Automatic gap adjusting mechanism for die roller
The automatic gap adjustment mechanism of the mold roll is achieved to accurately online adjustment of the gap between the ring mold granulator press roller and the ring mold, solving the low production efficiency and machine plugging problems caused by manual adjustment, and improving equipment performance and production stability.
Patent Information
- Application Number
- CN202422555416.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-22
- Publication Date
- 2025-09-02
- Estimated Expiration
- 2034-10-22
AI Technical Summary
The gap adjustment between the press roller and ring mold of the existing ring mold granulator relies on manual manual operation, and fully automatic adjustment cannot be achieved, resulting in inconsistent gaps, affecting production efficiency and equipment performance, and cannot be adjusted in real time during the production process, which is prone to problems such as blocking and uneven feeding.
The automatic mold roller gap adjustment mechanism is adopted, including a driving mechanism, a transmission mechanism, an actuator and a gap adjustment wheel. The eccentric pressure roller shaft and spline shaft are used to achieve accurate online adjustment of the gap between the press roller and the ring mold. Combined with motor monitoring and control and press roller speed monitoring, the wear amount is compensated in real time and prevented from being blocked.
Accurate online adjustment of the gap between the press roller and the ring mold is achieved, reducing the frequency of the blockage, improving production efficiency and equipment performance, supporting wear compensation and real-time monitoring, and reducing manual intervention and downtime.
Smart Images
Figure CN223288015U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of ring die granulation and forming, in particular to an automatic gap adjustment mechanism for a die roller. Background Art
[0002] The ring die pelletizer utilizes the interaction between the ring die and rollers to compress powdered materials into desired pellets. It offers advantages such as a continuous and stable production process, high production efficiency, strong adaptability to raw materials, low energy consumption, excellent pelletizing results, and a high pelletizing rate. As one of the four main components of feed processing equipment, it directly produces finished feed pellets, largely determining feed quality and yield. It is one of the most important feed processing equipment and plays a vital role in feed production.
[0003] The gap between the rollers and the die in a ring die pellet mill significantly impacts its performance, including its lifespan and pellet quality. If the gap is too small, the extrusion pressure between the rollers and the die increases, leading to increased resistance, component wear, and increased noise. If the gap is too large, discharging becomes difficult, pellet density is too low, and pellets become loose. Adjusting the gap between the rollers and the die is often complex. Currently, gap adjustment in ring die pellet mills is performed manually, without a fully automatic adjustment device or control method. Relying on worker experience to determine the timing and degree of gap adjustment can result in suboptimal adjustment intensity. Inconsistent adjustment intensity can still cause blockages or uneven feeding, and can even cause structural deformation, impacting proper operation and significantly negatively impacting overall performance. Furthermore, manual adjustment means the gap between the rollers and the die cannot be changed during production. If the gap is found to be inappropriate after startup, the machine must be shut down and cooled before readjustment can be performed, resulting in reduced production efficiency. In addition, the pellet mill often slips and blocks during operation, and the machine needs to be shut down for cleaning after blocking, which affects production efficiency and wastes manpower. Utility Model Content
[0004] In order to solve the above technical problems, the utility model provides a die roller automatic gap adjustment mechanism.
[0005] The technical solutions provided by this utility model are as follows:
[0006] A die roller automatic gap adjustment mechanism includes a driving mechanism, a transmission mechanism, an actuator, and a gap adjustment wheel connected to the pressure roller; the pressure roller is arranged in a ring die, and the pressure roller shaft of the pressure roller adopts an eccentric design; the actuator includes a telescopic structure, the end of the telescopic structure is connected to one end of the gap adjustment wheel, and the other end of the gap adjustment wheel is provided with an axial hole for transmission connection to the pressure roller shaft; the transmission mechanism includes a rotating shaft transmission-connected to the telescopic structure, the rotating shaft is used to drive the end of the telescopic structure to perform telescopic movement; the driving mechanism is used to drive the rotating shaft of the transmission mechanism to rotate.
