How to Scientifically Determine the Time to Replace the Crusher Liner?

Scientific judgment of the time of replacing the crusher liner needs to be achieved through multi-dimensional observation and dynamic monitoring. First, the wear morphology of the liner surface needs to be checked regularly in daily production: if the local wear depth exceeds 30% of the original thickness, continuous through cracks are formed on the edge, or the hole position in the bolt fixing area is deformed due to wear, it indicates that the liner is close to the critical point of failure. Secondly, pay attention to the change in the particle size of the crushed product. When the proportion of coarse particles exceeding the standard in the finished product continues to increase and cannot be improved after adjusting the discharge port, it usually reflects that the wear of the liner causes the deformation of the crushing chamber and affects the material crushing trajectory.

Equipment operation data monitoring is an important reference. Record the current fluctuation of the main motor. If the current value rises by more than 15% compared with the new liner stage when crushing materials of the same hardness, it may be due to abnormal energy consumption caused by increased friction resistance after the liner is worn. At the same time, combined with the vibration sensor data, when the vibration amplitude of the crusher body exceeds the initial baseline value by 20%, it is often related to internal imbalance caused by loose or severe wear of the liner. In addition, attention should be paid to changes in the equipment noise spectrum. The frequent occurrence of high-frequency metal collision sounds may indicate that the liner has fallen off or fragments have entered the crushing chamber.

Economic benefit analysis should be incorporated into the decision-making system. When the cost of crushing a ton of ore with a single batch of liners increases by more than 40% compared to the initial period, or the frequency of maintenance and downtime increases from once a month to once a week, the comprehensive cost of continuing to use the worn liners may be higher than the investment in replacing new parts. Finally, a preventive maintenance cycle should be formulated based on the historical operation records of the equipment. For equipment that processes highly abrasive ores, it is recommended to conduct an early assessment at the 80% stage of the theoretical life to avoid collateral losses caused by sudden damage. A dynamic balance between safety and economy can be achieved by combining quantitative indicators with empirical judgment.