Rotary material reduction tool

Abstract

To provide material reduction machines such as grinders, shredders, and chippers.SOLUTION: A rotary material reduction tool includes a drum, a collar, and a hammer. The drum has an outer surface extending about a rotational axis of the drum. The drum has a first opening defined in the outer surface of the drum. The collar is received in the first opening. A first portion of the collar extends into the drum and a flange of the collar extends beyond the first opening along the outer surface of the drum. The hammer extends through the collar into the drum. The hammer has an exposed portion. The flange of the collar and the outer surface of the drum are welded together.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to co-pending U.S. Provisional Patent Application No. 63 / 512,197, filed July 6, 2023, the entire contents of which are incorporated herein by reference.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates to material reduction machines such as grinders, shredders, and chippers. [Background technology]

[0003] Material reduction machines are used to reduce the size and volume of materials, such as waste materials. Exemplary waste materials include waste wood (e.g., trees, brush, stumps, pallets, railroad ties, etc.), peat, paper, wet organic materials, industrial waste, refuse, construction waste, etc. A typical material reduction machine, such as a grinder, chipper, or shredder, includes a rotor having a number of reduction devices (e.g., teeth, cutters, blades, abrasive tips, chisels, etc.) attached thereto. The reduction devices are typically mounted around the circumference of the rotor and are carried by the rotor around the axis of rotation of the rotor as the rotor is rotated. During reduction operations, the rotor is rotated and the waste material is fed adjacent to the rotor, whereby contact between the reduction devices and the waste material provides a reduction or comminuted grinding action on the waste material.

[0004] Grinders and chippers are typically configured to reduce material by direct impingement of a reduction device against the material. In contrast, shredders are generally configured to operate in cooperation with a reduction device and a comb structure that intermeshes with the reduction device as the rotor rotates. In a typical shredder operation, material fed to the shredder is forced by the reduction device through the comb structure as the rotor rotates, thereby providing a shredding action. It will be appreciated that during reduction operations, the rotors of grinders and chippers typically operate at a higher rotational speed than the rotors of shredders.

[0005] The reduction rotor of a material reduction machine is subjected to extreme loads. Although the loading action varies at different speeds, the reduction rotor must be robustly designed to withstand the loads. Furthermore, the reduction rotor and its attached components, such as hammers and cutters, can experience high wear rates, especially when the waste material is abrasive. For these reasons, the attached components are typically replaceable. Summary of the Invention [Means for solving the problem]

[0006] In one independent aspect, a method of assembling a rotary material reduction tool includes providing a drum having an outer surface extending about an axis of rotation of the drum. A collar is assembled into the outer surface of the drum from outside the drum and into a first opening until a portion of the collar extends into the drum and a flange of the collar extends along the outer surface of the drum beyond the first opening. The flange of the collar and the outer surface of the drum are welded together. A hammer is inserted through the collar, thus leaving a portion exposed. The hammer is secured to the collar.

