yield.

Oil in and out lines 42, and a bleeder line (not shown), are connected to motor 40. These are flexible lines with hard connections at either end, capable of handling a maximum pressure up to 3000 pounds per square inch. They are fully protected by wear resistant guards all the way from where they connect to the hydraulic motor 40 to where they exit the standard crusher hopper 90. Just after they exit the standard hopper 90, they are fitted with quick disconnect, self-sealing, hard connectors.

Figure 2 provides a front elevation view of a rotary feeder 10 shown together with a steep head cone crusher according to the present invention. Figure 2 is similar to Figure 1 above and is merely provided here to show the configuration of the rotary feeder with a complete steep head cone crusher 80.

Figures 3A-3D provide perspective views of the rotary feeder 10 of the present invention mounted on top of a steep head cone crusher in various stages of rotation. As shown, incoming rock material 102 forms a bed of rock materials 26 in distributor box 20. Distributor box 20 is located on top of motor 40 which is located on top of adaptor plate 60.

The reinforced top edge 22 of distributor box 20 ensures rigidity of the box shape when under load. Motor 40 (not shown) rotates distributor box 20 so that rock feed materials 102 coming off conveyor 400 through fixed chute 200 into distributor box 20, are discharged out of the distributor box discharge opening 24, then constrained within standard hopper 90, and then rill down into the crushing chamber, and thus are evenly distributed around all 360 degrees of the crushing chamber of the steep head cone crusher 80. Also shown are spider arms 82, which are protected by wear plates, and the wear plates in turn protect the oil lines 42 (not shown).

Figures 4A-4B provide side elevation views of a distributor box 20 according to the present invention. Figure 4 A shows a closed side of the distributor box 20. Distributor box 20 has a reinforced top edge 22. The bed of rock materials 26 is depicted at about a 30° rill angle towards the wear bar 34 and distributor box opening 24. The distributor box bottom 32 (10 Mm plate) is reinforced by plate 28. Figure 4B shows the distributor box 20 side containing the distributor box discharge opening 24, and wear bar 34 (25 Mm diameter).

Figure 5 provides a side elevation view of an adaptor plate 60 according to the present invention. Specifically, adaptor plate 60 is shown with indentation 64 to accommodate fitting to the crusher head and indentation 62 to accommodate fitting to motor 40 (not shown).

Indentation 64 is machined into adaptor plate 60 to provide enough clearance with the top of the main shaft, when the main shaft is adjusted up to its maximum vertical position, which is when the mantle nut touches the underside of the spider hub. Indentation 62 is fully machined to ensure that there is adequate clearance for the bottom of hydraulic motor 40 to be fastened in position in the adaptor plate 60, and to also have adequate room for the oil lines 42 (not shown) to be fitted into the hydraulic motor 40. Adaptor plate 60 is made of low carbon cast steel to specification BS3100: 1991, Grade Al, or equivalent, and is fully annealed, and is machined all over.

Figure 6 provides a front elevation view of a rotary feeder 10 according to the present invention as configured for use with a vibro feeder 300, feed chute 200, and steep head cone crusher 80. Feed chute 200 is a fixed chute with a circular discharge opening in the bottom of the chute, which directs the feed material 102 into the distributor box 20. Feed chute 200 would normally be supported by either the feeder support structure, or by the main structure supporting the crusher 80.

Figures 7A-7D provide perspective views of the rotary feeder 10 of the present invention mounted on top of a steep head cone 80 crusher in various stages of rotation as further configured for use with a vibro feeder 300 and feed chute 200.

Figure 8 provides a front elevation view of a rotary feeder 10 according to the present invention as configured for use with a conveyor belt 400, feed chute 200, and steep head cone crusher 80.

Figures 9A-9B provide close up and exploded views of the attachment of the motor 40 to the reinforcement plate 28 which is located on the outside surface of bottom plate 32 of distributor box 20 and the adaptor plate 60. Figure 9B depicts how the motor 40 fits within the reinforcement plate 28 of distributor box 20 and shows how motor 40 fits within adaptor plate 60.

The upper end of motor 40 is rigidly attached to the distributor box 20.

Specifically, motor 40 is bolted, using SAE grade 8 bolts 44, to the reinforcement plate 28 located on the outside surface of bottom plate 32 of distributor box 20. A spigot 46 on the motor end plate 48 fits neatly into the c'bore 27 in the reinforcing plate 28, and is securely fastened using bolts 44. The lower end of motor 40 is rigidly attached to adaptor plate 60 using bolts 44 which connect flange 63 located on motor 40 to the top surface 61 of adaptor plate 60. Bolts 44 may be of varying size, such as 14 Mm diameter and 12 Mm diameter. Also shown in Figure 9B are mating parts, including washers 520.