[0007] Furthermore, the telescopic structure adopts a spline shaft, the outer surface of the spline shaft is provided with a longitudinal keyway, and the rotating member sleeved on the spline shaft is provided with a corresponding keyway, and the rotating member is used to rotate the spline shaft and make the spline shaft slide longitudinally in the rotating member; the rotating member is fixedly set on the actuator, and the outer surface of the rotating member is provided with mating teeth that are transmission-connected to the rotating shaft.
[0008] Furthermore, a plurality of transmission teeth are provided on the end of the pressure roller shaft along the circumferential direction, and an inner surface of the shaft hole is provided on the circumferential direction with meshing teeth that match the transmission teeth on the pressure roller shaft.
[0009] Preferably, a through hole is provided at the end of the telescopic structure, and a fixing pin passes through the through hole to fix the end of the telescopic structure in a connecting groove provided at one end of the gap adjustment wheel, and both ends of the fixing pin are fixed to both sides of the connecting groove by fasteners.
[0010] Furthermore, the driving mechanism includes a motor and a monitoring and control module thereof, wherein the monitoring and control module is used to control the start and stop of the motor and detect the number of rotations of the motor in real time.
[0011] Furthermore, it also includes a pressure roller speed monitoring module for obtaining the speed of the pressure roller in real time.
[0012] Preferably, the pressure roller speed monitoring module adopts a proximity switch.
[0013] Compared with the prior art, the present invention has at least the following beneficial effects:
[0014] The utility model can accurately adjust the gap between the ring die and the pressure roller of the pelletizer online; when using only one sensor, the utility model can accurately calculate the real-time gap and wear between the ring die and the pressure roller; the utility model supports zero calibration during production on the client side, and effectively compensates for the wear during adjustment; the utility model supports the gear changing operation of the pressure roller shaft and the gap adjustment wheel, which can compensate for more wear and provide software prompts based on the wear; the utility model monitors the working condition of the pressure roller in real time, and can make timely responses when signs of machine blockage appear, thereby greatly reducing the frequency of machine blockage. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation to the present invention.
[0016] Figure 1 This is a schematic diagram of the overall structure of the die roller automatic gap adjustment mechanism provided by one embodiment of the utility model;
[0017] Figure 2 This is a schematic diagram of the gap adjustment principle provided by an embodiment of the present utility model;
[0018] Figure 3 Schematic diagram A of a partial structure of an automatic gap adjustment mechanism for a die roller provided in one embodiment of the present utility model;
[0019] Figure 4 FIG. 1 is a partial structural diagram B of an automatic gap adjustment mechanism for a die roller provided in one embodiment of the present utility model;
[0020] Figure 5 Schematic diagram C of the partial structure of the automatic gap adjustment mechanism of the die roller provided in one embodiment of the present utility model;
[0021] Figure 6 FIG. 2 is a partial structural diagram D of an automatic gap adjustment mechanism for a die roller provided in one embodiment of the present utility model;
[0022] Figure 7 Schematic diagram E of the partial structure of the automatic gap adjustment mechanism of the die roller provided in one embodiment of the present utility model;
[0023] Figure 8 This is a flow chart of an adjustment method for an automatic gap adjustment mechanism provided by an embodiment of the present utility model;
[0024] Figure 9 It is a flowchart of zero calibration compensation provided by an embodiment of the present utility model.
[0025] The reference numerals are as follows: 1-actuator, 101-telescopic structure, 2-gap adjustment wheel, 201-axis hole, 3-pressing roller, 301-pressing roller shaft, 4-transmission mechanism, 401-rotating shaft, 5-ring die. DETAILED DESCRIPTION
[0026] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the embodiments described are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, other embodiments obtained by ordinary technicians in this field without making creative efforts are all within the scope of protection of the present invention.
