Patent Publication Number: US-9427741-B2

Title: Two oil chamber counterweight

Description:
BACKGROUND 
     The present disclosure generally relates to rock crushing equipment. More specifically, the present disclosure relates to a cone crusher including a counterweight that rotates along with an eccentric and includes two separate oil chambers. 
     Rock crushing systems, such as those referred to as cone crushers, generally break apart rock, stone or other material in a crushing gap between a stationary element and a moving element. For example, a conical rock crusher is comprised of a head assembly including a crushing head that gyrates about a vertical axis within a stationary bowl indirectly attached to a main frame of the rock crusher. The crushing head is assembled surrounding an eccentric that rotates about a fixed main shaft to impart the gyrational motion of the crushing head which crushes rock, stone or other material in a crushing gap between the crushing head and the bowl. The eccentric can be driven by a variety of power drives, such as an attached gear, driven by a pinion and countershaft assembly, and a number of mechanical power sources, such as electrical motors or combustion engines. 
     The exterior of the conical crushing head is covered with a protective or wear-resistant mantle that engages the material that is being crushed, such as rock. stone, or other material. The bowl, which is indirectly mechanically fixed to the main frame, is fitted with a bowl liner. The bowl liner and bowl are stationary and spaced from the crushing head. The bowl liner provides an opposing surface from the mantle for crushing the material. The material is crushed in the crushing gap between the mantle and the bowl liner. 
     The gyrational motion of the crushing head with respect to the stationary bowl crushes rock, stone or other material within the crushing gap. Generally, the rock, stone or other material is fed onto a feed plate that directs the material toward the crushing gap where the material is crushed as it travels through the crushing gap. The crushed material exits the crushing chamber through the bottom of the crushing gap. The size of the crushing gap determines the maximum size of the crushed material that exits the crushing gap. 
     In currently available cone crushers, a supply of lubricating oil is directed to the bushing located between the eccentric and the stationary main shaft and to the bushing located between the head assembly and the eccentric. The lubricating oil drains through holes that are formed in the crushing head and eventually drops onto a moving counterweight that is attached to the eccentric. As the rotational speed of the eccentric and the attached counterweight increases, oil is flung around the interior of the counterweight. Some of this oil may escape out through seals within the cone crusher, which can result in the need for replacing the lost oil. 
     The counterweight has two main functions in a cone crusher. First, the counterweight functions to balance the centrifugal forces of the head and eccentric. Second, the counterweight functions to create a path and seal oil between the gyrating head and the stationary main frame. 
     Often, positive pressure air is added to the internals of the cone crusher to keep dust from being pulled in through the seals. The positive air pressure can amplify oil leakage in current designs. 
     SUMMARY 
     The present disclosure relates to a counterweight for use in rock crushing equipment, such as a cone crusher. The counterweight includes two separate oil chambers that receive lubricating oil and direct the lubricating oil to an oil sump. 
     The counterweight of the present disclosure is for use with a cone crusher that includes a stationary bowl. A head assembly is positioned for movement within the stationary bowl to create a crushing gap between the stationary bowl and the head assembly. The head assembly includes a crushing head and mantle. The head assembly is received around an eccentric that is in turn rotatable about a stationary main shaft. The configuration of the eccentric causes the head assembly to gyrate within the stationary bowl upon rotation of the eccentric around the main shaft. 
     The counterweight constructed in accordance with the present disclosure is mounted to the eccentric and rotates with the eccentric. The counterweight includes both an inner oil chamber and an outer oil chamber that each receive lubricating oil and direct the lubricating oil to a main oil sump of the cone crusher. 
     The eccentric includes a generally horizontal floor that extends from an inner edge to an outer edge. A vertical separating wall extends from the generally horizontal floor and is positioned at a location between the inner edge and the outer edge. The vertical separating. wall separates the inner oil chamber from the outer oil chamber. 
