Kaakbreker Kaakplaat: ultieme gids voor bediening, onderhoud en prestaties

Releasetijd: 21-11-2025
De kaakbreker is een van de meest essentiële apparaten in de mijnbouw-, bouw-, steengroeven- en recyclingindustrie. De kern van deze krachtige machine wordt gevormd door een cruciaal onderdeel dat rechtstreeks de breekprestatie bepaalt: de kaakplaat. Deze vervangbare, slijtvaste stalen componenten vormen de belangrijkste breekoppervlakken waar grondstoffen worden samengeperst, gebroken en omgezet in bruikbare aggregaten.
Het begrijpen van kaakplaten is van fundamenteel belang voor het maximaliseren van de efficiëntie van de breker, het verlengen van de levensduur van apparatuur en het optimaliseren van de operationele kosten. In deze uitgebreide gids vindt u alles wat u moet weten over de kaakplaten van kaakbrekers, van hun mechanische functies tot geavanceerde onderhoudsstrategieën.

Wat zijn kaakbreker-kaakplaten?

Kaakplaten zijn vervangbare, slijtvaste stalen componenten die de primaire breekvlakken van een kaakbreker vormen. Binnen de breekkamer werken twee kaakplaten samen: de ene blijft stilstaan ​​(vaste kaakplaat), terwijl de andere heen en weer beweegt in een heen en weer gaande beweging (beweegbare kaakplaat).
Belangrijkste kenmerken:

  • Vervangbaar ontwerp: In tegenstelling tot het brekerframe zijn de kaakplaten zo ontworpen dat ze bij slijtage gemakkelijk kunnen worden vervangen, waardoor de structurele integriteit van de machine wordt beschermd

  • Slijtvaste componenten: Ontworpen om alle directe impact en slijtage van het breekproces te absorberen

  • Materiaaloppervlakvariaties: Verkrijgbaar met vlakke, getande of gegolfde oppervlakken, afhankelijk van de toepassingsvereisten

  • Geschroefde/geklemde montage: stevig bevestigd aan de kaakstructuur voor een veilige, betrouwbare werking

Het geniale van het ontwerp van de kaakplaten ligt in hun opofferende karakter: ze absorberen alle verpletterende spanning zodat dure machineonderdelen beschermd blijven.

Kaakbrekerstructuur en de rol van kaakplaten

Om de kaakplaten volledig te begrijpen, is het belangrijk om hun plaats binnen de volledige kaakbrekerconstructie te herkennen:
Hoofdcomponenten:

  • Hoofdframe: De structurele ruggengraat die alle interne componenten ondersteunt en bestand is tegen verpletterende druk

  • Vaste kaakplaat: verticaal vastgeschroefd aan de voorkant van het frame, waarbij gebruik wordt gemaakt van gegolfd mangaanstaal om materiaal vast te pakken en te verpletteren

  • Beweegbare kaakplaat: bevestigd aan de zwenkkaak en beweegt heen en weer tegen de vaste plaat

  • Excentrische as: Zet motorrotatie om in heen en weer gaande kaakbeweging

  • Pitman: brengt beweging over van de excentrische as naar de beweegbare kaak

  • Toggle Plates: Veiligheidscomponenten die overbelastingskrachten absorberen

  • Vliegwiel: slaat energie op om een ​​consistente verpletterende werking te behouden

  • Lagers: Ondersteun de excentrische as en de zwenkbek

De kaakplaten werken binnen dit geïntegreerde systeem en zetten mechanische beweging om in krachtige breekkracht.

Hoe kaakplaten werken: de breekcyclus

De verpletterende actie vindt plaats in drie verschillende fasen, die elk van cruciaal belang zijn voor het begrijpen van de prestaties van de kaakplaat:

Voerfase

Het materiaal komt de breekkamer binnen via de bovenste trechter. De afstand tussen de kaakplaten is maximaal, waardoor grote stenen en ertsbrokken vrij in de breekholte kunnen vallen. De grootte van de invoeropening bepaalt direct de maximale materiaalgrootte die kan worden verwerkt.