[0007] In another independent aspect, a rotary material reduction tool includes a drum, a collar, and a hammer. The drum has an outer surface extending about an axis of rotation of the drum. The drum has a first opening defined in the outer surface of the drum. The collar is received within the first opening. A first portion of the collar extends into the drum and a flange of the collar extends along the outer surface of the drum beyond the first opening. The hammer extends through the collar into the drum. The hammer has an exposed portion. The flange of the collar and the outer surface of the drum are welded together. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a rear perspective view of a material reduction machine according to one embodiment of the present disclosure. [Diagram 2]2 is another rear perspective view of the material reduction machine of FIG. 1. [Diagram 3] FIG. 2 is a top view of the material volume reduction machine of FIG. 1. [Figure 4] FIG. 1 is a front perspective view of a volume reduced rotor system according to one embodiment of the present disclosure. [Diagram 5] FIG. 5 is a rear perspective view of the volume reduction rotor system of FIG. [Figure 6] FIG. 5 is a top view of the volume reduction rotor system of FIG. [Figure 7] FIG. 5 is a front perspective view of the volume reduction rotor system of FIG. 4 with the end caps removed. [Figure 8] FIG. 8 is an end view of the volume reduction rotor system of FIG. [Figure 9] FIG. 5 is a perspective view of a drum of the volume reduction rotor system of FIG. [Figure 10] FIG. 5 is a perspective view of a backing plate of the volume reduction rotor system of FIG. 4. [Figure 11] FIG. 11 is a top view of the backing plate of FIG. 10. [Figure 12] FIG. 5 is a perspective view of a collar of the volume reduction rotor system of FIG. [Figure 13] FIG. 13 is a top view of the collar of FIG. 12. [Figure 14] FIG. 13 is a side view of the collar of FIG. 12. [Figure 15] FIG. 13 is a bottom perspective view of the collar of FIG. 12. [Figure 16] FIG. 13 is a side view of the collar of FIG. 12 having an extension. [Figure 17] FIG. 17 is an end view of the collar of FIG. 16. [Figure 18] FIG. 17 is a bottom perspective view of the collar of FIG. 16. [Figure 19] 19 is a cross-sectional view of the collar taken along line 19-19 of FIG. 17. [Figure 20] FIG. 5 is a perspective view of a rotor weldment of the reduced volume rotor system of FIG. [Figure 21] FIG. 21 is an end view of the rotor weldment of FIG. [Figure 22] FIG. 8 is a detailed view of the volume reduction rotor system of FIG. [Diagram 23] FIG. 23 is an exploded end view of the volume reduction rotor system of FIG. [Figure 24] FIG. 24 is a detailed view of a portion of the exploded end view of FIG. 23. [Diagram 25] FIG. 8 is an exploded perspective view of the volume reduction rotor system of FIG. [Figure 26] FIG. 26 is a cross-sectional view of the volume reduction rotor system taken along line 26-26 of FIG. 6. [Figure 27] FIG. 27 is a detailed view of a portion of the cross section of FIG. 26. [Figure 28] FIG. 27 is a detailed view of a portion of the cross section of FIG. 26 according to another embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Before describing any embodiment, example, aspect or feature in detail, it is to be understood that these embodiments, examples, aspects, and features are not limited in their application to the details of construction and the arrangements of components set forth in the following description or illustrated in the following figures. Other embodiments, examples, aspects, and features are possible and can be practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0010] 1-3 show a material volume reduction machine 20, which is one example of a type of material volume reduction machine that may incorporate a volume reduction rotor according to the principles of the present disclosure. The rotary material volume reduction machine 20 is shown as a shredder, but it will be understood that aspects of the present disclosure are also applicable to other types of material volume reduction machines, such as grinders and chippers. In one optional example, the rotary material volume reduction machine 20 can be a relatively slow shredder (described in detail below) in which the rotor is operated at a speed of 40 revolutions per minute or less during shredding operations. It will be understood that the slower the operating rotor speed, the less important it is to maintain rotor balance, thus allowing for more flexibility in selecting various volume reduction rotor components and configurations. In another optional example, the rotary material volume reduction machine 20 can be a relatively high speed grinder or chipper in which the rotor is operated at a speed of more than 40 revolutions per minute during shredding operations.

[0011] The rotary material reduction machine 20 includes a main framework that defines a reduction box 22 within which a reduction rotor 24 is disposed. The reduction rotor 24 is mounted for rotation within the reduction box 22 about a central axis 26. The reduction rotor 24 may be rotatably mounted to the reduction box 22 via bearings. A plurality of reduction devices 28 are mounted on the exterior of the reduction rotor 24. When the reduction rotor 24 is rotated about the central axis 26, the reduction devices 28 are carried by the reduction rotor 24 along a circular reduction path that surrounds the central axis 26. The rotary material reduction machine 20 includes a hopper 30 above the reduction rotor 24 to allow material to be reduced to be fed into the reduction box 22. The hopper 30 optionally includes a screen (not shown) mounted below the volume reduction rotor 24 to control the size of the reduced product output from the volume reduction box 22. The rotary material volume reduction machine 20 may further include a chopping comb 32 mounted within the volume reduction box 22. The chopping comb 32 includes a plurality of comb teeth, and the chopping comb 32 is positioned relative to the volume reduction rotor 24 such that the volume reduction devices 28 of the volume reduction rotor 24 intermesh with the comb teeth of the chopping comb 32 when the volume reduction rotor 24 is rotated about the central axis 26. In other words, when the volume reduction rotor 24 rotates, the volume reduction devices 28 pass between the corresponding comb teeth of the chopping comb 32. The rotary material volume reduction machine 20 also includes a power train (not shown) for driving the rotation of the volume reduction rotor 24 about the central axis 26. The power train may include a prime mover (e.g., an engine) that provides the power required to drive rotation of the reduction rotor 24. The power train may also include a transmission for transferring power from the prime mover to the reduction rotor 24. The power may be transferred in the form of torque. The rotary material reduction machine 20 may also include one or more conveyors 34 for transporting reduced product discharged from the reduction box 22 away from the reduction box 22.

