Self-adaptive repairing method for roller surface abrasion of high-pressure roller mill

Abstract

The invention discloses a high-pressure roller mill roller surface wear self-adaptive repair method, and relates to the field of mine crushing, and the method comprises the following steps: S1, wear detection; step S2, performing pretreatment; s3, carrying out gradient restoration; step S4, curing and forming; and S5, performing adaptation verification. By the adoption of the self-adaptive repairing method for roller surface abrasion of the high-pressure roller mill, precise repairing and efficient repairing of roller surface abrasion are achieved, the abrasion resistance of a repairing layer and the binding force of a base body are improved, the service life of the roller surface is prolonged, the repairing cost and the operation and maintenance frequency are reduced, and meanwhile it is ensured that the repaired roller surface is matched with the crushing working condition.

Description

Technical Field

[0001] This invention relates to the field of mining crushing technology, and in particular to an adaptive repair method for wear on the roller surface of a high-pressure roller mill. Background Technology

[0002] High-pressure roller mills, as core equipment in the mining crushing field, are widely used in the crushing and processing of various minerals such as iron ore, non-ferrous metal ores, and non-metallic ores due to their advantages such as large crushing ratio, low unit energy consumption, high single-machine output, and uniform product particle size. The roller surface, as the core working component of the high-pressure roller mill, is in direct contact with the material and bears enormous compressive stress and friction. Operating in a high-intensity, high-wear environment for extended periods, it is highly susceptible to wear, scratches, and spalling.

[0003] Currently, existing methods for repairing worn roller surfaces in high-pressure roller mills have many shortcomings and fail to meet the actual needs of industrial production: First, the repair process is cumbersome, often requiring the entire roller to be disassembled and transported to a specialized repair site, resulting in a long repair cycle and impacting production progress. Second, the bonding force between the repair layer and the roller substrate is weak. Existing repair methods often employ single-coat spraying or welding, leading to poor metallurgical bonding between the coating and the substrate, resulting in problems such as repair layer peeling and cracking, leading to a short service life of the repaired roller surface and a high frequency of repairs. Third, the wear resistance is insufficient. Repair materials are mostly ordinary wear-resistant alloys, which cannot withstand high-intensity wear, and the repaired roller surface is prone to wear again in a short period of time, increasing maintenance costs. Fourth, there is a lack of adaptive adjustment capability. Repair parameters use fixed values ​​and cannot be adjusted according to the degree and pattern of roller surface wear, resulting in inconsistent repair effects and poor adaptability of the repaired roller surface to crushing conditions, affecting crushing efficiency and product quality. Summary of the Invention

[0004] The purpose of this invention is to provide an adaptive repair method for roller surface wear of a high-pressure roller mill, which can achieve precise and efficient repair of roller surface wear, improve the wear resistance of the repair layer and the bonding force with the substrate, extend the service life of the roller surface, reduce repair costs and maintenance frequency, and at the same time ensure that the repaired roller surface is compatible with the crushing conditions.

[0005] This invention provides an adaptive repair method for wear on the roller surface of a high-pressure roller mill, comprising the following steps: Step S1: Wear detection. A detection component consisting of a displacement sensor, a hardness sensor, and a vision sensor is used to perform an all-round scanning detection on the roller surface of the high-pressure roller mill to obtain the coordinates of the wear area, wear depth, and wear morphology data. The detection data is transmitted to the control terminal, which generates adaptive repair parameters based on a preset threshold. The repair parameters include the pretreatment temperature, the thickness of each coating layer, and the curing process parameters. Step S2: Pretreatment. Based on the wear area determined in step S1, high-pressure airflow is first used to remove dust, debris and oil stains from the wear area of ​​the roller surface. Then, sandblasting is used to roughen the surface of the wear area of ​​the roller surface. Subsequently, the roughened wear area is preheated in sections. Step S3: Gradient repair. Using a spraying device, according to the repair parameters generated in step S1, a gradient coating is sprayed on the pretreated wear area, and the primer, intermediate coat and top coat are sprayed in sequence. Step S4: Curing and shaping, the gradient coating after spraying is cured in sections; Step S5: Adaptation and verification. Install the repaired roller surface onto the high-pressure roller mill and conduct no-load and load test runs. Monitor the roller surface operating status, coating adhesion, and crushing effect in real time through the detection component. If the detection data meets the preset working condition requirements, the repair is completed. If not, return to step S1 to readjust the repair parameters and repeat steps S1-S4 until the adaptation requirements are met.