Figure 10 provides a front elevation view of a rotary feeder 10 as configured for use with a flat head cone crusher (not shown). Motor 40 fits within adaptor housing assembly 65 and is located adjacent to support beams 66. Adaptor housing assembly 65 contains one or more slots 68 for oil lines 42. Rotary feeder 10 is supported above the flat head crusher by support beams 66.

Figure 11 provides a front elevation view of a rotary feeder 10 shown together with a flat head cone crusher 88 according to the present invention. Motor 40 fits within adaptor housing assembly 65 and is located adjacent to support beams 66. Adaptor housing assembly 65 contains one or more slots 68 for lines 42. Rotary feeder 10 is supported above the flat head crusher by support beams 66.

Figure 12 provides a front elevation view of a rotary feeder 10 according to the present invention as configured for use with a conveyor belt 400, feed chute 200, and flat head cone crusher 88.

Figure 13 provides a front elevation view of a rotary feeder 10 according to the present invention as configured for use with a vibro feeder 300, feed chute 200, and flat head cone crusher 88. Feed chute 200 is a fixed chute with a circular discharge opening in the bottom of the chute, which directs the feed material 102 into the distributor box 20. Feed chute 200 may be supported by either the feeder support structure, or by the main structure supporting the crusher 88.

Figures 14A-14B provide side elevation views of an alternative 900 Mm distributor box 500 according to the present invention which can be used to process larger feed sizes, i.e., feed sizes greater than 150 Mm. Figure 14A shows a closed side of the distributor box 500. Distributor box 500 has a reinforced top edge 522, the outer dimensions of which measure 1012 Mm, and the inner dimension of which measure 900 Mm. The distributor box 500 is 900 Mm inside in plan and has a depth of 820 Mm. The distributor box opening 524 measures 690 Mm high by 750 Mm wide. The wear bar is indicated by reference number 534. Baffle plates 610 and 620 are fitted inside the distributor box to form a hollow compartment 600 at the lower right hand side of Figure 14 A. As depicted, baffle plate 610 is 476 Mm high at its outer edge and slants downward to an elevation of 250 Mm where it meets with baffle plate 620 at the centerline of rotation 710. The centerline 700 of the distributor box 500 is offset from the centerline of rotation 710. The distributor box 500 is fixed to the hydraulic drive motor by boss 532 (300 Mm in diameter and 38 Mm thick).

Figure 14B shows the side distributor box 500 comprising the distributor box reinforced top edge 522, the discharge opening 524, the wear bar 534, the relative elevations of plate 610 and 620, and the boss 532.

Claims

1. A rotary feed distributor comprising:

a distributor box;

a motor:

a motor attachment component selected from one of an adaptor plate and an adaptor housing assembly; and

a cone crusher selected from one of a steep head cone crusher and a flat head cone crusher.

2. The rotary feed distributor of claim 1, wherein the distributor box is located above the motor, the motor is located above the motor attachment component, and the motor attachment component is located above the cone crusher.

3. The rotary feed distributor of claim 1, wherein the distributor box, the motor, and the motor attachment component are rigidly attached.

4. The rotary feed distributor of claim 2, wherein the distributor box, the motor, and the motor attachment component are rigidly attached.

5. The rotary feed distributor of claim 2, wherein the motor is a hydraulic drive motor.

6. The rotary feed distributor of claim 2, further comprising a hollow compartment formed by one or more plates within the distributor box.

7. The rotary feed distributor of claim 2, wherein a centerline of the distributor box is offset from a centerline of rotation.

8. The rotary feed distributor of claim 2, wherein the distributor box is sized to distribute various feed sizes.

9. The rotary feed distributor of claim 2, wherein the motor is a variable speed motor that matches the rate of feed being fed to the cone crusher.

10. The rotary feed distributor of claim 2, wherein the cone crusher is a steep head cone crusher.

11. The rotary feed distributor of claim 2, wherein the cone crusher is a flat head cone crusher.

12. The rotary feed distributor of claim 10, wherein the motor attachment component is an adaptor plate.

13. The rotary feed distributor of claim 11 , wherein the motor attachment component is an adaptor housing assembly.

14. The rotary feed distributor of claim 13, wherein the adaptor housing assembly includes at least one opening.

15. The rotary feed distributor of claim 13, wherein the adaptor housing assembly is part of an external support framework.

16. The rotary feed distributor of claim 2, wherein the cone crusher is selected from one of a secondary stage cone crusher, a tertiary stage cone crusher, and a quaternary stage cone crusher.

17. A method for reducing the segregation of feed material introduced into a cone crusher comprising use of the rotary feed distributor of claim 2.

18. The method of claim 17, wherein the cone crusher is a steep head cone crusher.

19. The method of claim 17, wherein the cone crusher is a flat head cone crusher.

20. The method of claim 17, wherein the distributor box, the motor, and the motor attachment component are rigidly attached.