[0012] In operation of the rotary material reduction machine 20, material desired to be reduced is fed through a hopper 30 into the reduction box 22. Within the reduction box 22, the reduction rotor 24 is rotated about a central axis 26 by a power train. The material fed into the reduction box 22 is impinged by a reduction device 28 of the reduction rotor 24, which forces the material through a shredding comb 32, thereby reducing the size of the material by shredding. The shredded material forced through the shredding comb 32 may be deposited on a conveyor 34, which may transport the shredded material to a collection location, such as the bed of a truck or a pile on the ground. If the hopper 30 includes a sizing screen below the reduction rotor 24, the reduced material that is small enough to pass through the screen is deposited on the conveyor 34, while the remainder of the material is recirculated by the reduction rotor 24 back into the reduction box 22 for further processing until it is small enough to pass through the screen.

[0013] 4-8 show a volume reduction rotor system 50 having a drum 52 (e.g., a volume reduction rotor shown separately in FIG. 9) that can be integrated into a material volume reduction machine, such as the rotary material volume reduction machine 20. The volume reduction rotor system 50 is thus configured as a rotary material volume reduction tool. The volume reduction rotor system 50 is rotatable about a central rotation axis 54. The volume reduction rotor system 50 is mountable within the material volume reduction machine (e.g., within the volume reduction box 22 of the rotary material volume reduction machine 20), and when mounted within the rotary material volume reduction machine 20, the rotation axis 54 of the volume reduction rotor system 50 coincides with the central axis 26 of the rotary material volume reduction machine 20. The rotation axis 54 of the volume reduction rotor system 50 also extends through the center of the drum 52 to form the rotation axis of the drum.

[0014] The volume-reduced rotor system 50 includes a drum 52 ( FIG. 9 ) that is part of a rotor weldment 56 ( FIG. 20 ), a hammer 58 that is removably coupled to the rotor weldment 56, and a volume-reducing device 62 (e.g., teeth, cutters, blades, etc.) that is removably attached to the hammer 58. The volume-reduced rotor system 50 includes a first end cap 53 and a second end cap 55 opposite the first end cap 53, which portions may be removably coupled to ends of the rotor weldment 56. In use, the volume-reduced rotor system 50 may be rotationally driven by a torque source (e.g., a power train) to rotate about a rotation axis 54. The first end cap 53 of the volume-reduced rotor system 50 is the driven end such that it is connected to the torque source (e.g., a power train) and receives torque from the torque source. The second end cap 55 of the reduction rotor system 50 is a mounting end configured to support the reduction rotor system 50 within a material reduction machine (eg, within the reduction box 22).

[0015] The volume reduction rotor system 50 is rotated about the axis of rotation 54 in a direction of rotation 70. In the illustrated embodiment, the direction of rotation 70 is clockwise when the volume reduction rotor system 50 is viewed from the first end cap 53 (e.g., as shown in FIG. 4 ). The hammers 58 are disposed axially along the volume reduction rotor system 50 between the first end cap 53 and the second end cap 55. More specifically, each of the hammers 58 is positioned at a predetermined axial position along the length of the drum 52. As the volume reduction rotor system 50 rotates about the axis of rotation 54, the volume reduction device 62 travels along a circular volume reduction path that circumscribes the axis of rotation 54. In some embodiments, the volume reduction device 62 may be formed integrally with the hammers 58.

[0016] 9 illustrates drum 52. Drum 52 is an elongated cylindrical structure having an exterior surface 74 and an interior cavity 78. Exterior surface 74 extends from a first end of drum 52 to a second end of drum 52. The first end of drum 52 is adjacent first end cap 53 and the second end of drum 52 is adjacent second end cap 55. Exterior surface 74 also extends about axis of rotation 54.

[0017] The drum 52 further includes a number of openings 82 (e.g., collar locations) configured to receive the hammers 58 and additional support structure (described in more detail below). The openings 82 extend from the exterior surface 74 to the interior cavity 78. In the illustrated embodiment, the openings 82 have an oval shape, although in other embodiments the openings 82 may have a different elongated shape (e.g., rectangular).