[0027] This embodiment provides a die roller automatic gap adjustment mechanism, such as Figure 1 and Figure 2 As shown, the automatic die roller gap adjustment mechanism primarily comprises an actuator 1, a gap adjustment wheel 2, a transmission mechanism 4, and a drive mechanism (not shown). The pressure roller 3 is positioned within the ring die 5, and its roller shaft 301 is eccentric (i.e., not centered). Therefore, the gap between the pressure roller 3 and the ring die 5 can be adjusted by rotating the roller shaft 301. In this embodiment, the transmission mechanism 4 transmits the rotation of the drive mechanism to the actuator 1, which in turn drives the gap adjustment wheel 2 to rotate the roller shaft 301, thereby adjusting the gap between the pressure roller 3 and the ring die 5.
[0028] like Figures 3 to 6 As shown, the actuator 1 includes a telescopic structure 101. The distal end of the telescopic structure 101 is connected to one end of the gap adjustment wheel 2. The other end of the gap adjustment wheel 2 is provided with an axial hole 201 for connecting to a pressure roller shaft 301. The distal end of the pressure roller shaft 301 is provided with a plurality of transmission teeth along its circumference. The inner surface of the axial hole 201 is provided with mating teeth along its circumference that mesh with the transmission teeth on the pressure roller shaft 301. The extension and retraction of the telescopic structure 101 causes the gap adjustment wheel 2 to rotate about the pressure roller shaft 301. The meshing action of the mating teeth and the transmission teeth causes the pressure roller shaft 301 to rotate.
[0029] Combine Figure 5 and Figure 7 In this embodiment, the connection relationship between the telescopic structure 101 and the gap adjustment wheel 2 is specifically as follows: a through hole is opened at the end of the telescopic structure 101, and a fixing pin passes through the through hole to fix the end of the telescopic structure 101 in the connecting groove opened at one end of the gap adjustment wheel 2, and the two ends of the fixing pin are respectively fixed to both sides of the connecting groove by fasteners.
[0030] The transmission mechanism 4 includes a rotating shaft 401 connected to the telescopic structure 101, and the rotating shaft 401 rotates under the action of a driving mechanism (such as a pneumatic motor). One end of the rotating shaft 401 connected to the telescopic structure 101 is provided with an external thread or transmission teeth, which is used to drive the end of the telescopic structure 101 to extend and retract. In this embodiment, the telescopic structure 101 adopts a long spline shaft. The spline shaft is an existing mechanical transmission mechanism, and a longitudinal keyway is provided on the outer surface of the shaft. The rotating part sleeved on the shaft also has a corresponding keyway, which can keep rotating synchronously with the shaft, and while rotating, some can also slide longitudinally on the shaft. In this embodiment, the rotating part of the spline shaft is fixed to the actuator 1, and the outer surface of the rotating part is provided with matching teeth that match the external thread or transmission teeth at one end of the rotating shaft 401, such as Figure 6 As shown, when the rotating shaft 401 rotates, the rotating member also rotates accordingly. However, since the rotating member is fixed, the shaft of the spline shaft performs telescopic motion relative to the rotating member under the action of the keyway.
[0031] The driving step length (number of revolutions) of the driving mechanism (such as an air motor) and the distance the telescopic structure extends or shortens are in a fixed linear relationship. Assuming that when the air motor rotates one circle, the corresponding distance the telescopic structure extends or shortens is a, and the center distance of the gap adjustment wheel is b, then when the air motor rotates one circle, the corresponding rotation angle of the pressure roller shaft is The relationship between the roller shaft rotation angle and the die roller gap is as follows: Figure 2 As shown in the figure, x is the gap between the die rollers, α is the target angle, h is the distance between the center of the roller shaft and the center of the ring die, m is the inner diameter of the ring die, the eccentricity of the roller shaft (the distance between the center of the roller shaft and the center of the roller) is p, and the outer diameter of the roller is n. According to the cosine theorem, the following relationship can be obtained:
[0032]
[0033] In the above formula, the die-roll gap x is the set value, the target angle α is the value to be determined, and the remaining values are equipment parameters and are known quantities. Substituting x = 0 into the above formula, we can calculate α, which is the eccentric angle of the die roll corresponding to the zero position in the unworn state.
