NOVATEUR PUBLICATIONS

INTERNATIONAL JOURNAL OF INNOVATIONS IN ENGINEERING RESEARCH AND TECHNOLOGY [IJIERT]

ISSN: 2394-3696
VOLUME 3, ISSUE 9, Sep.-2016

SELF-CONTROLLING RIG FOR JAW CRUSHER ASSEMBLY

SAURABH JADHAV
Department of mechanical engineering,
P.D.V.V.P.C.O.E. Ahmednagar, India

SAGAR MORE
Department of mechanical engineering,
P.D.V.V.P.C.O.E. Ahmednagar, India

ABSTRACT
The aim of the work is to develop a method for easy assembly of the bearing in the housing
by standardized way. The assembly of bearing should take place on the atomized set up.
Based on this method a assembly setup was constructed which enables to assembly of the
shaft with bearing of different models of jaw crusher. First tests were done with manual
alignment and it shows that with proper alignment shaft assembly is very easy operation and
also safe. Results of those tests show that the developed system provides as good or better
results than the manual assembly method by placing on wooden block and aligns by using
jacking. The alignment process itself runs automatically. The results are reliable, independent
form the user and reproducible. Furthermore the whole assembling of the bearings on a shaft
should be automated without to interrupt the process of mounting in order to fatigue for
assembler and misalignment in bearing. The assembly of the shaft with bearing in the swing
jaw is very critical as well important so it needs attention because any mistake can cause the
failure of the system which result in breakdown and also the bearing failure which is the
highest cost element. so the propose system eliminate the manual alignment and the safety
issue and also the problem of incorrect assembly of the bearing in jaw by aligning the jaw
bore and then only pushing the shaft in straight line so there is no shock load on the bearing
which may result the misplacement and misalignment of the roller in the bearing housing.

KEYWORDS: Jaw crusher, bearing assembly, Automation, Safety.

INTRODUCTION
According to the standard procedure the swing jaw is first painted then allowed to dry.
Further the eccentric shaft assembly is assembled in the jaw, but before that the jaw is place
on the wooden blocks. As there is a very fine clearance available between the outer race of the
bearing and the jaw bore it is necessary that the alignment of their axis is perfect, also the line
of action of the lever hoist must coincide with the jaw bore centre. The present method to
accomplish this is to place the jaw on the wooden blocks as shown in the figure below.

Fig 1.1 Jaw Placed on the Wooden Blocks

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 NOVATEUR PUBLICATIONS
INTERNATIONAL JOURNAL OF INNOVATIONS IN ENGINEERING RESEARCH AND TECHNOLOGY [IJIERT]
ISSN: 2394-3696
VOLUME 3, ISSUE 9, Sep.-2016
A wooden wedge is placed under the circular surface of the jaw to achieve the variable height
occurring due change in the surface texture as the swing jaw is a casted part as well as the
different range of the products viz. CJ211, 409 and 411. The wedge takes care of the height
while the horizontal alignment of the Swing Jaw Bore is checked by spirit level. If the bore is
not perfectly aligned with reference to the ground it causes problem during the assembly,
hence a jack is placed beneath it to resolve it as shown in the figures below.

Fig 1.2 Wedge Placed beneath the Jaw Fig 1.3 Jack used to align the Jaw bore

When all this as completed then the further assembly procedure is carried out as follows:
1. Lift the Shaft using Belt and align its center with the jaw bore center.
2. Attach lever hoist chain to the eye bolt fitted in the shaft.
3. Push the shaft inside the Jaw bore and pull it from the other side by lever hoist
simultaneously.
4. While inserting the first bearing, make sure that the outer race of bearing is perfectly
aligned with the jaw bore for easy fitment of bearing in shaft. When it is done rest the
shaft on the wooden block.

Fig 1.4 Shaft Assembly with Jaw Fig 1.5 Pull the Shaft through guide side

Hence the preparations made before actually assembling the shaft with jaw are tedious and
time consuming, but are essential non value adding activities. They also induce more fatigue
on the production technologist working on the job.