[0006] Preferably, in step S1, the control terminal has a built-in wear level classification module, which classifies the wear level into slight wear, moderate wear and heavy wear according to the wear depth, and different repair parameters are corresponding to different wear levels.

[0007] Preferably, in step S2, the sandblasting process uses white corundum sand.

[0008] Preferably, in step S3, an inert gas is used for protection during the spraying process.

[0009] Preferably, in step S3, the chemical composition of the nickel-based alloy coating material is Cr, Mo, Ni, Si, and C, with the remainder being Fe and unavoidable impurities.

[0010] Preferably, in step S4, a stress detector is used to monitor the internal stress of the coating in real time during the curing process.

[0011] Preferably, in step S3, the inert gas is argon.

[0012] Preferably, in step S3, the primer is a nickel-based alloy coating material, the intermediate coating is a tungsten carbide-cobalt-based composite coating material, and the topcoat is an amorphous diamond-modified coating material.

[0013] Therefore, the present invention adopts the above-mentioned adaptive repair method for high pressure roller mill roller surface wear, so as to achieve precise and efficient repair of roller surface wear, improve the wear resistance of the repair layer and the bonding force of the substrate, extend the service life of the roller surface, reduce repair costs and maintenance frequency, and at the same time ensure that the repaired roller surface is compatible with the crushing conditions.

[0014] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0015] Figure 1 This is a schematic flowchart of an adaptive repair method for wear on the roller surface of a high-pressure roller mill according to the present invention; Figure 2 This is a schematic diagram of the gradient composite coating structure of an adaptive repair method for wear on the roller surface of a high-pressure roller mill according to the present invention; Figure 3 This is a schematic diagram of the wear state of the roller surface in the adaptive repair method for roller surface wear of a high-pressure roller mill according to the present invention. Detailed Implementation

[0016] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0017] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0018] The terms "first," "second," and similar words used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0019] Example 1 like Figures 1-3 As shown, the present invention discloses an adaptive repair method for high-pressure roller mill surface wear, targeting the repair of high-pressure roller mill surface with slight wear (wear depth 0.1~1mm), comprising the following steps: Step S1: Wear detection. A detection assembly consisting of a displacement sensor, a hardness sensor, and a vision sensor is used. The scanning frequency is set to 20 times / minute, and the detection accuracy is 0.01mm. The roller surface of the high-pressure roller mill is scanned from all directions to obtain the coordinates of the wear area, the wear depth (0.6mm), and the wear morphology data. The detection data is transmitted to the control terminal. The control terminal generates adaptive repair parameters based on preset thresholds. The repair parameters include a pretreatment temperature of 180℃, the thickness of each coating layer, and the curing process parameters; the primer thickness is 0.08mm, the intermediate coating thickness is 0.5mm, the topcoat thickness is 0.15mm, the spraying rate is 7mm / s, and the curing temperature is 280℃ (holding temperature for 70min) and 420℃ (holding temperature for 150min).

[0020] Step S2: Pretreatment. Based on the wear area determined in Step S1, first use a 0.7MPa high-pressure airflow to remove dust, debris, and oil from the wear area of ​​the roller surface. Then, roughen the surface by sandblasting with white corundum sand at a pressure of 0.6MPa, a blasting angle of 50°, and a blasting time of 8 min / m. 2 The surface roughness of the wear area of ​​the roller is Ra4.5μm. Then, the roughened wear area is preheated in sections at a rate of 12℃ / min. The preheating temperature is controlled at 180℃ and the preheating rate is 12℃ / min. After preheating, the temperature is held for 45min.

