Are you ready to learn about the power of precision? Hydraulic rock breakers are the ultimate solution for breaking solid rock, concrete, and other materials with ease. These powerful machines use hydraulic pressure to create a piston and chisel that generates a powerful impact on the surface. With full control of the impact force, hydraulic rock breakers are the ideal tool for working on delicate surfaces or near structures that need protection. In this article, we'll explore the technology behind hydraulic rock breakers, the different types available, and how to choose the right one for your project. So, let's dive in and check out the power of precision!
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Hydraulic rock breakers are powerful equipment that uses hydraulic pressure to easily break apart solid rock, concrete, and other materials! The technology behind hydraulic rock breakers is based on using a piston and chisel to create a powerful impact on the surface they're breaking, like a large-scale version of you using a pestle and mortar.
You typically see hydraulic rock breakers mounted on excavators and other heavy machinery. They're powered by a hydraulic system that delivers high-pressure fluid to the piston. The piston then strikes the chisel, which is in contact with the surface you want to break. The impact generated by the piston and chisel creates a crack in the surface, which widens as you move the breaker back and forth.
The hydraulic pressure helps amplify the impact's force, making it possible to break through even the toughest materials. The hydraulic system also allows for precise control of the impact force, which is essential when working on delicate surfaces or near structures that need protection.
A rock breaker is a powerful machine. That's why they're primarily used to break apart solid rock, concrete, and other materials. Hydraulic rock breakers are most often used in construction, mining, and demolition projects, as they can make quick work of even the hardest materials:
In construction projects, we often use hydraulic rock breakers to break apart concrete foundations, walls, and other structures we want to remove. A hydraulic rock breaker can also break up rocks and boulders in the way of specific construction projects, such as roads and bridges.
People also use rock breakers in mining operations to break apart solid rock and ore deposits, making it easier to extract valuable minerals. They can break up large rock pieces or create tunnels and access points for mining operations.
In demolition projects, hydraulic rock breakers are essential tools for breaking apart structures and removing debris. They can be used to break apart concrete walls, steel structures, and other materials that need to be removed during demolition projects.
Several hydraulic rock breakers are available, each with its features and capabilities. Here are some of the most common types of hydraulic rock breakers:
1. Top Type Breaker: This hydraulic rock breaker is designed to be mounted on the top of an excavator or other heavy machinery. People typically use these for breaking apart large rocks and boulders.
2. Side Type Breaker: This rock breaker is mounted on the side of an excavator or other heavy machinery. It's suitable for breaking apart concrete walls and other structures.
3. Box Type Breaker: These hydraulic rock breakers are the ones you see mounted on the front of an excavator or other heavy machinery. People use them to break apart large rocks and boulders.
4. Skid Steer Breaker: This type of hydraulic rock breaker is designed to be used with a skid steer loader. It's usually used for breaking apart concrete and other materials in tight spaces.
5. Backhoe Breaker: These rock breakers are great with a backhoe loader. They're generally used for breaking apart concrete and other materials in tight spaces.
Choosing the right hydraulic rock breaker for your project is an important decision, as it can impact the efficiency and safety of the job. Here are some factors to consider when choosing a hydraulic rock breaker:
1. Type of job: The job's size and weight will determine the type of hydraulic rock breaker needed. A more significant job will require a bigger, more powerful breaker.
2. Type of material: Different hydraulic rock breakers are better suited for breaking apart different materials. For example, a side-type breaker is better for breaking concrete walls, while a top-type breaker is better for breaking apart large rocks.
3. Machine compatibility: Ensure that the hydraulic rock breaker is compatible with the carrier machine, such as an excavator or backhoe loader used for the job.
4. Operating pressure and flow rate: The operating pressure and flow rate of the hydraulic system will determine the power of the hydraulic rock breaker. Choose a breaker compatible with the carrier machine's hydraulic system.
5. Noise level: If you're working in a residential area or other location where noise pollution is a concern, consider a silence-type breaker that operates at a lower noise level.
6. Maintenance requirements: Consider the maintenance requirements of the hydraulic rock breaker, including the frequency of routine maintenance and repair needs.
