インパクトクラッシャーとは何ですか?その仕組みはどのようなものですか?

impact crusher

インパクトクラッシャーとは何ですか?その仕組みはどのようなものですか?

What is an Impact Crusher?

An impact crusher is a type of secondary or tertiary crushing machine that uses impact force to break rocks and minerals. Unlike a jaw crusher or cone crusher, which crush materials by compression, an impact crusher breaks materials by high-speed collision with a rotating rotor and impact plates.

Impact crushers are widely used in:

  • Mining
  • Quarrying
  • Aggregate production
  • Cement plants
  • Construction waste recycling
  • Road building

Common materials processed:

  • 石灰岩
  • Granite (medium hardness)
  • Concrete
  • Asphalt
  • River stone
  • ドロマイト
  • Gypsum
  • 石炭

Main Parts of an Impact Crusher

1. Rotor

The rotor is the heart of an impact crusher.

Function:

  • Rotates at high speed
  • Provides kinetic energy
  • Throws material against impact plates

The rotor usually contains:

  • Rotor shaft
  • Rotor discs
  • Blow bars

2. Blow Bars (Hammers)

Blow bars are wear-resistant bars mounted on the rotor.

When the rotor spins:

  • Blow bars strike incoming material
  • The material is accelerated outward
  • High-speed impact breaks the rock

Common materials:

  • High chromium alloy
  • Manganese steel
  • Ceramic composite materials

3. Impact Plates (Breaker Plates)

Impact plates are fixed inside the crushing chamber.

Their functions:

  • Receive material thrown by the rotor
  • Create secondary impact crushing
  • Protect the crusher housing

4. Crushing Chamber

The crushing chamber is where the material reduction happens.

It contains:

  • Rotor
  • Blow bars
  • Impact plates
  • Side liners

The space between rotor and impact plates determines the final product size.


5. Feed Opening

Raw material enters from the top.

例:

Large stone
300 mm
   ↓
Impact Crusher
   ↓
20-40 mm product

6. Discharge Opening

The crushed material leaves through the bottom.

The discharge size can be adjusted by:

  • Changing impact plate position
  • Adjusting rotor speed
  • Controlling feed size

How Does an Impact Crusher Work?

Step 1: Feeding

Large rocks enter the crusher through the feed opening.

例:

Raw limestone
500 mm

↓


Step 2: Rotor Acceleration

The electric motor drives the rotor.

Typical rotor speed:

500–1000 rpm

The blow bars rotate at high speed.

↓


Step 3: First Impact Crushing

The blow bars hit the material with strong impact force.

The rock is:

  • Accelerated
  • Thrown forward
  • Broken into smaller pieces

↓


Step 4: Secondary Impact

The broken pieces hit the impact plates.

They are crushed again by:

  • Rotor impact
  • Plate impact
  • Rock-to-rock collision

↓


Step 5: Discharge

When the material reaches the required size:

  • It leaves through the discharge opening.
  • Oversized pieces remain for additional crushing.

Impact Crusher Working Diagram

              Feed Material
                   ↓

        ┌──────────────────┐
        │                  │
        │    ↻ Rotor       │
        │   [Blow Bars]    │
        │       ↓          │
        │      ★★★         │
        │                  │
        │  Impact Plates   │
        │      /\/\/\      │
        └────────┬─────────┘
                 ↓

          Crushed Product

Types of Impact Crushers

1. Horizontal Shaft Impact Crusher (HSI)

The most common type.

Structure:

  • Horizontal rotor shaft
  • Blow bars mounted on rotor
  • Impact plates around chamber

Applications:

  • Limestone crushing
  • Aggregate production
  • Recycling

メリット:

  • High reduction ratio
  • Good cubic-shaped products
  • High capacity

2. Vertical Shaft Impact Crusher (VSI)

Material enters the center of a high-speed rotor and is thrown outward.

Crushing methods:

  • Rock-on-rock
  • Rock-on-metal

Applications:

  • Manufactured sand production
  • Fine aggregate shaping

メリット:

  • Excellent particle shape
  • Produces high-quality sand

Impact Crusher Advantages

1. High Reduction Ratio

Typical crushing ratio:

10:1 to 30:1

A single impact crusher can significantly reduce material size.


2. Excellent Product Shape

Compared with compression crushers:

  • More cubic particles
  • Less needle-shaped stones
  • Better for concrete and asphalt aggregates

3. High Crushing Efficiency

Impact crushing uses:

  • Direct collision energy
  • Less compressive force

This gives high productivity for suitable materials.


4. Adjustable Product Size

Output size can be controlled by:

  • Rotor speed
  • Impact plate clearance
  • フィードサイズ

Impact Crusher Disadvantages

1. High Wear Cost

Main wear parts:

  • Blow bars
  • Impact plates
  • Side liners

They need regular replacement.


2. Not Suitable for Very Hard Rocks

Best for:

  • Mohs hardness < 6–7

Less suitable for:

  • クォーツ
  • Very hard granite
  • Abrasive ores

3. Higher Power Consumption

Because crushing depends on high-speed impact, it generally requires more energy than compression crushers.


Impact Crusher vs Hammer Crusher

特集Impact CrusherHammer Crusher
Crushing method影響影響
Main crushing partBlow barsHammer heads
Rotor speed中高高い
Product shapeBetter cubic shapeMore fine powder
容量Higher中
Wear rate高いVery high
Best materialsLimestone, aggregate, concreteCoal, gypsum, soft materials

Impact Crusher in a Crushing Plant

A typical aggregate production line:

Large Rock
    ↓
Jaw Crusher
    ↓
Impact Crusher
    ↓
Vibrating Screen
    ↓
Finished Aggregate

A typical mining line:

Ore
 ↓
Primary Crusher
 ↓
Impact Crusher
 ↓
Ball Mill
 ↓
Mineral Separation

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