[0021] Step S3, Gradient Repair: Using a spraying device, according to the repair parameters generated in step S1, a gradient coating is sprayed onto the pre-treated wear area. The spraying pressure is 0.4 MPa, the spraying distance is 180 mm, and the spraying angle is 90°. A primer, intermediate coat, and top coat are sprayed sequentially. The primer uses a nickel-based alloy coating material, the intermediate coat uses a tungsten carbide-cobalt-based composite coating material, and the top coat uses an amorphous diamond-modified coating material. The chemical composition of the nickel-based alloy coating material is 20% Cr, 10% Mo, 63% Ni, 1.5% Si, and 0.2% C, with the remainder being Fe and unavoidable impurities.

[0022] Step S4: Curing and shaping. The gradient coating after spraying is cured in stages. First, it is kept at 280℃ for 70 minutes, and then the temperature is increased to 420℃ at a rate of 10℃ / min and kept at 420℃ for 150 minutes. After curing, it is cooled to room temperature by natural cooling. During the cooling process, the coating stress is monitored in real time. The stress value does not exceed 350MPa to avoid cracking.

[0023] Step S5: Adaptation and Verification. Install the repaired roller surface onto the high-pressure roller mill and conduct no-load and load tests. The no-load test run is 1.5 hours (70 r / min), and the load test run is 4 hours (100 r / min, 70% of rated load). Monitor the roller surface operating status, coating adhesion, and crushing effect in real time using the detection component. If the detection data meets the preset working condition requirements, the repair is complete; if not, return to step S1 to readjust the repair parameters, and repeat steps S1-S4 until the adaptation requirements are met.

[0024] Example 2 like Figures 1-3 As shown, this invention provides an adaptive repair method for high-pressure roller mill surface wear, targeting the repair of high-pressure roller mill surfaces with moderate wear (wear depth 1~3mm), comprising the following steps: Step S1: Wear detection. A detection assembly consisting of a displacement sensor, a hardness sensor, and a vision sensor is used. The scanning frequency is set to 15 times / minute, and the detection accuracy is 0.01mm. A full-range scan of the high-pressure roller mill surface is performed to obtain the coordinates of the wear area, the wear depth (2.2mm), and the wear morphology data. The detection data is transmitted to the control terminal. The control terminal generates adaptive repair parameters based on preset thresholds. The repair parameters include a pretreatment temperature of 200℃, the thickness of each coating layer, and curing process parameters; primer thickness 0.1mm, intermediate coat thickness 1.2mm, topcoat thickness 0.2mm, spraying rate 6mm / s, and curing temperatures of 300℃ (80min) and 400℃ (160min).

[0025] Step S2: Pretreatment. Based on the wear area determined in step S1, first use a 0.8MPa high-pressure airflow to remove dust, debris, and oil from the wear area of ​​the roller surface. Then, roughen the surface by sandblasting with white corundum sand at a pressure of 0.7MPa, a blasting angle of 55°, and a blasting time of 9 min / m. 2 The surface roughness of the wear area of ​​the roller surface was reduced to Ra5.2μm. Subsequently, the roughened wear area was preheated in sections at a rate of 14℃ / min, with the preheating temperature controlled at 200℃ and the preheating rate at 14℃ / min. After preheating, the temperature was maintained for 50min.

[0026] Step S3, Gradient Repair: Using a spraying device, according to the repair parameters generated in step S1, a gradient coating is sprayed onto the pre-treated wear area. The spraying pressure is 0.5 MPa, the spraying distance is 190 mm, and the spraying angle is 90°. A primer, intermediate coat, and top coat are sprayed sequentially. The primer uses a nickel-based alloy coating material, the intermediate coat uses a tungsten carbide-cobalt-based composite coating material, and the top coat uses an amorphous diamond-modified coating material. The chemical composition of the nickel-based alloy coating material is 20% Cr, 10% Mo, 63% Ni, 1.5% Si, and 0.2% C, with the remainder being Fe and unavoidable impurities.

