Making a double roll crusher involves designing and assembling two counter-rotating rolls that crush material by compression. Below is a step-by-step guide to building a simple double roll crusher for small-scale applications.
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Materials & Tools Required
# Materials:
1. Rolls (Crushing Cylinders) – Made from hardened steel or manganese steel for durability.
2. Shafts – Steel rods to hold the rolls.
3. Bearings – To allow smooth rotation of the shafts.
4. Frame – Sturdy metal (steel or iron) structure to hold the assembly.
5. Drive Mechanism – Motor, belts, pulleys, or gears for power transmission.
6. Adjustment Mechanism – Springs or bolts to adjust the gap between rolls.
7. Hopper – For feeding material into the crusher.
8. Fasteners – Bolts, nuts, and washers.
# Tools:
– Welding machine
– Angle grinder
– Drill machine
– Spanners & wrenches
– Measuring tape
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Step-by-Step Construction Guide
# 1. Design the Roll Crusher
– Decide on the roll diameter (typically 6–24 inches for small crushers).
– Determine the required gap between rolls (adjustable for different particle sizes).
– Sketch a basic layout with dimensions.
# 2. Build the Frame
– Cut and weld steel beams/channels into a rigid rectangular frame.
– Ensure enough space for mounting rolls, motor, and adjustment mechanisms.
# 3. Fabricate the Rolls
– Cut two cylindrical steel rods (or use pre-made hardened steel rollers).
– Machine grooves or teeth if needed for better grip (optional).
– Weld or key them onto shafts with bearings at both ends.
# 4. Mount the Rolls in the Frame
– Install bearings on both sides of each shaft.
– Fix one roll in a stationary position.
– The second roll should be adjustable (using springs or bolts) to control crushing gap.
# 5. Install Drive Mechanism
– Use an electric motor (1–5 HP depending on size).
– Connect via V-belts & pulleys or gears to rotate rolls inward toward each other.
– Ensure proper speed ratio (typically 50–300 RPM).
# 6. Add Feed Hopper & Discharge Chute
– Weld a funnel-shaped hopper above the rolls for feeding material.
– Place a ch