     A splash shield is mounted to the vertical separating wall and is positioned to overhang at least a portion of the horizontal floor that is radially inward from the vertical separating wall. The splash shield further separates the inner oil chamber from the outer oil chamber and defines an upper barrier for the inner oil chamber as well as a lower barrier for the outer oil chamber. In one embodiment of the disclosure, the splash shield is formed from a plurality of shield plates that are each separately attached to the vertical separating wall. The splash shield extends around the entire internal circumference of the counterweight such that the inner oil chamber also extends around the entire circumference of the counterweight. The inner oil chamber includes a plurality of spaced inner chamber drain holes that allow oil to pass through the floor of the counterweight. 
     The counterweight further includes an outer oil chamber that is formed between the vertical separating wall and an inclined inner wall of the counterweight. The outer oil chamber is spaced radially outward relative to the inner oil chamber and separated from the inner oil chamber by the vertical separating wall and the splash shield. The outer oil chamber includes a plurality of spaced outer chamber drain holes that allow oil to pass from the outer oil chamber through the counterweight floor and into the main sump of the cone crusher. The outer chamber also extends the circumference of the counterweight. 
     An outer end of the splash shield is attached to the separating wall while an inner end of the splash shield is closely spaced to an outer surface of the crushing head. The small gap created between the crushing head and the inner end of the splash shield entraps most of the drained lubricating oil within the inner oil chamber. The portion of oil or oil mist that escapes through the gap between the splash shield and the crushing head is directed into contact with a head skirt. The head skirt is positioned to direct oil or the oil mist away from the seal between the counterweight and the crushing head such that the oil can be drained from the counterweight through the drain holes formed in the outer oil chamber. 
     The combination of the inner and outer oil chambers collects and drains the lubricating oil and prevents the lubricating oil from passing through the seal assemblies between the counterweight and the crushing head. The splash shield that forms a part of the inner oil chamber quickly directs most of the oil into the sump and greatly reduces the amount of oil that contacts the inclined inner wall of the counterweight, thereby reducing the amount of oil loss. The splash shield is constructed of multiple shield plates such that the splash shield can be easily assembled within the interior of the counterweight. 
     Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate the best mode presently contemplated of carrying out the disclosure. In the drawings. 
         FIG. 1  is a section view of a cone crusher incorporating the counterweight of the present disclosure. 
         FIG. 2  is a magnified section view similar to  FIG. 1  illustrating the flow of lubricating oil within the cone crusher. 
         FIG. 3  is a further magnified view illustrating the inner and outer oil chambers created by the counterweight of the present disclosure; 
         FIG. 4  is a further magnified view similar to  FIG. 3 ; 
         FIG. 5  is a view similar to  FIG. 4  showing the movement of oil within the inner and outer oil chambers of the counterweight; 
         FIG. 6  is a bottom section view illustrating the oil in both the inner oil chamber and the outer oil chamber; 
         FIG. 7  illustrates the inner and outer oil chambers aligned with the thick side of the eccentric; 
         FIG. 8  is a top section view of the counterweight; 
         FIG. 9  is a bottom section view of the counterweight; 
         FIG. 10  is an isometric view illustrating the counterweight; 
         FIG. 11  is a bottom view of the counterweight; and 
         FIG. 12  is a partial section view with the splash plate removed. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a section view of a cone crusher  10  that is operable to crush material, such as rock, stone, ore, minerals or other substances. The cone crusher  10  includes a main frame  12  having a mounting flange  14 . The cone crusher  10  can be any size rock crusher or include any type of crusher head. Mounting flange  14  rests upon a platform-like foundation that can include concrete piers (not shown), a foundation block, a platform or other supporting member. A central hub  16  of the main frame  12  includes an upwardly diverging vertical bore or tapered bore  18 . The bore  18  is adapted to receive a main shaft  20 . The main shaft  20  is held stationary in the bore  18  with respect to the central hub  16  of the frame  12 . 