LITRATURE SURVEY
Design and Development of Fixture for eccentric shaft: A Review-This paper shows a fixture
design system of eccentric shaft for ginning machine. Fixture is required in various industries
according to their needs. Designer design fixture according to dimension parameterized by
industry to get their production tar gate. In old system manufacturing process performing
operation on eccentric shaft is delicate. So gripping a work piece in required position during a
manufacturing operation fixture is very necessary and vital. Because the shaft is eccentric so
for this need of manufacturing process Designer design proper fixture for eccentric shaft.
Fixtures lowers operation time and up bring productivity and apex quality of operation is
possible.
Fixture designers support expert system and concurrent engineering-Researcher shows the
main outlines of their process, that fixture design support system is developed on the basis of

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 NOVATEUR PUBLICATIONS
INTERNATIONAL JOURNAL OF INNOVATIONS IN ENGINEERING RESEARCH AND TECHNOLOGY [IJIERT]
ISSN: 2394-3696
VOLUME 3, ISSUE 9, Sep.-2016
an expert system body. Researcher gives idea of how the use of that kind of tool is
determinant factor for reactivity in the fixture design protocols in concurrent engineering. The
paper aim for the development of fixture designer’s support. Researcher present a outlining of
the design method and expression of the trade norms in the expert system formalism.
Researcher has developed formulating industrial expertise SEACMU (System Expert d'Aide il
la Conception des Montages d'Usinage for expert system for final design). That is a fixture
designers' support expert system. SEACMU is based on a adapted part modeling to the fixture
design.

PROBLEM STATEMENT
The swing jaw of all the three models of Jaw Crusher is assembled on three wooden blocks.
As there are three different size models it becomes difficult to adjust the height of wooden
blocks as per the model. It is a time consuming process as the swing jaw weighs 8.1 Tonne
and requires continuous help of overhead crane and extra manpower. Problem also arises
because of the material of the swing jaw, is casted and every single piece of swing jaw has
different irregular outer surface which tends to improper resting on the wooden blocks.
During assembly of shaft into the bore of the swing jaw, due to improper resting of swing
jaw, another problem arises i.e. misalignment of line of action and centre bore. When the
shaft is pulled by lever hoist, because of no constraint in direction of pull the swing jaw tends
to move along with the shaft in the direction of force applied. Safety is another major
challenge in the assembly process as the blocks are a type of temporary support, constant
threat to the production technologist is there. In order to minimize the problems hydraulic
jacks are also used for vertical height adjustment and horizontal bore alignment and overhead
crane is in continuous use which increases the material, manpower and time requirement. Use
of conventional support like wooden blocks, hydraulic lift and extensive use of overhead
crane makes the work procedure more tedious and ergonomically it is not right procedure as it
creates fatigue and affects manpower’s health adversely.

METHODOLOGY
This phase of the fixture-design process requires the most creativity. A typical work piece can
be located and clamped several different ways. The natural tendency is to think of one
solution, then develop and refine it while blocking out other, perhaps better solutions.
The above problem can have solution as below
1. Wedge Operated Mechanically by using screw and nut mechanism
2. Two hydraulic jacks used to lift the rear end of the jaw to required height and degree
3. Two Screw Jacks used to lift the jaw.
From the above three the first option of mechanical wedge can take care of height adjustment
of the jaw, but no the horizontal alignment. The hydraulic jack system cannot be used as oil
spills from the system will cause slippery shop surfaces as well as raises the fire hazards as
during assembly process there may be need of welding and gas cutting during rejection and
rework. This leaves only the last option of having two screw jacks in conjunction with level
sensors beneath the jaw bore two lift it such that require height is achieved and the jaw bore
gets perfectly aligned.
Designing and fixtures depends upon so many factors. These factors are analysed to get
design inputs for jigs and fixtures. The list of such factors is mentioned below:
a. Study of Work piece and finished component size and geometry.
b. Type and capacity of the machine, its extent of automation.

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 NOVATEUR PUBLICATIONS
INTERNATIONAL JOURNAL OF INNOVATIONS IN ENGINEERING RESEARCH AND TECHNOLOGY [IJIERT]
ISSN: 2394-3696
VOLUME 3, ISSUE 9, Sep.-2016
c. Provision of locating devices in the machine.
d. Available clamping arrangements in the machine.
e. Available aligning devices, their accuracy.
f. Evaluation of variability in the performance results of the machine.
g. Rigidity and of the machine under consideration. .
h. Required level of the accuracy in the work and quality to be produced.

