World firsts with extra power

At the Bauma 2010 trade fair, Kleemann is exhibiting two completely newly developed, contractor-class mobile impact crushers.

The foremost goal during development was to ensure maximum power while simultaneously providing the highest economy and availability. The secret of success: improving the flow of material through the entire machine. "To attain genuinely better performance, we were not satisfied with just addressing individual components. The key to a real increase in performance is the redesign of the flow of material – encompassing all components," says Thomas Kühnle, Head of Technology at Kleemann.

In a class by itself in terms of capacity and availability: the new generation of mobile Kleemann impact crushers.

In a class by itself in terms of capacity and availability: the new generation of mobile Kleemann impact crushers.

Material flow concept is key to highest performance values

The new material flow concept consistently prevents narrowing of the material stream, and the system widths of the conveyor elements "open" in the material flow direction. This allows performance values to be attained that are unmatched in these size classes. For the smaller of the two machines, which has a crusher inlet opening of 1100 mm, input capacities of over 350 t/h are measured. For the larger system, which has an inlet opening of 1300 mm, input capacities of 450 t/h and higher are attained.

Direct drive: Versatile and economical

The outstandingly economical performance is made possible in part by the extremely efficient direct drive with which both machines are equipped. A latest-generation diesel engine transmits its power almost loss-free via a robust fluid coupling and the V-belts directly to the flywheel of the crusher. This drive concept also enables enormous versatility, as the rotor speed can be adjusted in four stages. For example, the machines are equally well suited to use in quarries and in recycling, where the input material is often highly inhomogenous, particularly for difficult processing of construction waste.

Innovations in the individual components

Of course, the most important new feature for the individual components is the heart of the machines, the completely newly developed impact crushers of the SHB series. They feature many convincing new detailed solutions that are unmatched: from the hydraulically actuated crusher inlet in extremely robust heavy-duty cast design to the optimised, steeper inlet angle to the new blow bar fastening system – these all have a positive effect on availability. In addition, they have an innovative fully hydraulic crushing gap adjustment that can be operated easily and in mere seconds from the operating panel. The crushing gap adjustment, zero gap measurement and overload protection functions are cleverly integrated into one compact unit.

The crusher bypass was also given a complete overhaul. An optimised flow of material ensures that the input material, which is screened off by the extremely effective double-deck pre-screening unit and cleaned, is continually moved past the crusher, even at high screening output. One critical effect of the restriction-free material flow is the considerably reduced wear, particularly in the areas of the crusher outlet, crusher bypass and discharge chute.

However, the crusher is not the only new feature. For example, there is a newly designed feeding hopper which, supported by a load-dependent control, enables continuous loading. Critical advances have also been made in the shape and drive of the discharge chute. Only its added discharge capacity makes it possible to manage the higher volumes of material in the critical outlet area of the crusher.

Another extremely important feature for capacity and quality is the new classifying screening unit, which has been enlarged by 45% and which enables a closed circuit and thus the production of a defined final grain. Even for sieving grains up to 35 mm, the machine can make use of its full capacity without reducing the input volume. A swivelling return conveyor enables optional discharge of oversized particles to the waste rock pile.

Fast changeover times, high availability

In addition, the development process placed special emphasis on high availability and fast changeover times. Thus the hopper walls of the input unit are now not only lifted hydraulically, but also locked automatically by a new bolt system – without the need for any additional manual intervention.

The bottom line: with these two machines, Kleemann is starting a new chapter in terms of both capacity and economy.

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