Compressiefase

De excentrische as drijft de pitman omhoog en duwt de tuimelplaten naar buiten. Deze beweging dwingt de beweegbare kaakplaat met enorme kracht naar de vaste plaat. Het materiaal dat tussen de twee platen gevangen zit, ervaart:

  • Compressiekrachten: Het materiaal tussen de kaken samenknijpen

  • Buigkrachten: Terwijl het materiaal tegen de kaakoppervlakken buigt

  • Splitsende krachten: breuken langs natuurlijke zwakke punten

De beweging aan de bovenkant van de breekkamer is elliptisch met maximale kaakbeweging, terwijl het afvoergebied minimale beweging ondervindt. Dit ontwerp zorgt voor een geleidelijke verbrijzeling: grote stukken breken in kleinere fragmenten terwijl ze naar beneden reizen.

Ontladingsfase

Terwijl de pitman zijn cyclus voltooit en naar beneden begint te bewegen, ontspannen de tuimelplaten en keert de beweegbare kaakplaat terug naar zijn oorspronkelijke positie. Het vermalen materiaal valt door de afvoeropening aan de onderkant, waar het op transportbanden terechtkomt voor verdere verwerking of screening.
Deze continue cyclus herhaalt zich honderden keren per minuut, waarbij grote volumes materiaal worden verwerkt tot kleinere, beter hanteerbare formaten.

De complexe beweging van kaakplaten

De beweging van kaakplaten is complexer dan een eenvoudige heen-en-weerbeweging:
Elliptische beweging bij de invoeropening: De beweegbare kaak vertoont elliptische beweging aan de bovenkant van de breekkamer, waardoor maximale beweging van de kaak ontstaat en een betere grip van het materiaal wordt vergemakkelijkt.
Halvemaanvormige beweging bij afvoer: Bij de onderste afvoeropening wordt de kaakbeweging een dunne halvemaanvormige vorm met een opwaartse helling, waardoor een soepele materiaalstroom wordt gegarandeerd en brugvorming wordt voorkomen.
Verticale en horizontale componenten: Op elk punt in de breekkamer bevat de beweging van de kaak zowel verticale (op en neer) als horizontale (vooruit-achteruit) componenten, waardoor een krachtige schommelbeweging ontstaat die de breekefficiëntie maximaliseert.
Dit verfijnde bewegingspatroon, ook wel 'schommelbeweging' genoemd, maakt kaakbrekers zo effectief bij het primair verpletteren van grote, harde materialen.

Vaste kaakplaat versus beweegbare kaakplaat

Hoewel beide platen er hetzelfde uitzien, hebben ze verschillende functies:
Vaste kaakplaat:

  • Blijft stationair, vastgeschroefd aan het brekerframe

  • Biedt het referentieoppervlak waartegen materiaal wordt verpletterd

  • Ervaar meer uniforme slijtagepatronen

  • Vereist bij sommige toepassingen minder frequente vervanging dan de beweegbare plaat

Beweegbare kaakplaat:

  • Bevestigd aan de zwenkbek en aangedreven door het excentrische mechanisme

  • Voert de actieve verpletterende beweging uit

  • Ervaart variabele slijtagepatronen (doorgaans sneller bovenaan, langzamer bij ontlading)

  • Meer vatbaar voor ongelijkmatige slijtage vanwege de complexe schommelbeweging

Beide platen moeten in harmonie samenwerken om optimale breekresultaten te bereiken.

Materialen en prestaties van kaakplaten

Materiaalkeuze is de meest kritische factor voor de prestaties en levensduur van de kaakplaten. Verschillende materialen blinken uit onder verschillende breekomstandigheden.