[0018] The openings 82 include a first opening 82a, a second opening 82b, a third opening 82c, and a fourth opening 82d defined in the outer surface 74 of the drum 52. The openings 82 are grouped into axial sets spaced apart along the length of the drum 52. The first set of openings includes a first opening 82a and a second opening 82b. The first and second openings 82a, 82b are located at the same axial location along the drum 52. The first and second openings 82a, 82b are located diametrically opposite one another such that the first and second openings 82a, 82b are spaced 180 degrees apart. Stated another way, the first and second openings 82a, 82b are diametrically opposed on the drum 52. In the illustrated embodiment, each of the axial sets of openings includes two openings 82 (e.g., a first opening 82a and a second opening 82b), although in other embodiments, the sets of openings may include more openings 82 spaced equally around the circumference of the drum 52. In some embodiments, the sets of openings may include only one opening.

[0019] The third opening 82c and the fourth opening 82d form a second set of openings that are similar to the first set of openings (e.g., the first and second openings 82a, 82b) and are axially spaced apart from the first set of openings. In the illustrated embodiment, the second set of openings is also angularly offset from the first set of openings. In the illustrated embodiment, the sets of openings are offset by 60 degrees, although in some embodiments the angular offset may be greater or less.

[0020] 4-8 and 20-22, the hammer 58 is removably coupled to the drum 52 by a collar (e.g., a mount or support). The volume reduction rotor system 50 may include a plurality of collars 106 that removably couple the hammer 58 to the drum 52 and provide support for the hammer 58. Each of the collars of the plurality of collars 106 is at least partially received within one of the openings 82.

[0021] The plurality of collars 106 includes a first collar 106a and a second collar 106b (FIGS. 21, 22). The first collar 106a is at least partially received in the first opening 82a, and the second collar 106b is at least partially received in the second opening 82b. In the illustrated embodiment, the first collar 106a is coupled to and supports one end of the hammer, while the second collar 106b is coupled to and supports the other end of the hammer. In the illustrated embodiment, the second collar 106b is similar to the first collar 106a, and therefore only the first collar 106a will be described in detail. In some embodiments, the second collar 106b may be different from the first collar 106a.

[0022] 12-19, the first collar 106a may be a monolithic body. The first collar 106a may be a forged body. The first collar 106a has an inner portion 118 (e.g., a first portion), an outer portion 122 (e.g., a second portion), and a hammer cavity 126 extending between the inner portion 118 and the outer portion 122. When the first collar 106a is received (e.g., disposed within or coupled to) the opening 82a, the inner portion 118 extends into the drum 52 and the outer portion 122 extends along the outer surface 74 of the drum 52. In the illustrated embodiment, the inner portion 118 is smaller than the opening 82a such that when the first collar 106a is positioned within the opening 82a, a clearance gap exists between the inner portion 118 and the opening 82a. In some embodiments, the inner portion 118 is the same size as the opening 82a such that when the first collar 106a is positioned within the opening 82a, the inner portion 118 fits snugly against the opening 82a.

[0023] The outer portion 122 includes a flange 150 (e.g., a flared portion). The flange 150 is the widest portion of the first collar 106a, which defines an outer perimeter of the first collar 106a. The outer perimeter is greater than the perimeter of the opening 82a. In the illustrated embodiment, the flange 150 extends continuously along the entire perimeter of the first collar 106a. In some embodiments, the flange 150 may extend only along a section of the first collar 106a. For example, the flange 150 may extend only along an end of the first collar 106a, or the flange 150 may be formed of interrupted sections that extend along the perimeter of the collar 106a.

[0024] The flange 150 and the outer periphery of the first collar 106a form a curved surface. The curved surface has a similar (e.g., matching) curvature to the outer surface 74 of the drum 52 such that when the first collar 106a is received within the opening 82a, the flange 150 extends beyond the opening 82a. The flange 150 extends along the outer surface 74 of the drum 52. In the illustrated embodiment, a clearance gap exists between the flange 150 and the outer surface 74 of the drum 52. In some embodiments, the flange 150 flush against the outer surface 74 of the drum 52.

[0025] In some embodiments (not shown), the flange 150 includes a set of contact points (e.g., bosses, knobs, or protrusions) such that when the first collar 106a is inserted into the opening 82a, the flange 150 contacts the outer surface 74 of the drum 52 only at the contact points. The flange 150 may include three or more contact points spaced along the flange 150. The contact points may be integrally formed with the first collar 106a.