Fig 4.1 Setup of the Fixture Fig 4.2 Setup while assembly
ANALYTICAL CALCULATION:
1. DESIGN POWER SCREW
Material: Alloy steel
Dc = 23mm
Nominal diameter = 26mm
Major diameter = 26mm
Length of the screw = 100mm
2. DESIGN OF NUT
Nut diameter = 26.5
P= 2mm
Dm = =25mm
3. WORM & WORM GEAR DESIGN
OD of worm = Dow = 37
= 78 mm
Throat diameter = 83.99
Face width =b = 30mm
4. WORM GEAR
Speed = 1750
Velocity ratio = 26
No of start = 1
No of teeth = 26
Standard module = 3mm
Centre distance = 43.44 mm
Diameter of worm = 32.21
Face length = 70mm
5. GEAR PAIR DIMENSIONS
a. Pinion
Module (m) = 5
No of Teeth = 12
P.C.D = 60
Face Width = 50

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INTERNATIONAL JOURNAL OF INNOVATIONS IN ENGINEERING RESEARCH AND TECHNOLOGY [IJIERT]
ISSN: 2394-3696
VOLUME 3, ISSUE 9, Sep.-2016
Shaft Size = 25
Key Size = 8X7X60
b. Gear
Module (m) = 5
No Of Teeth = 42
P.C.D = 210
Face Width = 50
Shaft Size = 35
Key Size = 10X8X60

ANALYSIS OF REAR END ASSEMBLY FRAME

In any analysis software to give accurate results it is necessary that the constraints and the
load application must be as per actual conditions on the system. The analysis of the rear end
frame is as shown in the fig below

Fig 5.1 Load analysis

As the maximum stress induced is 107. 38Mpa on the top plate which is less than allowable
stress hence the design is safe.

1. JACKLEG ASSEMBLY

Fig 5.2 Buckling Load analysis

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INTERNATIONAL JOURNAL OF INNOVATIONS IN ENGINEERING RESEARCH AND TECHNOLOGY [IJIERT]
ISSN: 2394-3696
VOLUME 3, ISSUE 9, Sep.-2016
2. SCREW

Fig 5.3 Buckling Load analysis

3. GEARBOX DRAWING

Fig 6.1 Gearbox Automated system Fig 6.2 Gearbox details

4. DESIGN OF CONTROL SYSTEM

Fig 5.1 Block Diagram of electrical Circuit

5. MOTOR
We have output power requirement of 100 W from prime mover to rotate the input worm at
desirable speed and rated torque. So to meet this requirement we decided to use 0.5 HP ( i.e.
373 W ) DC motor for this specific application.
Specification-
 Volts-12 , Amps- 45

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INTERNATIONAL JOURNAL OF INNOVATIONS IN ENGINEERING RESEARCH AND TECHNOLOGY [IJIERT]
ISSN: 2394-3696
VOLUME 3, ISSUE 9, Sep.-2016
 0.15 - 0.5 HP, 0.1 - 0.4 KW
 Shaft Diameter: 0.625" - 15.9 mm
 Face Mount in Any of the Direction
 Operates in Both two Directions
 All Ball Bearing Construction
 Brush Life 3,000 Hrs Minimum
 Ambient Temp 40 degrees C
 Insulation Class

6. DPST SWITCH- (DOUBLE POLE SINGLE THROW)

Fig 6.2.1 DPST Switch

Each terminals of a double pole single switch can be in the (closed) or in the off (open)
condition .A Double Pole Single Switch has a lot of versatility or the variation being that it
accepts 2 inputs, which makes it able to drive 2 different outputs in a circuit. . It drives
depends on the circuit design and what the circuit is intended to do. But DPST have enormous
applications in circuits.
Reasons for using the DPST switch-
a. Manual operation of the motors in case of failure of the sensors
b. To move the fixture up & down as per the operators requirements
c. To control speed & direction of rotation of the motor output shaft

