I. General Work Process

The material is evenly fed through the feeding device into the crushing chamber, where it undergoes compression, shearing, and crushing between two counter-rotating rollers. After crushing and sand formation are completed, the material is discharged from the bottom. The entire process is continuous and stable, ensuring efficient medium and fine crushing with particle formation.

II. Principles of Key Technologies

1. Differential Drive System

• Single Motor Drive One motor drives the driving roller through the transmission, significantly reducing energy consumption and operating costs.
• Driving-Following Configuration One roller is the driving roller, the other is the driven roller, which rotates due to material friction.
• Speed Difference Formation A difference in rotational speed is created between the rollers; the driving roller rotates slightly faster than the driven one.
• Material Layer Effect The speed difference helps form a stable layer of material between the roller surfaces, with particles rotating 360°.

2. Double Curvature Roller Design

• Curvilinear Design The roller surface has a special double curvature geometry, rather than the traditional flat or single-arched shape.
• Increased Contact Area Compared to traditional flat rollers, the effective contact area is increased by more than 30%.
• Double Crushing The material undergoes two full cycles of rotational crushing at 360° inside the crushing chamber.
• Trajectory Optimization The curvilinear structure guides the material along an optimal trajectory, improving crushing efficiency.

3. Layered Crushing Mechanism

• Layer Formation Due to the speed difference, the material naturally accumulates, forming a layer of a certain thickness.
• Interlayer Crushing Particles in the layer compress each other; more than 80% of the material is crushed by the "stone on stone" principle.
• Stress Transmission Roller pressure is evenly transmitted through the material layer, avoiding direct impact wear on the roller surfaces.
• Shape Optimization Repeated compression and crushing smooth sharp edges, producing high-quality particles close to spherical shape.

III. Crushing Process Analysis

Stage 1: Material Loading

Material from the loading port enters the wedge-shaped zone between the rollers, undergoing preliminary compression and directed movement.

Stage 2: Primary Crushing

The material rotates with the driving roller, entering the first crushing zone at 360°. Due to the speed difference, a material layer forms; particles compress and shear each other during primary crushing.

Stage 3: Secondary Grinding

After primary crushing, the material continues moving with the roller surface into the second grinding zone at 360°, where under the guidance of the curvilinear structure it undergoes intensive compression and grinding for further crushing and shaping.

Stage 4: Discharge and Separation

Material of the required size is discharged through the gap between the rollers; larger particles continue circulating in the crushing process until the required size is reached.

IV. Technological Advantages Manifestation

1. Energy Consumption Reduction The single motor system saves 20-30% energy compared to a two-motor system.
2. Extended Liner Service Life Layered crushing reduces direct wear, increasing service life by 2-3 times.
3. Excellent Particle Shape Double 360° grinding makes the product close to cubic shape, with needle-like and flaky particles less than 5%.
4. Low Overgrinding Interlayer crushing avoids excessive grinding; the overgrinding coefficient is controlled within 8%.
5. Increased Productivity Increasing the contact area by 30% correspondingly increases productivity per unit time.