Hydraulic breakers, also known as hydraulic hammers, are essential tools used in construction, demolition, and mining. They use hydraulic power to generate high-impact force for breaking rocks, concrete, and other hard materials. A hydraulic breaker is composed of several main components that work together to deliver consistent, powerful strikes. Here’s an overview of the primary components of a hydraulic breaker—such as the chisel, piston, and control valve—and their functions and working principles.
1. Chisel (Tool)
The chisel, or tool, is the part of the hydraulic breaker that directly contacts the material to be broken. Made from hardened steel, it comes in various shapes, such as pointed, flat, or blunt, to suit different applications.
- Function: The chisel transmits the hydraulic breaker’s impact force to the material, breaking it down through a series of high-energy strikes.
- Working Principle: During operation, the chisel is driven into the material with each impact cycle, fracturing and breaking the material into smaller pieces. The chisel’s design (shape and size) can be adapted to specific types of tasks, such as breaking hard rock or chipping away at softer materials.
2. Piston
The piston is a critical component inside the hydraulic breaker that converts hydraulic energy into mechanical impact force. It moves back and forth within the breaker’s cylinder, striking the chisel to generate the force needed to break materials.
- Function: The piston creates powerful impacts by repeatedly striking the chisel. It is responsible for converting the hydraulic pressure from the excavator or hydraulic system into the force needed for breaking.
- Working Principle: Hydraulic fluid enters the breaker, pushing the piston upward. When the hydraulic flow is redirected, the piston is released, allowing it to strike downwards against the chisel. This cycle of upward pressurization and downward release generates the repeated impacts that the hydraulic breaker delivers.
3. Control Valve (Distribution Valve)
The control valve, or distribution valve, regulates the flow of hydraulic fluid within the breaker, controlling the timing and force of the piston’s movements.
- Function: The control valve directs hydraulic oil between the upper and lower chambers of the breaker, which governs the piston’s upward and downward movement.
- Working Principle: The control valve opens and closes in sync with the hydraulic breaker’s cycle. When open, it allows hydraulic fluid to enter the upper chamber, lifting the piston. Once closed, the fluid pressure is cut off, causing the piston to move downward. This controlled cycling ensures a consistent rhythm of impact force.
4. Cylinder
The cylinder in a hydraulic breaker houses the piston, providing a controlled environment where it can move up and down to deliver impacts. The cylinder is designed to withstand high pressures and intense impact forces.
- Function: The cylinder guides the piston’s movement and holds the hydraulic fluid that powers the piston’s motion.
- Working Principle: The hydraulic fluid enters the cylinder under high pressure, moving the piston in controlled cycles. The cylinder’s tight design ensures that hydraulic fluid is contained properly and that the piston’s energy is efficiently directed towards the chisel for maximum impact.
5. Accumulator
The accumulator in a hydraulic breaker is an auxiliary component that stores hydraulic energy and dampens pressure fluctuations. By acting as a buffer, it helps to stabilize the hydraulic flow and reduce the risk of pressure surges.
- Function: The accumulator maintains consistent hydraulic pressure and reduces strain on the excavator or hydraulic system, improving the breaker’s efficiency and extending its lifespan.
- Working Principle: Inside the accumulator, a gas-charged chamber compresses when hydraulic pressure increases, storing energy. When hydraulic pressure drops, the accumulator releases the stored energy back into the system. This process smooths out pressure variations, ensuring steady operation.
6. Front Head and Back Head
The front head and back head are the structural components that enclose the cylinder, piston, and other internal parts. They provide housing for these critical parts, protecting them from external impacts and environmental exposure.
- Function: These heads contain the internal components, secure the tool/chisel, and help absorb shock during operation.
- Working Principle: The front head and back head work as protective barriers for the internal parts of the hydraulic breaker. The front head typically has a retaining pin that holds the chisel in place, while the back head often contains a gas chamber that works alongside the accumulator to assist in pressure regulation.
7. Bushings
The bushings are cylindrical sleeves located within the front head that support the chisel and allow for its smooth movement during impact cycles. Bushings are subject to significant wear and tear and must be replaced periodically.
- Function: Bushings help guide the chisel during operation, absorbing part of the impact force and reducing friction between the chisel and the front head.
- Working Principle: The bushings provide a smooth, controlled pathway for the chisel’s movement while absorbing some of the shock from each impact, which minimizes wear on other components and prolongs the life of the chisel and the breaker itself.
8. Nitrogen Chamber
The nitrogen chamber (often part of the back head) is a pressurized gas chamber containing nitrogen gas. This chamber aids the accumulator in managing pressure levels, ensuring steady impacts.
- Function: The nitrogen chamber increases the force of each impact by compressing nitrogen gas to provide additional pressure, enhancing the breaker’s performance.
- Working Principle: During the piston’s movement, nitrogen gas is compressed in the chamber, which assists in pushing the piston down with added force. This compression cycle helps achieve stronger, more consistent impacts by supplementing the hydraulic pressure with gas pressure.
Summary of the Hydraulic Breaker’s Working Mechanism
The hydraulic breaker operates by converting hydraulic energy from the excavator or other hydraulic system into powerful impact force. Hydraulic fluid enters the breaker, pressurizing the piston and pushing it upwards within the cylinder. The control valve directs the fluid flow to create a cyclic movement, allowing the piston to strike downwards against the chisel. Each impact transfers energy to the chisel, which breaks the material in front of it. Components like the accumulator and nitrogen chamber help regulate and enhance this energy transfer, ensuring consistent, powerful impacts for efficient material breaking.
Through the coordinated function of these components, hydraulic breakers can deliver precise, high-energy impacts, making them invaluable tools for heavy-duty applications across construction and mining industries. Proper maintenance of each component is essential for reliable operation and optimal performance in demanding environments.