Choosing the most suitable hydraulic rock breaker requires careful consideration of the specific application and job needs. Contact us today to select the right hydraulic rock breaker for your project!
This article is a complete guide to everything you need to know about hydraulic breaker hammers.
It will cover everything from construction, components and working principles to tips on buying, maintaining and repairing hydraulic hammers.
We'll also include a FAQ and troubleshooting guide that covers every detail you need to know.
To help beginners and professionals better understand the hydraulic crusher hammer.
Among them, "hydraulic hammer ultimate Purchase guide" is divided into six chapters.
Hydraulic breaker hammer definition. Its history, type and application are briefly introduced.
Structure of hydraulic hammer. This section describes the main components and provides an overall schematic of the structure.
Working principle of hydraulic hammer.An informative section explaining the technical principles of operating hydraulic hammers with diagrams and videos.
How to choose hydraulic hammer. Here are six of the most practical tips for choosing the right hammer; This section is intended to provide general advice in the form of a buying guide.
Hydraulic hammer maintenance guide. Common maintenance suggestions and videos. A complete PDF maintenance guide is available for download.
A list of frequently asked Questions about daily use, repair, maintenance and troubleshooting - all the details you need to know!
What is a hydraulic breaker hammer?
Hydraulic crushing hammer is a heavy construction machinery, installed in excavators, backhoe, skid steering, small excavators and fixed equipment.
It is hydraulically driven to break rocks into smaller sizes or concrete structures into manageable fragments.
They are such versatile tools that can handle a wide variety of jobs and come in different sizes and models to meet specific needs.
A good hammer is built durable and is commonly used in a variety of applications such as demolition, construction, road-building, mining and quarrying, tunneling, and landscaping.
Hydraulic Breaker hammer Structure
In order to understand how hydraulic hammers work, or what is the working principle of hydraulic hammers, it is necessary to first clarify the structure and main components of hydraulic hammers.
Hydraulic crusher hammer is mainly composed of three parts: back head (nitrogen chamber), cylinder assembly, and front head.
We'll talk about them separately.
1. Back (nitrogen chamber)
The rear head is a container for storing nitrogen.
Under high pressure, the nitrogen-filled chamber acts as a damper for the piston's return trip.
As the piston moves downward, it also acts as an impact enhancer.
2. Cylinder assembly
Hydraulic crushing hammer cylinder assembly is the core component of hydraulic crushing hammer.
It is mainly composed of cylinder, piston and control valve.
The piston and valve are the only two moving parts of the hydraulic hammer.
The piston moves up and down, hits the tool, and the valve rotates to control the flow of oil.
It is where motion takes place and where water power is produced.
The oil is controlled by the main valve, and the hydraulic flow drives the piston to produce impact energy.
The cylinder is equipped with a sealing kit to prevent oil leakage.
3. Front Head
This is where the piston is attached to the chisel (or working tool).
The chisel is secured with bushings and pins, and this is the part most in need of replacement.
The front side is in direct contact with the working surface, and the box case prevents wear and tear and provides longer service life.
A hammer has dozens of accessories in addition to these three main parts.
Hydraulic Breaker Hammer Working Principle
Now comes the crucial part.
This chapter contains a great deal of technical information.
If you have an engineering background, this section will help you understand the technical aspects of how hydraulic hammers work and operate.
If you think these flowcharts are boring and incomprehensible, you can jump right to the conclusion.
As described in the previous chapter, the main valve controls the flow of oil in and out, and the hydraulic flow drives the piston up and down, producing impact energy.
In this chapter, four flow charts are used to illustrate the process.
Remarks
1.High-pressure oil enters and fills chambers 1 and 8, acting on the end face of the piston and pushing the piston upwards.
2. When the piston moves up to the limit, chamber 1 is connected with chamber 2, and oil flows from chamber 2 to chamber 6.
Control valve due to pressure difference upward (6 chamber oil pressure is higher than 8 chamber oil pressure).
3. When the control valve reaches the upper limit, the input hole connects the oil flow of cavity 8 to make the oil flow into cavity 4.
Due to the high oil pressure in chamber 4, supported by nitrogen, the piston moves downward.
