Study on the motion characteristics and trajectory of material in the crushing chamber of an eccentric roller crusher under cyclic compression conditions

This paper reveals the reversal motion mechanism of the roller body in an eccentric roller crusher (ERC) under loaded conditions, a phenomenon fundamentally different from traditional cone and gyratory crushers. A novel kinematic-dynamic coupling model is established, incorporating both bearing friction and material-induced torque, to quantify the roller’s reverse rotation characteristics. It is discovered that the instantaneous center of rotation (ICR) position critically governs the reversal angular velocity, with maximum reversal occurring when the ICR aligns horizontally with the roller center, a finding that provides a theoretical basis for roller surface wear prediction and liner profile optimization. Furthermore, the material motion within the crushing chamber is systematically classified into three regimes (sliding, free-fall, and compression), and a choke-level velocity-position distribution model is developed to link roller kinematics with material flow behavior. This work not only advances the fundamental understanding of ERC material dynamics but also establishes a transferable modeling framework applicable to other crusher types, offering direct guidance for chamber design and operational parameter selection to enhance throughput and product quality.