Hoog mangaanstaal (Mn13, Mn14, Mn18, Mn22)

Waarom staal met een hoog mangaangehalte de industrie domineert:
Hoog mangaanstaal blijft de industriestandaard voor kaakplaten vanwege zijn uitzonderlijke hardingseigenschappen. Wanneer het materiaal wordt onderworpen aan schokbelasting, verhardt het en wordt het steeds harder naarmate het wordt gebruikt. Dankzij deze eigenschap kan mangaanstaal een hardheid van 350-450 HB bereiken tijdens typische breekbewerkingen, en zelfs tot 500 HB onder aanhoudende breekspanning.
Specifieke kwaliteiten voor verschillende toepassingen:

  • Mn13: Optimaal voor het breken van zachte stenen met lagere slagkrachten

  • Mn14: Veelzijdige keuze voor primaire breektoepassingen

  • Mn18: Uitstekend geschikt voor materialen met gemiddelde hardheid en gemengde steenverwerking

  • Mn22: Premium kwaliteit voor het moeilijk, schurend en gestraald breken van steen

  • Chroomvarianten (Mn14Cr2, Mn18Cr2, Mn22Cr2): Verbeterde slijtvastheid voor extreem schurende materialen en langere levensduurvereisten

Voordelen van hoog mangaanstaal:

  • Superieure weerstand tegen impactbelasting

  • Uitstekende taaiheid die scheuren voorkomt

  • Kosteneffectief voor de meeste toepassingen

  • Continue krachttoename tijdens gebruik

  • Bewezen betrouwbaarheid in duizenden installaties

Gemiddeld mangaanstaal

Door het mangaangehalte aan te passen en extra legeringselementen te introduceren, hebben fabrikanten middelmatig mangaanstaal ontwikkeld dat een ongeveer 20% langere levensduur biedt vergeleken met standaard hoog mangaanstaal, terwijl de kosten gelijk blijven.

Gietijzer met hoog chroomgehalte

Gietijzer met een hoog chroomgehalte biedt uitzonderlijke slijtvastheid, waardoor het ideaal is voor het vermalen van zeer schurende materialen zoals gerecycled asfalt, verweerd graniet en verontreinigde aggregaten. De lagere taaiheid kan echter leiden tot scheuren onder zware schokbelastingen.
Composietoplossing: Veel geavanceerde fabrikanten gebruiken nu een composietbenadering, waarbij gietijzer met een hoog chroomgehalte op het slijtvaste oppervlak wordt gecombineerd met een achterkant van hoog mangaanstaal om superieure slijtvastheid te bereiken met behoud van voldoende taaiheid.

TIC (wolfraamcarbide) inzetkaakplaten

Voor extreme bedrijfsomstandigheden vormen TIC-inzetkaakplaten de premium oplossing. Deze platen zijn voorzien van een stalen basis met strategisch geplaatste wolfraamcarbide inzetstukken op slijtgevoelige punten.
Prestatievoordelen:

  • 2-3 keer langere levensduur vergeleken met standaard mangaanstaal in zeer schurende toepassingen

  • Superieure slijtvastheid voor recyclingactiviteiten met verontreinigde materialen

  • Verminderde vervangingsfrequentie en bijbehorende uitvaltijd

  • Lagere totale eigendomskosten ondanks hogere initiële investeringen

Hoewel TIC-inzetplaten vooraf aanzienlijk duurder zijn, maken de aanzienlijk langere levensduur en verminderde onderhoudsvereisten ze economisch aantrekkelijk voor veeleisende toepassingen.

Selectiecriteria voor materiaalsoort

Kies uw kaakplaatmateriaal op basis van:
FactorBeste materiaal
Primaire verbrijzeling met hoge impactHoog mangaanstaal (Mn22)
Standaard primair vermalenHoog mangaanstaal (Mn14, Mn18)
Zeer schurende materialenHoog chroom gietijzer + Mn staalcomposiet
RecyclingactiviteitenGetand mangaanstaal of chroomcomposiet
Extreme slijtagesomstandighedenTIC-inzetstukken (wolfraamcarbide).
Budgetbewuste bedrijfsvoeringStandaard mangaanstaal (Mn13, Mn14)

Kaakplaatprofielen en oppervlakteontwerpen

Naast de materiaalsamenstelling is het oppervlakteprofiel van de kaakplaten ontworpen voor specifieke breekscenario's en materiaalsoorten.