     The main shaft  20  radially supports an eccentric  22  that surrounds the main shaft  20 . The head assembly  24  is supported on the top end of the main shaft  20 . The eccentric  22  rotates about the stationary main shaft  20 , thereby causing the head assembly  24  to gyrate within the cone crusher  10 . Gyration of the head assembly  24  within a bowl  26  that is directly fixed to an adjustment ring  28  supported by the main frame  12  allows rock, stone, ore, minerals or other materials to be crushed between a mantle  30  and a bowl liner  32 . The gyrational motion of the head assembly  24  crushes rock in a crushing gap  34  and the force of gravity causes additional material to move toward the crushing gap  34 . The bowl liner  32  is held against the bowl  26  by a wedge  44  and the mantle  30  is attached to a crushing head of the head assembly  24 . The gyrational movement of the head assembly  24  forces the mantle  30  toward the bowl liner  32  to create the rock crushing force within the crushing gap  34 . 
     As can be understood in  FIG. 1 , when the cone crusher  10  is operating, drive shaft  40  rotates the eccentric  22  through the interaction between the pinion  38  and the gear  42 . Since the outside diameter of the eccentric  22  is offset from the inside diameter, the rotation of the eccentric  22  creates the gyrational movement of the head assembly  24  within the stationary bowl  26 . The gyrational movement of the head assembly  24  changes the size of the crushing gap  34  which allows the material to be crushed to enter into the crashing gap. Further rotation of the eccentric  22  creates the crushing force within the crushing gap  34  to reduce the size of particles being crushed by the cone crusher  10 . The cone crusher  10  can be one of many different types of cone crushers available from various manufacturers, such as Metso Minerals of Waukesha, Wis. As an example, the cone crusher  10  shown in  FIG. 1  can be an MP® series rock crusher, such as the MP®2500 available from Metso Minerals. However, different types of cone crushers could be utilized while operating within the scope of the present disclosure. 
     During operation of the cone crusher  10 , material is crushed by the gyrating movement of the head assembly  24  in the crushing gap  34  formed between the outer surface of the mantle  30  and the bowl liner  32 . Both the bowl liner  32  and the mantle  30  are designed as replaceable equipment such that the cone crusher can be refurbished upon wear. 
     The cone crusher  10  includes an oil lubrication system that provides a supply of lubricating oil between the moving components within the cone crusher. The lubrication system includes an inlet  46  that receives a supply of lubricating oil. The inlet  46  directs lubricating oil to a central passage  48  that extends through the center of the main shaft  20 . The central passage  48  extends to the top end  50  of the main shaft  20  where the oil leaves the main shaft  20  and lubricates the gyrational point of contact between the head ball  52  and the socket liner  54 . The lubricating oil distributed through the top end  50  of the main shaft  20  pools within an upper sump  56  and passes through the lower portion  58  of the crushing head  36  through a series of drain holes  60 . 
     In addition to the central passage  48 , the main shaft  20  includes a radial passage  62  that distributes lubricating oil between the rotating eccentric  22  and the main shaft  20  and between the crushing head  36  and the eccentric. 
     The lubricating oil passes through the crushing head  36  and is collected within a main frame oil sump  64 , which in turn is drained through a lubrication outlet  66 . The lubrication outlet  66  directs the lubricating oil back to a pumping, cooling and filtering system where the lubricating oil is filtered and supplied back to the inlet  46  for redistribution within the cone crusher. 
       FIG. 2  illustrates the flow of lubricating oil through the central passageway  48 , as illustrated by a series of arrows. As described, the lubricating oil exits the top end  50  of the main shaft  20  and lubricates the head ball  52  and socket liner  54 . There is also oil from end leakage from the eccentric to the main shaft bushing and crushing head to the eccentric bushing. The oil then flows into the upper sump  56 . The oil collected within the upper sump  56  passes through the series of drain holes  60  formed in the lower portion  58  of the crushing head  36 . The oil leaving the lower end of each of the drain holes  60  falls onto a radial flange  68  of the eccentric  22  or onto the floor  84  of the counterweight  70 . 