DESIGN OF MANUAL SYSTEM

1. MANUAL GEARBOX
The Manual system consist only screw of gear box arrangement without having motor as the
prime mover. This will make the system less complicated and also reduce the cost of the
motor. Easier way is that to operate the screw directly with the hand lever, but according to
the ergonomic study the max Grip force applied by an average human being is 100N while we
need the a Torque of 250Nm approx. to lift the jaw.
As we know that

As it is not feasible to have such a long lever there is need of reduction gearbox as well as we
have to transmit the torque at right angles to lift the load vertically, hence, it is convenient to
use the worm and worm wheel drive. The worm gears are widely used for transmitting power
at high velocity ratios between non-intersecting shafts that are generally, but not necessarily,
at right angles. It can give velocity ratios as high as 300:1 or more in a single step in a
minimum of space, but it has a lower efficiency. As the worm and worm designed earlier in

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INTERNATIONAL JOURNAL OF INNOVATIONS IN ENGINEERING RESEARCH AND TECHNOLOGY [IJIERT]
ISSN: 2394-3696
VOLUME 3, ISSUE 9, Sep.-2016
the above gearbox is compatible with the manual design it will have of 26, calculating the
torque applied on worm

Now the length of lever

Which means the technologist can use a spanner of 100mm length to operate the screw.We
can develop a feature of bolt head on the worm shaft so that it can also be operated using
impact wrench. As there are same axial loading conditions the bearings and bearing covers
selected are same as that of automated gearbox. The detailed structure of the gearbox
designed is as shown in the figure below

Fig 7.1 Gearbox for manual system Fig 7.2 Gearbox details

CONCLUSION
A set up to aligning the bore and pulling centre line Developed. Based on assembly of the
bearings done Jaw crusher which enables the easy assembly increased safety and also reduces
the chances of the premature bearing failure because of pulling shock load. Results of these
fixture implementations are there will be lot of time saving along with increased life of
bearing as misalignment in spherical roller bearing is not there. Also earlier this is very
critical operation so skilled manpower and continue use of crane required which is also
eliminated the next stage of the project is to calculate the pulling force of the bearing in jaw
according to required fit type and pulling withy sensor which compare the force required
actual so there are no chances of the loose and tight fit of bearing in jaw and if jaw bore size
is within limit then only the bearing assembly will be done.

ACKNOWLEDGEMENT
We take immense pleasure in thanking our college management for having permitted us to
carry out this project work. Words are inadequate in offering our thanks to our respected co-
operation in carrying out project work in the starting phase of the project like requirement
analysis and literature survey. We also express our at most gratitude to Dr. K. B. Kale Head
of department of Computer Engineering, for this valuable co-operation in selecting the project
topic and guiding us stepwise ahead. Inspiration and guidance are invaluable in every aspect
of life, especially in field of education, which we have received from our respected project
guide Dr. R. R. Navthar who has helped a lot In first two phase of project like topic selection
then information gathering and guide us to throughout the project work and gave earnest co-
operation whenever required. We would like to express sincere gratitude towards him. At last,
we would like to take this opportunity to convey thanks to all my staff members, who directly

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 NOVATEUR PUBLICATIONS
INTERNATIONAL JOURNAL OF INNOVATIONS IN ENGINEERING RESEARCH AND TECHNOLOGY [IJIERT]
ISSN: 2394-3696
VOLUME 3, ISSUE 9, Sep.-2016
or indirectly encouraged and helped us project work. Finally yet importantly, we would like to
express heartfelt thanks to our beloved parents for their blessings, our friends/classmates for
their and helps and wishes.

REFERENCES
1) Meridith Grimsley and Birmingham, Slide assembly fixture for rear hub assembly,
United States patent, Patent No. 7225516, (2007).

2) Frank M Prucha and Birmingham, Ring assembly fixture, United States patent, Patent
No. 2865091, (1958).

3) William Hunter, Upland, Gerard A Naab and Morton, Assembly and test fixture,
United States patent, Patent No. 160394, (1964).

4) Shalette Farmer, Instrument panel assembly fixture, United States patent, Patent
No.2010/00450651A1, (2010).

5) John B. Gray 3 and William R. Yeich, Assembly Fixture, United States patent, Patent
No. 2801329, (1957).

6) Arthur Richard Baker Jr., Fixture for assembling electronic circuit modules, United
States Patent, Patent No.5732462, (1998).

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