Gladde/platte kaakplaten

Kenmerken: Glad, ononderbroken oppervlak zonder tanden of ribbels
Beste voor:

  • Primair breken van zacht tot middelhard gesteente

  • Toepassingen die specifieke uitvoergroottebereiken vereisen

  • Minimale boetegeneratie

  • Materialen met natuurlijke splijtneigingen (graniet, kalksteen)

Voordelen:

  • Consistente verpletterende actie

  • Lagere productie van boetes

  • Gemakkelijker schoon te maken en te onderhouden

Getande of gegolfde kaakplaten

Kenmerken: Meerdere tanden of golfpatronen creëren een agressief grijpoppervlak
Beste voor:

  • Het verpletteren van hardere, resistentere materialen

  • Recyclingtoepassingen (beton, asfalt)

  • Materialen die gevoelig zijn voor uitglijden tussen gladde platen

  • Secundaire breekoperaties

  • Toepassingen waarbij het verwijderen van boetes noodzakelijk is

Voordelen:

  • Superieure grip op gladde materialen

  • Betere controle van de deeltjesvorm

  • Verminderde materiaalterugslag

  • Verbeterde breekefficiëntie op taaie materialen

Zware kaakplaten

Kenmerken: Aanzienlijk dikkere en sterkere constructie dan standaardplaten
Beste voor:

  • Verlengde levensduurvereisten

  • Ultrahoge productievolumes

  • Verwerking van uitzonderlijk harde of schurende materialen

  • Kostenreductie op lange termijn door minder vervangingen

Kritieke prestatie-indicatoren: slijtagepatronen en detectie

Door slijtagepatronen te begrijpen, kunnen we vervangingsbehoeften voorspellen en operationele problemen identificeren:

Normaal slijtageverloop

Onder ideale bedrijfsomstandigheden slijten de kaakplaten gelijkmatig over hun oppervlak. Slijtage begint doorgaans aan de bovenkant, waar het materiaal voor het eerst in contact komt met de platen, en ontwikkelt zich in de loop van de tijd naar beneden. Normale vervangingsintervallen zijn afhankelijk van:

  • Materiaalhardheid en abrasiviteit

  • Consistentie van de voergrootte

  • Breeksnelheid en instellingen

  • Materiaalvolume verwerkt

Waarschuwingssignalen van overmatige slijtage

Ongelijke slijtagepatronen: Als de ene kant aanzienlijk sneller slijt dan de andere, onderzoek dan de voerdistributiesystemen en de uitlijning van de kaken.
Horizontale slijtage (vlakke gebieden): Geeft aan dat de kaakplaten tegen het materiaal schuren in plaats van het te verpletteren, waardoor de efficiëntie aanzienlijk wordt verminderd.
Verticale groeven: Diepe groeven creëren spanningsconcentraties die kunnen leiden tot scheuren en catastrofaal falen.
Materiaalophoping: Verpletterd materiaal dat zich ophoopt op de kaakplaten duidt op verlies van grijpvermogen en een dreigende vervangingsbehoefte.
Verminderde brekeropbrengst: Wanneer de doorvoer afneemt zonder wijzigingen in de invoergrootte of de brekerinstellingen, zijn versleten kaakplaten doorgaans de oorzaak.
Verhoogde trillingen en geluiden: ongebruikelijke geluiden en trillingspatronen duiden vaak op versleten of ongelijkmatig versleten kaakplaten.

Vervangingsrichtlijnen

Beste praktijken uit de sector suggereren:

  • Vervang de kaakplaten als de eenzijdige slijtage groter is dan 3 mm

  • Houd maandelijks de voortgang van de slijtage in de gaten met behulp van schuifmaten of laserafstandsmeters

  • Vervangen bij 30% eenzijdige slijtage als vervanging lastig is (plan voor gemakkelijke stilstand)

  • Rijd nooit met ernstig versleten platen, omdat hierdoor aangrenzende onderdelen beschadigd raken

Geavanceerde onderhoudsstrategieën om de levensduur van de kaakplaat te verlengen

  1. Optimaliseer feedbeheer

Zorg voor de juiste voergrootte:

  • Verwijder overtollig materiaal voordat u de breker betreedt

  • Gebruik vibrerende scalpeerschermen om overmaat te elimineren

  • Zorg voor consistente voedingssnelheden om drukschommelingen te voorkomen

Controle voerverdeling:

