The crawler-type mobile crushing plant is a comprehensive crushing and screening solution that integrates feeding, crushing, screening, iron removal, and material conveying into one unit. It is composed of several subsystems, including the feeding system, crusher unit, power system, conveyor system, walking (track) system, and hydraulic system. Among these, the power system is the “heart” of the equipment. There are five major types of drive systems used in such plants: Direct Drive + Hydraulic Drive, Direct Drive + Electric Drive, Full Hydraulic Drive, Mains Electricity Drive, and Diesel-Electric Drive. This article provides a detailed analysis and comparison of each.
1. Direct Drive + Hydraulic Drive
This method uses a diesel engine as the power source. Through a power take-off gearbox, two output terminals are split:
- The main output is connected to a clutch or hydraulic coupler to drive the crushing unit directly.
- The secondary output drives the hydraulic pump group, which powers walking, feeding, conveying, and folding auxiliary functions.
the most commonly adopted globally. Manufacturers such as XCMG, Metso, Sandvik, Kleemann, and Keestrack all offer this configuration.
Advantages:
- Compact design
- High transmission efficiency
Limitations:
- Higher operational costs compared to mains-electric drive, which is a limiting factor for its large-scale promotion.
2. Direct Drive + Electric Drive
Also diesel-powered, this setup uses a gearbox to produce three output terminals:
- One terminal drives the crushing host through a clutch or hydraulic coupler.
- The second terminal powers the hydraulic pump for the track and other hydraulic actuators.
- The third terminal powers a generator, which supplies electricity to motors driving the feeding and conveyor units.
widely used by manufacturers like RM (Rubble Master) and Kleemann.
Advantages:
- Easier maintenance compared to pure hydraulic systems.
Limitations:
- The high power demand of the walking system requires larger pumps, increasing manufacturing costs.
- The layout is complex, and operational cost remains high due to diesel usage.
3. Full Hydraulic Drive
In this mode, a diesel engine powers a series of hydraulic pumps that supply pressurized oil to the entire system. The crushing host is typically driven by a variable plunger pump, while other components are controlled through other pump and valve assemblies.
Widely adopted by: Metso, particularly in smaller models.
Advantages:
- Lower manufacturing cost
- Simple layout and control
Limitations:
- The crushing unit requires high torque at startup and high speed during operation, making this method more suitable for smaller equipment.
- High dependency on imported hydraulic parts, which increases maintenance costs.
4. Mains Electricity Drive
Here, the walking system is powered by a diesel engine + hydraulic pump + track motor, while all other operations (crushing, feeding, conveying) are powered by grid electricity.
Advantages:
- Lowest operating cost
- Simple maintenance and spacious internal layout
Manufacturers:
- Common among Chinese producers, such as Nanchang Mining Machinery.
- Frequently used in semi-mobile plants.
Limitations:
- Restricted to locations with access to stable grid power, requiring long cable connections at mining or demolition sites.
5. Diesel-Electric (Hybrid) Drive
This mode allows switching between grid electricity and a diesel generator. The walking mechanism uses a combination of electric motors and hydraulic pumps, while other systems are fully electric. Refer to Figure 7.
Key Feature:
- Works like a plug-in hybrid vehicle, allowing seamless switching between power sources depending on site conditions.
Advantages:
- Can use grid electricity for cost savings on large projects
- Flexible and mobile on smaller, remote jobsites using diesel
Industry Trend:
- Considered the future of mobile crushing technology due to its adaptability and energy efficiency