     Since the eccentric  22  is rotating at a relatively high rate of speed, oil falling onto the radial flange  68  is flung radially outward and into contact with the counterweight  70  that is securely attached to and rotatable with the eccentric  22 . In accordance with the present disclosure, the counterweight  70  includes a pair of oil chambers, to be described below, that each include separate drain holes that allow the oil to pass through the counterweight and be collected Within the main frame oil sump  64 . 
       FIG. 10  is an isometric, view of the counterweight  70  constructed in accordance with the present disclosure. The counterweight  70  is a generally cylindrical component that is mounted to the eccentric for rotation with the eccentric. The counterweight assembly  70  balances the eccentric and crushing head. The counterweight  70  includes a series of tanks  72  formed on a heavy side  74  of the counterweight. The light side  76  of the counterweight does not include any tanks. When the counterweight  70  is mounted to the eccentric, the heavy side  74  is aligned with the thin side of the eccentric while the light side  76  of the counterweight  70  is aligned with the thick side of the eccentric. The series of tanks  72  are typically filled with dense material, such as lead or tungsten rods, to provide the required weighting for the heavy side  74 . A cover  78  is attached to the upper surface  80  of the counterweight  70  through a series of individual fasteners  82 . The cover  78  is attached to the counterweight  70  after each of the tanks  72  are filled with the weighted material to protect the counterweight  70  from wear. In the embodiment shown in  FIG. 10 , the cover  78  is formed from welding a flat top plate  79  to a depending cylindrical bottom plate  81 . However, the cover  78  could be formed as a complete, unitary component. 
       FIGS. 8 and 9  are upper and lower cross-sectional views of the counterweight  70 . As can be seen in  FIG. 8 , the counterweight  70  includes a generally horizontal floor  84  that extends radially outward from an inner edge  86  to an outer edge  88 . A recessed mounting groove  90  is formed in the floor  84  and receives a T-seal  92 , which in turn is received within a U-seal  94  mounted to the main frame . The counterweight further includes a lower vertical flange  96  that extends vertically below the floor  84 . 
     The horizontal floor  84  includes a series of attachment holes  98  positioned near the inner edge  86 . The attachment holes  98  allow the entire counterweight  70  to be attached to the eccentric for rotation with the eccentric. 
     The counterweight  70  further includes a vertical separating wall  100  that extends upward from the horizontal floor  84  at a location between the inner edge  86  and an inner wall  102 . As illustrated in  FIG. 8 , the inner wall  102  extends both upwardly and inwardly relative to the horizontal floor  84 . The inner wall  102  defines the height of the counterweight and supports a U-seal  104 , as best illustrated in  FIG. 9 . The U-seal  104  interacts with a mating T-seal  106  formed in a groove  108  formed in the crushing head  36 , as best shown in  FIG. 5 . 
     Referring back to  FIG. 8 , a splash shield  110  is mounted to the vertical separating wall  100  and extends over a portion of the horizontal floor  84 . In the embodiment illustrated, the splash shield  110  is formed from multiple sections that are joined to each other. The use of multiple sections to form the splash shield  110  facilitates the ease of installation since each of the separate sections can be individually placed within the counterweight  70  prior to attachment to each other to form the splash shield  110 . The multi-section splash shield  110  is also required due to the geometry of the counterweight  70 . Specifically, the top opening of the counterweight  70  is smaller in diameter than the diameter of the vertical separating wall  100  that supports the splash shield  110 . Thus, forming the splash shield in multiple sections is required in the embodiment illustrated. The splash shield  110  includes a series of outer fasteners  112  that each are received within a bore  114  formed in the vertical separating wall  100 . A series of inner fasteners  116  are used to attach the separate sections that form the splash shield  110 . 