  • Zorg voor een gelijkmatige materiaalverdeling over de kaakbreedte

  • Slecht verdeelde voedingen veroorzaken asymmetrische slijtage, waardoor voortijdige plaatvervanging nodig is

  • Verbeteringen in het hopperontwerp implementeren voor uniforme distributie

  1. Nauwkeurige parameteraanpassing

Instelling gesloten zijde (CSS):

  • Onderhoud CSS binnen de specificaties van de fabrikant

  • Strakkere CSS verhoogt de druk en slijtage van de kaakplaat

  • Te losse CSS vermindert de breekefficiëntie en verhoogt de boetes

Excentrische worp en snelheid:

  • Werk met het door de fabrikant aanbevolen toerental

  • Een te hoge snelheid versnelt de slijtage en verhoogt het energieverbruik

  • Onvoldoende snelheid vermindert de productie en verlengt de cyclustijden

  1. Uitgebreid smeerprogramma

Strategische smeervoordelen:

  • Minimaliseert wrijving tussen bewegende componenten

  • Vermindert de warmteontwikkeling (een belangrijke slijtageversneller)

  • Verlengt de levensduur van lagers en excentrische as

Beste praktijken:

  • Volg het smeerschema van de fabrikant nauwkeurig

  • Gebruik uitsluitend de aanbevolen soorten en kwaliteiten smeermiddelen

  • Controleer het smeerniveau voortdurend

  • Controleer de lagertemperatuur regelmatig (overmatige hitte duidt op onvoldoende smering)

  1. Proactieve inspectie en monitoring

Wekelijkse inspecties:

  • Visuele controle op losse bouten op kaakplaten, wangplaten en frame

  • Controleer het juiste olie-/vetpeil bij alle smeerstations

  • Luister naar ongebruikelijke geluiden tijdens het gebruik

  • Controleer op materiaallekkage uit ongepaste gebieden

Maandelijkse gedetailleerde inspectie:

  • Meet de dikte van de kaakplaat op meerdere punten om de voortgang van de slijtage te volgen

  • Inspecteer op scheuren met behulp van visuele inspectie of ultrasone tests

  • Controleer de integriteit van de schakelplaat

  • Controleer de uitlijning van de excentrische as

Driemaandelijkse uitgebreide beoordeling:

  • Volledige systeemtrillingsanalyse

  • Documentatie met hoge resolutie van slijtagepatronen

  • Beoordeling van materiaaldistributie

  • Volledige lager- en asinspectie

  1. Strategische onderhoudsplanning

Voordelen van geplande downtime:

  • Plan vervanging van de kaakplaat tijdens een geschikte downtime

  • Combineer meerdere onderhoudstaken om verstoring te minimaliseren

  • Zorg voor reserveplaten voor noodvervanging

  • Coördineer vervanging met productieschema's

Conditiegebaseerd onderhoud:

  • Trillingssensoren inzetten voor continue monitoring (alarm bij > 5 mm/s RMS)

  • Gebruik laserafstandsmeters voor realtime tracking van kaakplaatslijtage

  • Implementeer geautomatiseerde vervangingsherinneringen bij een slijtagedrempel van 30%

  • Verzamel operationele gegevens voor voorspellend onderhoud

Resultaten van prestatie-optimalisatie in de praktijk

Bedrijven die uitgebreide strategieën voor kaakplaatoptimalisatie implementeren, rapporteren indrukwekkende resultaten:
Resultaten casestudy:

  • 22% toename van de productiecapaciteit

  • 18% reductie in energieverbruik

  • 50% verlenging van de levensduur van de kaakplaat

  • Aanzienlijke vermindering van ongeplande downtime

Deze verbeteringen tonen aan dat systematische aandacht voor de selectie, bediening en onderhoud van de kaakplaten aanzienlijke zakelijke voordelen oplevert.

