Under the double promotion of infrastructure frenzy and green mine construction, the annual demand of global sand and gravel aggregate has exceeded 50 billion tons. Traditional sand making equipment has been criticized for its long maintenance period and high energy consumption, while the hydraulic open box sand making machine has come out of nowhere, with innovative functions such as “one-key open box” and “intelligent adjustment”, it has set off a technological revolution in the sand and gravel production line.
1、Hydraulic system: the leap from mechanical transmission to intelligent control
Traditional sand making machine relies on bolts to fix the box, and replacing wear-resistant parts takes 4-8 hours to dismantle dozens of sets of bolts. The hydraulic box-opening technology, however, realizes the automatic opening of the box side panels within 30 seconds by integrating the hydraulic cylinder group. Measured data from a cement group shows that the technology has improved equipment maintenance efficiency by 83% and reduced the loss of unplanned downtime by 62%.
More noteworthy is the extended application of the hydraulic system:
Real-time pressure monitoring: dynamic tracking of crushing chamber pressure through sensors, automatically adjusting the hydraulic cylinder thrust
Over-iron protection mechanism: in case of unbreakable objects, the hydraulic system releases the pressure within 0.3 seconds to avoid spindle breakage
Remote diagnostic interface: support for IoT platform access to achieve the prediction of life of the wear parts
2. Energy optimization: the secret of direct reduction of the cost of gravel by 0.8 yuan per ton
In the Fujian Granite Sand Making Project, the hydraulic opener In the Fujian granite sand making project, the hydraulic box opener showed amazing advantages over traditional equipment:
Indicators Traditional equipment Hydraulic model Reduction
Electricity consumption (kWh/ton) 2.8 2.1 25% ↓
Wear parts cost 1.2 yuan/ton 0.8 yuan/ton 33% ↓
Product rate (0-5mm) 78% 92% +14% ↑
This leap originates from the three major innovations in design:
Laminar crushing principle: through the hydraulically adjusted impact angle, so that the material to achieve multiple collision crushing
Vortex cavity pressurization technology: increase the airflow rate by 30%, reducing the repeated crushing of fines
Modular wear-resistant liner: the use of chromium-molybdenum alloy + tungsten carbide coating, life expectancy has been extended to 4,000 hours
3, environmental breakthrough: the synergistic management of noise and dust
Hunan, a gravel plant’s test cases show that the hydraulic open box sand maker supporting a new type of After the environmental protection system:
The working noise is reduced from 112dB(A) to 85dB(A)
The dust concentration is controlled at 8mg/m³ (the national standard is 20mg/m³)
The water consumption is reduced to 0.15m³/tonne (the traditional wet method requires 0.3m³)
This is due to the hydraulic-driven closed structure and three patented technologies:
Pulse blowback dust removal: the use of hydraulic power to realize the automatic cleaning of the filter bag
atomization water curtain system: precise control of water pressure to 0.5MPa, the formation of μm-level dust suppression barrier
Resonance noise reduction chamber: hydraulically adjusted rubber shock absorber stiffness, blocking the path of acoustic wave transmission
4, Selection Guide: matching the capacity and raw material characteristics of the Golden Rule
When selecting and purchasing a hydraulic open box sand maker, you need to focus on the consideration of the three dimensions:
Raw material hardness: Moh’s hardness>7 materials recommended to choose double hydraulic cylinder to strengthen the structure
Capacity requirements: 300t/h below the model should be driven by a single motor, 500t/h above the recommended double motor configuration
Product specifications: the need for multi-stage sand, preferably equipped with hydraulic adjustment of the discharge port model
A mechanism of the sand project, for example, the use of HX-800 hydraulic sand making machine to deal with the river pebbles:
Feed size: ≤50mm
Fineness modulus of finished product: 2.6-3.0 adjustable
Needle flake content: <8%
Equipment utilization rate: up to 91.7% (the industry average is 76%)
5. Operation and maintenance revolution: from passive maintenance to predictive maintenance
The intelligent operation and maintenance system of the hydraulic sand making machine with hydraulic open box contains three core modules:
Vibration spectrum analysis: real-time monitoring of abnormal vibration of bearings and gears through 16 sensors
Oil cleanliness detection: automatically sampling and analyzing the metal particle content of hydraulic oil every 8 hours
Lining thickness scanning: laser ranging accuracy up to ±0.1mm, with a warning of replacement needs 30 days in advance
After applying the system in a quarry, the annual maintenance cost dropped by 41%, and the rate of accidental failures was reduced by 79%. Its equipment management personnel feedback: “Now the system will push the maintenance work order two weeks in advance, and even automatically generate the parts procurement list.”
With the deep integration of 5G + Industrial Internet, the hydraulic open box sand making machine is evolving from a single device to an intelligent production node. In the future, this equipment, which integrates high-efficiency crushing, intelligent control, and green production, will surely become the core engine of modernized sand and gravel aggregate production lines.