[0034] When the equipment leaves the factory, the gap between the ring die and the roller is manually adjusted to zero. At this time, the software is factory-calibrated to zero, and the current state is determined as the reference point for subsequent adjustments. 当前 Adjust to x 目标 , just enter x on the software screen 目标 Then the background calculation will convert x 当前 with x 目标 Substituting into the above formula, we can calculate α 当前 With α 目标 , and then calculate Δα=α 目标 -α 当前 , and then calculate the number of revolutions of the air motor required for adjustment: Use a proximity switch to monitor the speed of the pneumatic motor. When the speed reaches the target value, the solenoid valve is disconnected to end the movement, and the adjustment can be achieved. The corresponding flow chart is as follows: Figure 8 shown.
[0035] At the same time, in addition to directly inputting the target gap for adjustment, the user can also long press the increase gap or decrease gap button to achieve continuous adjustment. During adjustment, the software background will calculate the Δα value based on the pneumatic motor speed c. Then calculate α 调节后 =Δα+α 当前 , change α 调节后 Substituting into the above formula, we can get x 调节后 By using this method, it is possible to output and display the adjusted die roller gap value in real time while achieving continuous adjustment.
[0036] After the ring die pellet mill has been working for a period of time, the roller and the ring die will wear out, and some parameters will change. When the equipment is worn out, the user can adjust the ring die and the roller to a state without gaps through continuous adjustment. After adjustment, click on the client zero calibration on the software, and the software will calculate the wear amount at this time and compensate for the wear amount in subsequent calculations to ensure the accuracy of adjustment. The specific process of zero calibration compensation is as follows: Figure 9 shown.
[0037] After the program is factory-calibrated, it will start recording the number of revolutions of the pneumatic motor. One clockwise revolution is recorded as +1, one counterclockwise revolution is recorded as -1, and the sum of the two is counted as k. After the user clicks on the factory zero calibration, the software will calculate the corresponding roller eccentricity angle at this time. Substituting α0′ into formula (1), we can calculate an x value, which is defined as x′0. x′0 is a negative number, and its absolute value is the total wear of the roller and the ring die at this time. When adjusting it later, the calculation formula is changed from formula (1) to:
[0038]
[0039] Where m′=m+2x′0|, and the rest of the adjustment logic is the same as when there is no wear. The wear value will be displayed on the screen, and the user can decide whether to replace the relevant accessories based on the wear condition.
[0040] The actuator stroke in the automatic gap adjustment mechanism provided in this embodiment is limited, so the adjustable gap range is also limited. When the wear is large, it may be impossible to adjust to zero gap. In this case, a tooth replacement method is required. When the adjustment amount is insufficient, the user can replace the matching teeth of the gap adjustment wheel and the pressure roller shaft, such as Figure 7 As shown, when leaving the factory, the mark on the pressure roller shaft is aligned with the gap adjustment wheel No. 1. If the adjustment amount is insufficient during use, it can be replaced with No. 2 for alignment.
[0041] After the replacement, you only need to enter the current tooth number in the software. After the tooth is replaced, it is usually necessary to perform a production zero calibration. Due to the introduction of the tooth number, the calculation formula for the production zero calibration will change.
[0042]
[0043] Where s is the tooth number at this time, z is the number of teeth on the pressure roller shaft and the gap adjustment wheel. Substituting α0″ into formula (1), the same as above can be obtained to obtain x′0′. When making adjustments thereafter, the calculation formula is changed from formula (2) to
[0044]
[0045] Where m″=m+2x′0′|.
[0046] During equipment operation, uneven moisture content or the presence of impurities in the material can cause the rollers and the ring die to slip, leading to machine blockage. Before a machine blockage occurs, the rollers will slip and stall. After the stall, a large amount of material to be extruded accumulates between the ring die and the rollers, causing the machine blockage. If the gap between the die rollers can be reduced during the initial slippage stage, there is a chance to prevent the machine blockage. In this embodiment, a speed measuring block is installed on the end face of the roller, and a proximity switch is used to calculate the number of pulses per unit time and convert it into roller speed. This allows real-time speed monitoring of the roller to determine whether a stall or slippage has occurred. In the event of a stall or slippage, the gap between the die rollers is automatically adjusted.