Veelvoorkomende operationele fouten die u moet vermijden

Overtredingen van de feedgrootte

Het probleem: het toevoeren van te groot materiaal dat de nominale capaciteit van de breker overschrijdt
De impact: Enorme impactkrachten op kaakplaten, waardoor snelle slijtage of breuk ontstaat
De oplossing: materiaal vooraf zeven om overmaat te verwijderen; scalpersystemen implementeren

Onvoldoende smering

Het probleem: Onvoldoende of onregelmatige smering van lager- en excentrische systemen
De impact: verhoogde wrijving en warmteontwikkeling, versnelde slijtage van componenten
De oplossing: volg de smeerschema's van de fabrikant; gebruik de juiste smeermiddelsoorten

Slijtagemonitoring negeren

Het probleem: werken met ernstig versleten kaakplaten
De impact: schade aan frame, excentrische as en lagers; catastrofaal faalrisico
De oplossing: Implementeer systematische slijtagemonitoring en proactieve vervanging

Onjuiste materiaaldistributie

Het probleem: ongelijkmatige voeding over de kaakbreedte
De impact: asymmetrische slijtage die frequente vervanging vereist
De oplossing: Verbeter het ontwerp van de trechter; voersysteem inspecteren en onderhouden

Werkend buiten de specificaties

Het probleem: hardlopen met te hoge snelheden of met gesloten instellingen die strakker zijn dan aanbevolen
De impact: versnelde slijtage en overmatig energieverbruik
De oplossing: Houd u strikt aan de specificaties van de fabrikant

Kosten-batenanalyse: strategische investeringen in hoogwaardige kaakplaten

Terwijl premium kaakplaten in eerste instantie meer kosten, bevordert een uitgebreide kostenanalyse kwaliteitsinvesteringen:
Vergelijking van de totale eigendomskosten:
Voor een grote kaakbreker die jaarlijks 500 ton graniet per dag verwerkt gedurende 250 bedrijfsdagen:

  • Standaard mangaanstaalplaten: lagere initiële kosten, hogere vervangingsfrequentie, meer uitvaltijd

  • Premium mangaanstalen platen: gematigde initiële kosten, evenwichtige vervangingsfrequentie, standaard uitvaltijd

  • TIC-inzetplaten: hoogste initiële kosten, laagste vervangingsfrequentie, minimale uitvaltijd

Over een bedrijfsperiode van vijf jaar zijn de totale eigendomskosten (inclusief vervangende onderdelen, stilstand en productieverlies) doorgaans 15-25% gunstiger voor de optie van premium kwaliteit.

Conclusie

Kaakplaten van kaakbrekers zijn veel meer dan eenvoudige slijtageonderdelen; ze vertegenwoordigen de kritische interface tussen uw grondstof en uw productiedoelen. De juiste selectie, bediening en onderhoud ervan bepalen rechtstreeks de efficiëntie, betrouwbaarheid en winstgevendheid van uw breker.
Belangrijkste afhaalrestaurants:

  1. Materiaal is belangrijk: Selecteer kaakplaatmateriaal op basis van uw specifieke materiaaltype en bedrijfsomstandigheden: hoog mangaanstaal voor toepassingen met impactgedomineerde toepassingen, composieten voor schurende materialen, TIC-wisselplaten voor extreme omstandigheden

  2. Preventie is economisch: proactief onderhoud en monitoring kosten veel minder dan noodreparaties en ongeplande stilstand

  3. Uitgebreide aanpak: Succes vereist systematische aandacht voor voerbeheer, parameteroptimalisatie, smering, inspectie en onderhoudsplanning

  4. Prestatiemonitoring: Implementeer moderne monitoringtechnologieën om slijtagepatronen bij te houden en vervanging op optimale tijdstippen te plannen

  5. Operationele uitmuntendheid: Strikte naleving van de specificaties van de fabrikant voor invoergrootte, snelheid en instellingen voor de gesloten zijde zorgt voor een maximale levensduur van de componenten

Door deze strategieën te implementeren en kaakplaten te erkennen als de basis voor breekefficiëntie, kunnen operaties aanzienlijke verbeteringen in productiviteit, betrouwbaarheid en winstgevendheid bereiken. De investering in het begrijpen en optimaliseren van kaakplaten betaalt zich uit gedurende de gehele levensduur van uw breker.
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