4. When the piston moves down and hits the chisel, chamber 3 is connected to chamber 2, and they are both connected to chamber 6.
Due to the high oil pressure in chamber 8, the control valve moves down and the input hole is connected to chamber 7 again.
Then a new cycle begins.
Conclusion
One sentence is enough to summarize the working principle of the hydraulic hammer: 'The relative position change of piston and valve, which is driven by oil flow going 'in' and 'out,' transforms hydraulic power into impact energy.'
Watch the short video for a detailed explanation.
How to choose a hydraulic breaker hammer?
Now that you know what a hydraulic circuit breaker is, you're going to buy one.
A hydraulic crusher is not a small investment, nor is it built for the convenience of life.
Choosing the right hammer can save a lot of money in the long run and improve your efficiency.
We've compiled six practical tips to explain how to choose the right hydraulic hammer.
1.
Size
Hydraulic hammer must be installed on suitable size carrier. The right mix can optimize efficiency and protect your valuable investment.
Since there is no general industry standard, crusher size can be measured by weight ratio, impact energy level, chisel/piston diameter, etc.
Each has its own advantages, the piston/chisel diameter is what I consider most.
In short, larger tools and chisels generally result in higher power and lower frequencies. The circuit breaker is fitted with a heavier carrier.
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For example, a 140mm tool diameter hammer is a good match for the 20 ton class, such as the Cat 320C, Komatsu PC200 excavator.
And a 45 mm chisel diameter crusher is a good fit for your 2 ton Bobcat skidding or 1.8 ton Kubota mini excavator.
2. Projects and applications
Hydraulic hammers are versatile enough to work in a variety of applications, so matching your machine to the intended project is critical.
In mining or quarrying, impact power is most important, which may require a larger hammer and slower speed to break rock or limestone into smaller pieces.
In road demolition or tunnel construction, penetration and impact rate are key factors to improve efficiency. The 10-ton medium hammer is a good choice.
For rear hole excavation or landscaping, anti-skid steering or small excavators fitted with a 1 ton crusher work best.
Demolishing the road with a 30 ton hammer is your choice, but I think it's a waste.
3. Aropriate hydraulic flow
The hydraulic crusher is driven and powered by the hydraulic flow of the excavator. Some can handle a wide range of traffic, and some can't.
Overflow can damage the hammer due to the extra pressure. And without enough flow, the hammer will become slow, weak, and ineffective.
In principle, the wider the scope, the better the universality, the greater the capacity of the narrow flow crusher.
For example, the Cat 130H hydraulic crusher hammer (tool diameter 129.5mm, excavator class 18-36 tons) has a flow range of 120-220 L /min.
Its best match is about 20 tons; It is most suitable for road construction and construction.
There's no doubt that it can work at higher oil flows and heavier loads (which means wider applications like mining and quarrying),
This may not be a perfect choice.
In this case, a new hammer with a larger piston and tool diameter might work better.
For example, a heavier hydraulic hammer, a 155mm diameter chisel and piston are more powerful and productive in a quarry.
So do you choose one for better versatility or multiple for better flow matching? This is your number.
4. Type of housing
There are three types of shells or casings, each with its own characteristics.
Choose a box, or a silent one, and make the most of it, not just for noise reduction.
The fully enclosed shell made of thickened wear-resisting steel plate protects the main body and front head from wear and impact.
The rock breaker is not easy to use, and better protection will extend the service life, thus protecting your investment.
5. Maintenance costs
When choosing a hydraulic crusher, maintenance costs are a long-term cost to consider.
Hydraulic circuit breakers cost money to maintain and are worth every dollar you spend.
This happens when parts wear out and need to be replaced regularly.
Ask your dealer or service center for retail prices of pins, bushings, chisels and seals, and replacement intervals.
Then figure out how much you're willing to pay for it.
Regularly and properly maintain your hydraulic crusher to ensure working efficiency and service life.
6. Used and rebuilt hydraulic hammers
Hydraulic hammers are not toys and usually work in harsh environments.
Sometimes it needs to be rebuilt.
Hammers can indeed be rebuilt, which is a great way to extend the working time of hammers.
But this can be a problem when buying a used or rebuilt home.