     Although a series of inner fasteners  116  are illustrated to attach the separate sections of the splash shield  110 , it is contemplated that other attachment methods could be utilized while operating within the scope of the present disclosure. As an example, the splash shield sections could be joined using other types of hardware, welding or attachment methods. Additionally, although the embodiment illustrates mounting the splash shield sections to the vertical separated wall  100 , it is contemplated that the vertical separating wall and splash shield sections could be integrally molded and the integrally molded piece would be bolted to the horizontal floor  84 . 
     When the splash shield  110  is mounted to the vertical separating wall  100 , an outer end  118  of the splash shield is generally aligned with the outermost surface of the vertical separating wall  100 . An inner end  120  of the splash shield  110  extends radially inward, as shown in  FIG. 9 . As can be understood in  FIG. 9 , the inner end  120  is spaced radially inward from the inner edge  86  of the floor  84 . The combination of the floor  84 , the vertical separating wall  100  and the splash shield  110  define an inner oil chamber  122 . 
     As further illustrated in  FIG. 9 , the inner wall  102 , the splash shield  110  and the vertical separating wall  100  combine to define an outer oil chamber  124 . The inner and outer oil chambers are thus separated by the vertical separating wall  100  and the splash shield  110 . The outer oil chamber  124  includes an open upper end  126  that allows oil to enter into the outer oil chamber  124 , as will be described. 
     Referring now to  FIGS. 9 and 11 , the floor  84  of the counterweight  70  includes a series of drain holes that allow oil to pass through the floor and be drained out of the cone crusher. Specifically, the floor includes a series of spaced inner chamber drain holes  128  and a second series of outer chamber drain holes  130 . The inner and outer chamber drain holes  128 ,  130  are located on opposite sides of the vertical separating wall  100 , as best shown in  FIG. 8 . The inner chamber drain holes  128  allow oil accumulated within the inner oil chamber  122  to drain through the counterweight while the outer chamber drain holes  130  allows oil accumulated within the outer oil chamber to also drain through the counterweight  70 . Although the inner and outer oil chamber drain holes  128 ,  130  are shown in  FIG. 9  as being generally aligned with each other and separated by solid divider  131 , it should be understood that the spacing between the inner chamber drain holes  128  and the outer chamber drain holes  130  could be varied while operating within the scope of the present disclosure. 
       FIGS. 3 and 4  illustrate the position of the counterweight  70  relative to the crushing head  36  along the thin side of the eccentric  22 . As discussed previously, the drain holes  60  deposit oil collected from the upper sump  56  onto the radial flange  68  of the eccentric  22  and the horizontal floor of the counterweight  84 . The counterweight  70  is attached to the radial flange  68  through the series of fasteners  132 . In this position, the inner oil chamber  122  receives the oil from the drain holes  60  that is flung radially outward by the rotating eccentric  22 . 
     As illustrated in  FIG. 4 , the inner end  120  of the splash shield  110  is very closely spaced relative to the surface  134  of the crushing head  36 . The close spacing between the inner end  120  of the splash shield  110  and the surface  134  greatly restricts the amount of oil that can splash over the splash shield  110 . As stated previously, the inner oil chamber is generally defined by the splash shield  110 , the floor  84  and the vertical separating wall  100 . During operation, oil flung radially outward by the rotating eccentric  22  is entrapped within the inner oil chamber  122  and quickly drains through the series of inner chamber drain holes  128 . Since the oil is forced radially outward by the centrifugal force created by the rotating eccentric  22 , the inner chamber dram oil holes  128  are positioned as close as possible to the vertical separating wall  100  to prevent oil from pooling within the inner oil chamber  122 . The oil drained through the inner chamber drain holes  128  passes through the counterweight and is ultimately collected within the main frame oil sump  64 . 