[0027] Step S4: Curing and shaping. The sprayed gradient coating is cured in stages. First, it is kept at 300℃ for 80 minutes, and then the temperature is increased to 440℃ at a rate of 11℃ / min and kept at that temperature for 160 minutes. After curing, it is cooled to room temperature naturally. During the cooling process, the coating stress is monitored in real time. The stress value does not exceed 340MPa to avoid cracking.

[0028] Step S5: Adaptation and Verification. Install the repaired roller surface onto the high-pressure roller mill and conduct no-load and load test runs. The no-load test run is 2 hours (80 r / min), and the load test run is 5 hours (110 r / min, 75% of rated load). The roller surface operating status, coating adhesion, and crushing effect are monitored in real time using the detection component. If the detection data meets the preset working condition requirements, the repair is complete; if not, return to step S1 to readjust the repair parameters, and repeat steps S1-S4 until the adaptation requirements are met.

[0029] like Figures 1-3 As shown, this invention discloses an adaptive repair method for high-pressure roller mill surface wear, specifically for repairing severely worn (wear depth 3-5 mm) high-pressure roller mill surfaces, comprising the following steps: Step S1: Wear detection. A detection assembly consisting of a displacement sensor, a hardness sensor, and a vision sensor is used. The scanning frequency is set to 10 times / minute, and the detection accuracy is 0.01mm. A full-range scan of the high-pressure roller mill surface is performed to obtain the coordinates of the wear area, the wear depth (4.1mm), and the wear morphology data. The detection data is transmitted to the control terminal. The control terminal generates adaptive repair parameters based on preset thresholds. The repair parameters include a pretreatment temperature of 220℃, the thickness of each coating layer, and curing process parameters; primer thickness 0.1mm, intermediate coat thickness 1.8mm, topcoat thickness 0.3mm, spraying rate 5mm / s, and curing temperatures of 300℃ (90min) and 450℃ (180min).

[0030] Step S2: Pretreatment. Based on the wear area determined in Step S1, first use a 0.9MPa high-pressure airflow to remove dust, debris, and oil from the wear area of ​​the roller surface. Then, roughen the surface by sandblasting with white corundum sand at a pressure of 0.8MPa, a blasting angle of 60°, and a blasting time of 10 min / m. 2 The surface roughness of the wear area of ​​the roller surface was reduced to Ra6.0μm. Subsequently, the roughened wear area was preheated in sections at a rate of 15℃ / min, with the preheating temperature controlled at 220℃ and the preheating rate at 15℃ / min. After preheating, the temperature was maintained for 60min.

[0031] Step S3, Gradient Repair: Using a spraying device, according to the repair parameters generated in step S1, a gradient coating is sprayed onto the pretreated wear area. The spraying pressure is 0.6 MPa, the spraying distance is 200 mm, and the spraying angle is 90°. A primer, intermediate coat, and top coat are sprayed sequentially. The primer uses a nickel-based alloy coating material, the intermediate coat uses a tungsten carbide-cobalt-based composite coating material, and the top coat uses an amorphous diamond-modified coating material. The chemical composition of the nickel-based alloy coating material is 20% Cr, 10% Mo, 63% Ni, 1.5% Si, and 0.2% C, with the remainder being Fe and unavoidable impurities.

[0032] Step S4: Curing and shaping. The gradient coating after spraying is cured in stages. First, it is kept at 300℃ for 90 minutes, and then the temperature is increased to 450℃ at a rate of 12℃ / min and kept at 450℃ for 180 minutes. After curing, it is cooled to room temperature by natural cooling. During the cooling process, the coating stress is monitored in real time. If the stress value does not exceed 360MPa, the heating rate is adjusted to 7℃ / min and the holding time is extended by 25 minutes. The stress is reduced to 330MPa to avoid cracking.

