The ZPE series jaw crusher, a specialized fine crushing equipment, is designed to reduce pre-crushed materials to 5–50 mm with a crushing ratio of 8–12. Its structure, optimized from the PE series, features a deep crushing chamber (15°–18° angle), double-wave high-chromium jaw plates, and a "small eccentricity + high speed" transmission system, paired with hydraulic adjustment and overload protection for precision and efficiency.
Manufacturing involves CNC welding (frame), precision machining of 42CrMo eccentric shafts (eccentricity tolerance ±0.03 mm), and composite jaw plate casting (bond strength ≥200 MPa). Quality control includes wear testing (rate ≤0.1 mm/100 hours), hydraulic cycling checks, and particle size validation (≥90% ≤10 mm product at 10 mm discharge).
Widely used in aggregate production, mining secondary crushing, and industrial waste processing, it offers superior fine crushing performance with lower flakiness (≤15%) and higher continuity, making it ideal for lines requiring ≤50 mm finished products.
Detailed Introduction to ZPE Series Fine Jaw Crushers (Fine Crushing Type)
The ZPE series jaw crusher is a specialized jaw crushing equipment designed for fine crushing operations (where "Z" in "ZPE" typically stands for "Fine Crushing" or "Secondary Crushing"). It is primarily used to further crush pre-crushed materials to finer particle sizes (discharge opening adjustable from 5–50 mm) with a crushing ratio of 8–12, making it suitable for production lines requiring fine finished products. Its structure is optimized from the traditional PE series with improved crushing chamber design and motion parameters, adopting a "deep cavity crushing + small stroke high frequency" configuration that combines the stability of jaw crushers with the efficiency of fine crushing equipment.
I. Composition and Structure of ZPE Series Jaw Crushers
The core components of the ZPE series are similar to the PE series but feature targeted improvements in the crushing chamber, transmission system, and adjustment device. The specific structure and characteristics are as follows:
Main Frame
Constructed with high-strength welded Q355B steel plates (16–30 mm thick) or small cast steel components (ZG230-450), the overall weight is 10%–15% lighter than comparable PE models. However, frame rigidity is enhanced through optimized stiffeners (20% increase in rib density) to withstand high-frequency impact loads (300–400 cycles/min).
The top feed opening width is similar to PE models, but the crushing chamber depth is increased (deep cavity design with a steeper profile, angle reduced from 20°–25° in PE series to 15°–18°), reducing material blockage and improving crushing efficiency.
Crushing Mechanism
Fixed and Moving Jaws: The fixed jaw mounting surface has a larger inclination angle (30°–35° from horizontal), and the moving jaw is 10%–15% longer to ensure multiple compression cycles of materials in the chamber. The moving jaw is made of low-alloy cast steel (ZG30CrNiMo) with quenched and tempered hardness of 25–30 HRC, offering better fatigue resistance than PE series.
Fine Crushing Jaw Plates: Adopt a "double-wave" tooth design (tooth height 3–8 mm, pitch 5–12 mm) made of high chromium cast iron (Cr28) or composite material (high chromium working layer with high manganese steel base). Wear resistance is 30% higher than PE series jaw plates, suitable for crushing hard rocks like quartz and granite.
Transmission System
Eccentric Shaft: Eccentricity is reduced to 0.7–0.8 times that of comparable PE models, but rotational speed is increased by 20%–30% (with same motor power) to achieve fine particle crushing through "small eccentricity + high speed." Shaft diameter is increased by 5%–10%, made of 42CrMo (quenched and tempered to 30–35 HRC) for higher bending strength.
Bearings and Pulley: Tapered roller bearings (e.g., model 3520 series) handle greater axial forces; the pulley diameter is reduced (matching higher speeds) and made of ductile iron QT600-3 to reduce weight while maintaining strength.
Adjustment and Safety Devices
Hydraulic Adjustment Device: Standard hydraulic cylinder adjustment (unlike PE series shim adjustment) uses two symmetrically arranged cylinders (working pressure 16–20 MPa) to move the toggle plate seat with adjustment precision of ±0.5 mm, supporting remote control (linked to PLC systems).
Overload Protection: In addition to toggle plate fracture protection, a hydraulic overload relief function is added (pressure sensors monitor chamber pressure; cylinders relieve pressure and retract the moving jaw when exceeding limits, automatically resetting after 排出异物). This avoids frequent toggle plate replacement and improves continuity.
Auxiliary Components
Dust Prevention System: Rubber dust curtains are installed at the chamber top, and bearing housings use labyrinth + skeleton oil seal dual sealing to reduce dust ingress (suitable for high-dust fine crushing conditions).
Vibration Damping: Rubber pads (60 Shore A hardness) under the frame reduce high-frequency vibration impact on foundations (vibration velocity ≤0.08 mm/s).