You never know if the piston is broken or the cylinder is scratched.
There may be sealing kit damage after a week, or due to cylinder rust and oil leakage.
Buying a substandard rebuild fracking hammer may seem cheap at first, but after a few months of use it can cost thousands of dollars.
Make sure you buy used or rebuilt hydraulic hammers from a trusted rebuilding center. Or buy a new one.
Hydraulic hammer maintenance guide
Proper maintenance and regular replacement of parts can make your hydraulic hammer performance better.
Is the key factor that makes its service life long.
To get an overview of it, we've summarized the most common maintenance tips to clear up your daily confusion.
Greasing
Proper lubrication is very important for prolonging the service life of rock breaker.
We recommend oiling the hammer every two hours.
Irregular oiling will significantly increase wear rates and reduce the life of your tools, bushings and front components.
Storage
Hydraulic crushing hammers can be stored vertically or horizontally. For long-term storage, it's best to keep it upright.
This will allow the weight of the crusher to push the tool and piston inside the crusher.
If you hold them on their sides for a long time, all seals have to support heavy internal components such as pistons.
O-rings and support rings are not used for carrying.
Nitrogen check & Nitrogen charging
Click the link below for a step-by-step video guide.
FAQ & Troubleshooting Guide
1. What are the factors that affect the power of hydraulic hammer?
There are three main factors that affect the power of hydraulic hammer: nitrogen pressure (back pressure), hydraulic flow rate and impact rate.
The amount of nitrogen is very specific; Overcharging will stop hammering, while low nitrogen pressure will weaken hammering.
Hydraulic flow directly affects working pressure. Overflow can quickly damage the hammer, so be sure to work within the proper hydraulic range.
A frequency valve in the cylinder block is responsible for the impact rate. Adjust manually according to working conditions.
Basically, under certain working conditions, the slower the impact rate, the stronger the impact, the higher the frequency, the lighter the impact.
2. How often do sealing kits need to be replaced?
It depends on working conditions, gender and age. We recommend once every three months.
3. Can the broken piston be repaired?
No, a broken hydraulic hammer piston can never be fixed or chrome plated. Tight tolerances and impact energy make it impossible. It can damage your cylinders and cost thousands of dollars in the long run.
4. What are the common causes of piston damage?
Contaminated oil, excessive wear of liner and lack of grease may cause piston damage. Remember, pistons can't be repaired, so be sure to replace damaged pistons immediately.
5. Can the hydraulic fracturing oil cylinder be repaired?
Yes, normal scratches can be repaired and polished, but only once! This is because the thickness of the carburizing layer after heat treatment is about 1.5-1.7mm, so there is still about 1mm after polishing, and the surface hardness is still guaranteed. This repair is only possible for the first time.
6. Why does the hydraulic hammer suddenly stop hammering?
Rear top pressure is too high. Release nitrogen and replenish as required.
The barrel was filled with oil. Remove the rear cover and replace the seal.
The control valve is stuck. Remove and clean valve and replace worn valve.
Insufficient oil flow. Repair pump, adjust hammer valve.
7. Why is the impact so weak?
Back pressure is too low. Check the back pressure and charge as needed.
Oil pollution. Replace hydraulic fluid and filter.
Low operating pressure. Check pump and reducing valve.
The loopback voltage is too high. Procedure Check the connection between filter and hose.
The working tools are not fully engaged. Use the right downward pressure. Ensure steel and front cover are not worn and properly greased.
8. Why does the hydraulic hammer not work after installation?
Improper bushing replacement. Reinstall the liner sleeve. Always use the original manuscript.
The quick connector is incorrectly installed. Check the connectors and replace them as needed.
The supply hose is upside down. The pressure line from the pump must be connected to the port marked IN. The return line connects to the port marked OUT.
The nitrogen pressure is too high. Release nitrogen and replenish it as needed.
Stop valve closes. Open stop valve.
9. Why is hydraulic hammer air injection prohibited?
When the tool is not in contact with the work surface, the hammer stroke of the piston is called "blank firing".
This can cause serious damage to the hydraulic hammer. Because of the tremendous impact energy, the pins and bolts may crack and the front end may break.
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