[0033] Step S5: Adaptation and Verification. Install the repaired roller surface onto the high-pressure roller mill and conduct no-load and load test runs. The no-load test run is 2 hours (80 r / min), and the load test run is 5 hours (120 r / min, 80% of rated load). The roller surface operating status, coating adhesion, and crushing effect are monitored in real time using the detection component. If the detection data meets the preset working condition requirements, the repair is complete; if not, return to step S1 to readjust the repair parameters, and repeat steps S1-S4 until the adaptation requirements are met.

[0034] Therefore, the present invention adopts the above-mentioned adaptive repair method for high pressure roller mill roller surface wear, so as to achieve precise and efficient repair of roller surface wear, improve the wear resistance of the repair layer and the bonding force of the substrate, extend the service life of the roller surface, reduce repair costs and maintenance frequency, and at the same time ensure that the repaired roller surface is compatible with the crushing conditions.

[0035] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for adaptive repair of roller surface wear in a high-pressure roller mill, characterized in that, Includes the following steps: Step S1: Wear detection. A detection component consisting of a displacement sensor, a hardness sensor, and a vision sensor is used to perform an all-round scanning detection on the roller surface of the high-pressure roller mill to obtain the coordinates of the wear area, wear depth, and wear morphology data. The detection data is transmitted to the control terminal, which generates adaptive repair parameters based on a preset threshold. The repair parameters include the pretreatment temperature, the thickness of each coating layer, and the curing process parameters. Step S2: Pretreatment. Based on the wear area determined in step S1, high-pressure airflow is first used to remove dust, debris and oil stains from the wear area of ​​the roller surface. Then, sandblasting is used to roughen the surface of the wear area of ​​the roller surface. Subsequently, the roughened wear area is preheated in sections. Step S3: Gradient repair. Using a spraying device, according to the repair parameters generated in step S1, a gradient coating is sprayed on the pretreated wear area, and the primer, intermediate coat and top coat are sprayed in sequence. Step S4: Curing and shaping, the gradient coating after spraying is cured in sections; Step S5: Adaptation and verification. Install the repaired roller surface onto the high-pressure roller mill and conduct no-load and load test runs. Monitor the roller surface operating status, coating adhesion, and crushing effect in real time through the detection component. If the detection data meets the preset working condition requirements, the repair is completed. If not, return to step S1 to readjust the repair parameters and repeat steps S1-S4 until the adaptation requirements are met.

2. A method for adaptive repair of wear on the roller surface of a high-pressure roller mill according to claim 1, characterized in that, In step S1, the control terminal has a built-in wear level classification module, which classifies the wear level into slight wear, moderate wear and heavy wear according to the wear depth. Different wear levels correspond to different repair parameters.

3. A method for adaptive repair of wear on the roller surface of a high-pressure roller mill according to claim 1, characterized in that, In step S2, white corundum sand is used for sandblasting.

4. A method for adaptive repair of wear on the roller surface of a high-pressure roller mill according to claim 1, characterized in that, In step S3, an inert gas is used for protection during the spraying process.

5. A method for adaptive repair of wear on the roller surface of a high-pressure roller mill according to claim 1, characterized in that, In step S3, the chemical composition of the nickel-based alloy coating material is Cr, Mo, Ni, Si, and C, with the remainder being Fe and unavoidable impurities.

6. A method for adaptive repair of wear on the roller surface of a high-pressure roller mill according to claim 1, characterized in that, In step S4, a stress detector is used to monitor the internal stress of the coating in real time during the curing process.

7. A method for adaptive repair of roller surface wear in a high-pressure roller mill according to claim 4, characterized in that, In step S3, the inert gas is argon.

8. A method for adaptive repair of wear on the roller surface of a high-pressure roller mill according to claim 1, characterized in that, In step S3, the primer is a nickel-based alloy coating material, the intermediate coating is a tungsten carbide-cobalt-based composite coating material, and the topcoat is an amorphous diamond modified coating material.

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