     During high speed operation of the cone crusher, the eccentric  22  is rotating at a relatively high speed which causes oil being drained through the drain holes  60  to be thing into the inner oil chamber  122 . This oil can create very small particles of oil or a mist that may not be entrapped and contained within the inner oil chamber  122 . This additional oil is then received within the outer oil chamber  124 . The outer oil chamber  124  is defined as the area above the splash shield  110  and between the vertical separating wall  100  and the inner wall  102  of the counterweight  70 . Any oil received within the outer oil chamber  124  collects and is drained out of the outer oil chamber through the outer chamber drain holes  130 . As described above, since the eccentric  22  is rotating, any oil received within the outer oil chamber  124  is forced radially outward through the centrifugal force created by the rotating eccentric. Thus, the outer chamber drain holes  130  are positioned adjacent the inclined inner wall  102  of the counterweight  70  to help eliminate pooling of the oil within the counterweight. The oil drained through the outer chamber drain holes  130  is also directed to the main frame oil sump  64  by the vertical flange  96 . The flange  96  protects the lower seal formed between the T-seal  92  mounted to the counterweight and the U-seal  94  mounted to the main flame  12 . 
     As illustrated in  FIG. 4 , a head skirt  136  is mounted to the crushing head  36  to further deflect oil away from the seal created by the U-seal  104  and the T-seal  106 . The head skirt  136  is attached to the crushing head  36  through a series of spaced connectors, such as bolts. Although the head skirt  136  deflects the oil-air mist away from the seals  104 ,  106 , the head skirt  136  may not be required depending upon the close spacing between the inner end  120  of the splash shield  110  and the surface  134  of crushing head  36 , which controls how much oil enters the outer oil chamber  124  and the direction and velocity at which the oil enters the outer oil chamber  124 . 
       FIG. 5  illustrates the general flow of lubricating oil within both the inner oil chamber  122  and the outer oil chamber  124 . As previously described, lubricating oil from the drain hole  60  contacts the radial flange  68  of the eccentric  22  and the floor  84  of the counterweight and enters into the inner oil chamber  122 . The oil within the inner chamber  122  is entrapped by the generally horizontal splash shield  110  and the vertical separating wall  100 . This collected oil drains through the inner chamber drain holes  128  and ultimately travels to the main frame oil sump. Although most of this oil is captured in the inner oil chamber  122 , an oil-air mist may pass between the slight gap formed between the inner end  120  of the splash shield  110  and the surface  134 . This oil mist contacts the head skirt  136  and is directed downward onto the upper surface of the splash shield  110 . The rotational movement of the eccentric and counterweight cause this small amount of oil to be flung radially outward and into contact with the inclined inner wall  102 . The oil quickly drains out through the outer chamber drain holes  130  positioned on the opposite side of the vertical separating wall  100  from the inner chamber drain holes  128 . In this manner, the oil from both the inner chamber drain holes  128  and the outer chamber drain holes  130  move toward the main frame oil sump. 
       FIG. 6  clearly illustrates the position of the outer chamber drain holes  130  and the inner chamber drain holes  128  on the opposite sides of the vertical separating wall  100 . The lower portion of the vertical separating wall  100  forms the divider  131  between the drain holes  128  and  130 . Further,  FIG. 6  illustrates the separation between the inner oil chamber  122  and the outer oil chamber  124 . 
       FIG. 7  illustrates the inner and outer chambers relative to the thick side of the eccentric  22 . As illustrated in  FIG. 7 , the radial width of the splash plate  110  is less at the location aligned with the thick portion of the eccentric as compared to the thin portion of the eccentric shown in  FIG. 3  due to the increased eccentric thickness. However, the splash shield  110  still combines with the vertical separating wall  100  to define the inner oil chamber  122 . The outer oil chamber  124  is positioned on an opposite side of the vertical separating wall  100 . Oil from drain holes  60  in this position drops directly onto the horizontal counterweight floor  84 . 
       FIG. 12  illustrates that the height of the vertical separating wall  100  changes from the heavy side  74  to the light side  76  of the counterweight  70 . Since the heavy side  74  of the counterweight  70  is aligned with the thin side of the eccentric, the height of the vertical separating wall  100  changes to accommodate the configuration of the eccentric and the resulting position of the head. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.