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In the field of mining machinery, the hammer crusher and VSI sand making machine are two commonly used pieces of equipment, each serving distinct roles in crushing and sand making processes. Although they both play crucial roles in mineral processing, they differ significantly in terms of working principles, application scenarios, structural design, and performance. This article will explore the differences between the hammer crusher and VSI sand making machine from multiple perspectives, helping readers to better understand these two machines and make more informed decisions in practical applications.
The hammer crusher and VSI sand making machine have distinct differences in structural design.
The main structure of the hammer crusher includes the rotor, hammer head, screen plate, lining plate, and casing.
The rotor drives the hammer head to rotate at high speed through the main shaft, with the number and quality of hammer heads directly affecting the crushing effect and production efficiency of the machine.
The size of the screen plate's apertures determines the discharge particle size. The overall structure is relatively simple, making it easy to maintain and operate.
The VSI sand making machine consists of a feeding system, distributor, impeller, main shaft, lining plate, and base.
The impeller is the core component of the VSI sand making machine, determining the material's acceleration and sand-making effect.
The VSI sand making machine typically employs a dual motor drive structure with high rotational speed and kinetic energy. Moreover, its internal design is more complex, particularly the material distributor and impeller structure, which require regular maintenance and replacement of wear parts.
The working principles of the hammer crusher and VSI sand making machine are among their most significant differences.
The hammer crusher primarily relies on impact force to achieve crushing, making its effectiveness closely related to the hardness and brittleness of the material.
The hammer crusher crushes materials through the high-speed rotation of its hammer head. When the material enters the crushing chamber, the hammer head impacts the material at high speed, causing it to break due to the intense force.
The material is repeatedly struck between the hammer head and the lining plate until its size is smaller than the gap between them, at which point it is discharged from the bottom of the machine.
The VSI sand making machine primarily relies on impact and shearing forces for crushing, making it particularly suitable for sand making and shaping hard materials.
The VSI sand making machine operates on the "rock-on-rock" and "rock-on-iron" principles. When the material enters the machine, it is first accelerated to high speed and then enters the high-speed rotating impeller through the distributor.
The material gains kinetic energy in the impeller and then strikes the surrounding lining plate or collides with other materials at high speed, resulting in crushing and shaping.
The hammer crusher and VSI sand making machine also differ significantly in their application scenarios.
The hammer crusher is typically used for crushing medium-hard and brittle materials, such as limestone, coal, salt, gypsum, bricks, and tiles. Due to its simple structure, large crushing ratio, and strong production capacity, it is widely used in the primary or secondary crushing processes in industries such as mining, building materials, chemicals, and cement.
More importantly, the hammer crusher can achieve a "one-time forming" process, meaning that even at the primary or secondary crushing stage, it can directly produce the desired particle size without the need for multiple crushing stages.
The VSI sand making machine is mainly used for sand making and shaping hard materials, such as granite, basalt, river pebbles, and iron ore. It is often used as a secondary or tertiary crushing machine in sand production lines, typically in the third crushing stage.
Since the VSI sand making machine has excellent grain shape control capabilities, it is particularly suitable for producing sand and gravel aggregates with high requirements for grain shape, such as in highway, railway, bridge, hydropower engineering, and construction sand applications.
The hammer crusher and VSI sand making machine also differ significantly in terms of performance, particularly in crushing ratio, discharge particle size, output, and energy consumption.
| Hammer Crusher | VSI Crusher | |
| Applicable Stages | Primary or secondary crushing | Tertiary crushing |
| Compressive strength of materials | ≤200 MPa | ≤350 MPa |
| Crushing Ratio | between 10-25, can reach up to 50 | between10-20,can reach up to 50 |
| Feed size | ≤1525mm | ≤60mm |
| Discharge Size | ≤70mm | ≤5mm |
The hammer crusher has a larger crushing ratio and can typically reduce large pieces of material to the desired size in one step. However, the discharge particle size is relatively coarse, and the shape is irregular. In contrast, the VSI sand making machine has a relatively smaller crushing ratio, but its discharge particle size is more uniform, and the shape is better, making it particularly suitable for producing sand and gravel with high requirements for grain shape.
The hammer crusher generally has a higher output, making it suitable for large-scale production. However, since it relies on high-speed impact between the hammer head and the material for crushing, it has higher energy consumption, especially when processing hard materials, where the wear on the hammer head is also more severe. The VSI sand making machine, on the other hand, has relatively lower energy consumption during the sand-making process, and because it uses the "rock-on-rock" working principle, it experiences less wear and has a longer service life.
Maintenance and upkeep are crucial for ensuring the long-term stable operation of the equipment. The hammer crusher and VSI sand making machine have different requirements in this regard.
The structure of the hammer crusher is relatively simple, with wear parts mainly being the hammer head, screen plate, and lining plate, which need to be inspected and replaced regularly. Since the hammer head is directly involved in material crushing, it wears out quickly, especially when processing hard materials, leading to a shorter service life. The size and wear of the screen plate also directly affect the discharge particle size and output, so regular inspection and replacement are necessary.
The internal structure of the VSI sand making machine is more complex, with critical components like the impeller and lining plate requiring careful maintenance. The impeller is the core part of the equipment, and its wear directly affects the sand-making effect and output. Therefore, it is essential to regularly inspect and replace the impeller. Additionally, since the VSI sand making machine often processes hard materials, the wear on the lining plate is also significant, requiring regular replacement. Compared to the hammer crusher, the maintenance cycle of the VSI sand making machine is relatively long, but the time and cost required for each maintenance operation are also higher.
When selecting crushing equipment, investment costs and economic benefits are key concerns for enterprises. The hammer crusher and VSI sand making machine also have notable differences in this aspect.
The hammer crusher has a relatively low equipment cost due to its simple structure and mature production technology, resulting in lower initial investment expenses. Additionally, the maintenance costs of the hammer crusher are also relatively low, making it suitable for small to medium-sized enterprises with limited budgets. However, its high energy consumption during long-term operation increases operating costs, especially when processing hard materials, where the frequent replacement of hammer heads also raises maintenance costs.
The initial investment cost of the VSI sand making machine is relatively high, especially for high-quality equipment. Furthermore, the maintenance costs of the VSI sand making machine are higher, as wear parts like the impeller and lining plate require regular replacement, increasing maintenance expenses. However, due to its low energy consumption and excellent sand-making effect, particularly in producing high-quality sand and gravel aggregates, the VSI sand making machine can generate higher economic benefits. Therefore, for large enterprises seeking long-term economic returns, the VSI sand making machine is a more ideal choice.
The hammer crusher and VSI sand making machine have significant differences in working principles, application scenarios, structural design, performance, maintenance, and investment costs.
The hammer crusher is suitable for processing medium-hard and brittle materials, primarily used in primary and secondary crushing stages, offering low investment costs and simple maintenance.
In contrast, the VSI sand making machine is more suited for processing hard materials, mainly used for sand making and shaping in the third crushing stage, offering low energy consumption and excellent sand-making results.
Depending on the specific production needs, enterprises can choose the appropriate equipment to achieve optimal production efficiency and economic benefits.
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