II. Manufacturing Process of ZPE Series Jaw Crushers
To meet fine crushing requirements, ZPE series manufacturing processes enhance precision control and wear part processing beyond PE series standards:
Frame Manufacturing
Welded frames use CNC cutting (tolerance ±0.3 mm) with pre-welding plate preparation (sandblasted to Sa2.5). Robot welding achieves weld reinforcement ≤2 mm, followed by vibratory stress relief (≥80% stress reduction) to prevent in-service deformation.
Bearing housing bores are machined on CNC boring mills with coaxiality ≤0.03 mm (better than PE series' 0.05 mm). Bore surfaces undergo nitriding (hardness ≥500 HV, depth 0.1–0.2 mm) to reduce bearing wear.
Key Component Manufacturing
Eccentric Shaft: 42CrMo steel is forged (forging ratio ≥4), rough machined, and fully heat-treated (880°C quenching + 600°C tempering). Precision grinding ensures journal roundness ≤0.005 mm and eccentricity error ≤0.03 mm, with UT inspection to detect internal defects ≥φ2 mm.
Composite Jaw Plates: Lost foam casting combines Cr28+1.0%Mo high chromium cast iron with ZGMn13 high manganese steel, achieving interface bonding strength ≥200 MPa. Working surfaces are water-quenched (hardness ≥60 HRC) while maintaining toughness in non-working areas (impact energy ≥80 J).
Hydraulic System: Cylinder barrels use 27SiMn seamless steel tubes (inner diameter tolerance H8). Piston rods have 0.1–0.15 mm hard chrome plating (porosity ≤1/cm²) and undergo 1.5× working pressure testing (1-hour hold, no leakage).
Assembly and Commissioning
Assembly strictly controls parallelism between moving and fixed jaws (gap difference ≤0.3 mm). Bearing preload is precisely adjusted via nuts to eliminate axial play.
No-load testing: 4-hour continuous operation monitors bearing temperature (≤65°C) and noise (≤82 dB), with balancing tests (residual unbalance ≤5 g·mm/kg).
Load testing: 8-hour continuous crushing of 50–100 mm granite (discharge opening set to 20 mm) requires ≥85% of product to be ≤20 mm. Hydraulic adjustment response time ≤1 second (reset within 3 seconds after clearing debris).
III. Quality Control Processes for ZPE Series Jaw Crushers
To meet high fine crushing requirements, ZPE series quality control adds these critical steps beyond PE series standards:
Wear Part Performance Testing
Jaw plates undergo wear testing (standard sand erosion, wear rate ≤0.1 mm/100 hours) and impact toughness testing (-20°C impact energy ≥50 J to prevent cold brittleness).
Composite jaw plate interfaces undergo PT inspection to ensure no cracks or delamination.
Hydraulic systems undergo 1000 adjustment cycles with cylinder synchronization error ≤1 mm, no leakage or jamming.
Fine Crushing Effect Verification
Particle size distribution testing: Crushing 200 MPa limestone at rated capacity with 10 mm discharge opening produces ≥90% ≤10 mm product with ≤15% flakiness (superior to PE series' 25%).
IV. Application Scenarios in Production Lines
As fine crushing jaw crushers, ZPE series are mainly used in production lines requiring fine finished products (typically ≤50 mm) without subsequent secondary crushing, or as secondary crushers to complement primary crushing:
Fine Aggregate Production Lines
In sand-making lines, as secondary crushers to reduce 50–100 mm PE-crushed material to 5–20 mm for direct feeding to sand makers (replacing cone crushers to reduce investment). For example, ZPE500×750 processes PE600×900 output to ≤15 mm in 100–300 t/h quartz sand lines.
Mining Secondary Crushing
Used for secondary crushing in small-to-medium metal mines (iron, gold), reducing 30–80 mm primary crushed ore to 5–15 mm for direct ball mill feeding. Hydraulic adjustment quickly adapts to varying ore hardness (automatically increasing discharge opening for hard lumps).
Road Base Material Production
Crushes limestone and basalt to produce ≤30 mm road base aggregates (e.g., cement-stabilized macadam). The "double-wave" jaw plates reduce over-crushing (ultrafine content ≤5%).
Industrial Solid Waste Processing
Processes steel slag and mineral slag to ≤20 mm for non-fired brick production or concrete admixtures. Hydraulic overload protection handles metal contaminants in waste, reducing downtime.
V. Operational Characteristics and Considerations
Feed Control: Strictly limit maximum feed size to ≤80% of feed opening width to prevent localized jaw plate wear. Use frequency-controlled vibrating feeders for uniform feeding and avoid chamber overloading.
Maintenance Focus: Weekly checks of hydraulic oil level and contamination (NAS 8 or better); replace hydraulic filters every 300 hours. Flip jaw plates every 100 hours (utilizing double-wave symmetry to extend life).
Differences from PE Series: ZPE series better suits secondary crushing of fine-grained, high-hardness materials. While 15%–20% more expensive than PE models, it reduces subsequent equipment costs, offering better overall efficiency in lines requiring ≤50 mm products.
Through structural optimization and process upgrades, ZPE series jaw crushers fill the gap between traditional jaw crushers and cone crushers for fine crushing, making them ideal for small-to-medium fine crushing production lines
