Differences between Gyratory Crusher and Single-Cylinder Crusher

Gyratory crushers (gyratory crushers) and single-cylinder crushers (single-cylinder hydraulic cone crushers) differ significantly in their crushing principles, structural configurations, application scenarios, performance characteristics, and maintenance costs. A detailed analysis is provided below:

1. Crushing Principle and Process Differences
Gyratory Crusher
Crushing Method: The gyratory motion of the moving cone within the cone cavity of the housing continuously squeezes, splits, and bends the material, achieving coarse crushing.
Motion Path: The moving cone, suspended on the crossbeam bearing seat, performs periodic horizontal circular motion around the centerline of the machine, forming a crushing zone with varying depths with the fixed outer cone.
Crushing Effect: Continuous crushing action and high production efficiency make it particularly suitable for processing large-diameter materials (such as blasted rock blocks exceeding 1000mm).

Single-Cylinder Crusher
Crushing Method: Utilizing a laminated extrusion and progressive crushing mechanism, the movable cone is mounted upright within an eccentric sleeve and performs an eccentric oscillating motion around the centerline of the frame, cyclically crushing the material through the gradient area between the static cone’s mortar wall and the movable cone’s crushing wall.
Motion Trajectory: The movable cone oscillates back and forth within the crushing chamber and slowly rotates, achieving dynamic, proportional collision and stratification of rock fragments of varying particle sizes.
Crushing Result: The finished product is cubic, with a needle-like flake rate approximately 40% lower than that of conventional mechanical crushing, making it suitable for medium-, fine-, and ultra-fine crushing.
2. Comparison of Structure and Core Components
Gyratory Crusher
Structural Composition: The upper end of the main shaft is supported within a crossbeam bushing, while the lower end rests in an eccentric hole in the shaft sleeve. The movable cone’s gyratory motion is driven by a bevel gear transmission.
Discharge Adjustment: The crushing cone position is adjusted mechanically (using an adjusting nut) or hydraulically (using a hydraulic cylinder plunger). Overload protection is provided by a safety pin that disconnects the drive pulley in the event of an overload. Equipment Features: Complex structure and high height, requiring impact-resistant vibration damping springs, resulting in high infrastructure costs.
Single-Cylinder Crusher
Structural Composition: Consists of seven major components: upper frame, lower frame, main shaft assembly, eccentric sleeve, and bottom hydraulic cylinder. It also integrates a locking hydraulic cylinder assembly and energy storage assembly.

Discharge Opening Adjustment: Automatic adjustment is achieved by raising and lowering the movable cone via a single hydraulic cylinder. The opening size can be displayed, and it supports under-load starting.
Equipment Features: Compact structure, simple appearance, small size and light weight. The movable cone has a 70-degree top angle, making it suitable for water- and mud-containing ores.
3. Application Scenarios and Capacity Differences
Gyratory Crusher
Applicable Applications: Coarse crushing of raw stone in large-scale mineral processing lines, particularly suitable for processing mixed ore bodies with uneven hardness.
Capacity Data: Taking the HGT5065 model as an example, it has a rated processing capacity of 380-420 tons of basalt per hour, and after cavity optimization, its peak flow rate can reach 520 tons.
Advantages: It can directly process large-size materials by filling the feedstock, reducing front-end process steps.

Single-Cylinder Crusher
Applicable Applications: Secondary crushing in stone production lines, or medium, fine, and ultra-fine crushing of metal ores and construction sand and gravel.
Capacity Data: Taking the GYS500 model as an example, it can process 150-180 tons of basalt per hour, with an average unit energy consumption 23% lower than that of a gyratory crusher.
Advantages: High discharge adjustment accuracy (±3mm error threshold), uniform finished product particle size, and low flake content.

4. Performance Characteristics and Maintenance Cost Comparison
Gyratory Crusher
Performance Characteristics: High crushing ratio and high production efficiency, but complex structure, difficult maintenance, and high repair costs.
Maintenance Costs:
The average annual wear cost of the crossbeam assembly bearing is approximately 150,000 yuan;
The lower support housing anti-vibration gaskets need to be replaced completely every three years;
The spherical bearing sealing system requires 1.25 standard man-hours of maintenance per month.
Single-Cylinder Crusher
Performance Characteristics: High crushing ratio, high production efficiency, low consumption of wearing parts, low operating costs, and support for intelligent control. Maintenance Costs:
Annual oil consumption is less than 6,000 yuan;
Part replacement requires only a few bolts;
After cumulative crushing hours exceed 10,000, the cost of disassembling the powertrain is equivalent to 78% of the price of a new machine.

Selection Recommendations:

If you need to process blasted rock particles exceeding 1,000 mm in diameter, or if you require extremely high coarse crushing capacity, a gyratory crusher is preferred.
If you need to control the amount of needle-like flakes in the finished product (such as those required for Class I building materials), or if you require low energy consumption and easy maintenance, a single-cylinder crusher is preferred.
For mixed ore bodies with uneven hardness, a combination of gyratory and cone crushers in series or in parallel may be considered.