[0047] The theoretical speed of the pressure roller is g (rpm), and the number of speed measuring blocks is q. The theoretical number of pulses per 100ms is gq / 600. The software calculates the actual average number of pulses in the previous 500ms every 100ms and compares it with the theoretical number of pulses. If it is lower than 85% of the theoretical value, it is judged to be slipping. At this time, the gap is automatically reduced by 0.2mm. After the reduction is completed, it is judged for 1s. If 8 of the 10 average pulses within 1s are higher than 85% of the theoretical value, it is considered to have recovered to normal. After stabilizing for 2s, the gap is restored to the value before adjustment; if it is judged for 1s after the first adjustment and still does not meet 85% of the theoretical value, it is reduced by 0.2mm again. After the reduction, it is judged again for 1s. If 8 of the 10 average pulses within 1s meet the conditions, it is considered to have recovered. After 2s, the gap value before the two adjustments is restored.
[0048] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Under the idea of the present invention, the technical features in the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations in different aspects of the present invention as described above. For the sake of simplicity, they are not provided in detail. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in this field should understand that they can still modify the technical solutions recorded in the above embodiments, or make equivalent replacements for some of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of this application.
Claims
1. A die roller automatic gap adjustment mechanism, characterized in that: It includes a driving mechanism, a transmission mechanism, an actuator, and a gap adjustment wheel connected to the pressure roller; the pressure roller is arranged in the ring die, and the pressure roller shaft of the pressure roller adopts an eccentric design; the actuator includes a telescopic structure, the end of the telescopic structure is connected to one end of the gap adjustment wheel, and the other end of the gap adjustment wheel is provided with an axial hole for transmission connection to the pressure roller shaft; the transmission mechanism includes a rotating shaft transmission-connected to the telescopic structure, the rotating shaft is used to drive the end of the telescopic structure to perform telescopic movement; the driving mechanism is used to drive the rotating shaft of the transmission mechanism to rotate.
2. The automatic gap adjustment mechanism for the die roller according to claim 1, characterized in that: The telescopic structure adopts a spline shaft, the outer surface of the spline shaft is provided with a longitudinal keyway, and the rotating member sleeved on the spline shaft is provided with a corresponding keyway. The rotating member is used to rotate the spline shaft and make the spline shaft slide longitudinally inside the rotating member; the rotating member is fixedly set on the actuator, and the outer surface of the rotating member is provided with matching teeth that are transmission-connected to the rotating shaft.
3. The automatic gap adjustment mechanism for the die roller according to claim 1, characterized in that: The end of the pressure roller shaft is provided with a plurality of transmission teeth along the circumference, and the inner surface of the shaft hole is provided with matching teeth matching the transmission teeth on the pressure roller shaft along the circumference, and the matching tooth sequence of the matching teeth and the transmission teeth supports adjustment.
4. The automatic gap adjustment mechanism for the die roller according to claim 1, characterized in that: A through hole is provided at the end of the telescopic structure, and a fixing pin passes through the through hole to fix the end of the telescopic structure in a connecting groove opened at one end of the gap adjustment wheel. Both ends of the fixing pin are fixed to both sides of the connecting groove by fasteners.
5. The automatic gap adjustment mechanism for the die roller according to claim 1, characterized in that: The driving mechanism includes a motor and a monitoring and control module thereof, wherein the monitoring and control module is used to control the start and stop of the motor and detect the number of rotations of the motor in real time.
6. The automatic gap adjustment mechanism for the die roller according to claim 1, characterized in that: It also includes a pressure roller speed monitoring module for obtaining the speed of the pressure roller in real time.
7. The automatic gap adjustment mechanism for the die roller according to claim 6, characterized in that: The pressure roller speed monitoring module adopts a proximity switch.