[0026] The hammer cavity 126 is configured to at least partially receive one of the hammers 58. The hammer cavity 126 has a generally rectangular cross-section (as seen in FIG. 13). In the illustrated embodiment, the hammer cavity 126 has rounded edges. The hammer cavity 126 is sized to fit one of the hammers 58. The hammer cavity 126 may be slightly larger than one of the hammers 58. The hammer cavity 126 may be centered on the first collar 106a such that its center is aligned with the center of the first collar 106a. The hammer cavity 126 may be formed during the forging process of the first collar 106a, or the hammer cavity 126 may be formed by machining (e.g., cut or drilled) after the first collar 106a is forged. In some embodiments, the hammer cavity 126 may be off-centered on the first collar 106a.

[0027] The hammer cavity 126 may include an inner profile 142 (FIG. 19) disposed along a periphery of the hammer cavity 126. The inner profile 142 is configured to receive a sleeve (discussed in detail below). The inner profile 142 is disposed on a distal end of the inner portion 118 (e.g., the end of the first collar 106a opposite the flange 150). The inner profile 142 extends partially from the distal end of the first collar 106a toward the flange 150. The inner profile 142 may extend one-fifth of the length of the inner portion 118. In some embodiments, the inner profile 142 may extend one-third of the length of the inner portion 118. In some embodiments, the inner profile 142 may extend the length of the inner portion 118. In some embodiments, the inner profile 142 may extend the entire length of the first collar 106a.

[0028] The first collar 106a may further include a wedging side 110 (e.g., a first side) and a support side 114 (e.g., a second side). The hammer cavity 126 is between the wedging side 110 and the support side 114. In the illustrated embodiment, when the first collar 106a is disposed within the opening 82a, the wedging side 110 is in a forward direction relative to the rotational direction 70 and the support side 114 is in a rearward direction relative to the rotational direction 70. In some embodiments, the support side 114 may be in a forward direction relative to the rotational direction 70. In some embodiments, the first collar 106a may include two wedging sides 110 (e.g., a front wedging side and a rear wedging side) and no support side. In some embodiments, the first collar 106a may include two support sides 114 (eg, a front support side and a rear support side) and no wedging side.

[0029] The wedging side 110 includes a wedging cavity 130 that extends within the length of the first collar 106a. The wedging cavity 130 and the hammer cavity 126 may be open to one another directly or indirectly. The wedging cavity 130 and the hammer cavity 126 may be directly adjacent to one another and open directly to one another. In the illustrated embodiment, the wedging cavity 130 is continuous with (e.g., fluidly connected to) the hammer cavity 126. The wedging cavity 130 may be formed during the forging process of the first collar 106a, or the wedging cavity 130 may be formed by machining (e.g., cut or drilled) after the first collar 106a is forged. In some embodiments, the wedging cavity 130 may extend only partially through the length of the first collar 106a.

[0030] 24 and 27, a wedging assembly 204 is disposed within the wedging cavity 130. The wedging assembly 204 removably secures the hammer 58 to the first collar 106a. The wedging assembly 204 is actuated to exert a force on the hammer 58 that is perpendicular to the length of the hammer 58 to pinch or wedge the hammer 58 to the first collar 106a. The wedging assembly 204 may include a first wedge portion 208, a second wedge portion 212, and a fastener 214 (e.g., a bolt). The fastener 214 extends through the first wedge 208 and the second wedge 212. The fastener 214 does not extend through the hammer 58 or the volume reduction device 62.

[0031] The first wedge portion 208 includes a recess 218, an angled contact surface 221, and a wedge surface 223. The recess is configured to receive a portion of the fastener 214. The wedge surface 223 is opposite the angled contact surface 221. The wedge surface 223 is adjacent to the collar 106.

[0032] The second wedge portion 212 has an L-shape. The second wedge portion 212 includes a base 228, an angled contact surface 232, and a wedge surface 234. The base 228 includes a recess 225 that receives a portion of the fastener 214. The base 228 is disposed below the first wedge portion 208. The angled contact surface 232 is disposed between the angled contact surface 221 of the first wedge portion 208 and the hammer 58. The angled contact surface 232 of the second wedge portion 212 is configured to engage with the angled contact surface 232 of the first wedge portion 208. The wedge surface 234 is opposite the angled contact surface 232. The wedge surface 234 is adjacent to the hammer 58 and applies a force to the hammer 58. The force is perpendicular to the length of the hammer 58.

[0033] The fastener 214 is received within both the first wedge portion 208 and the second wedge portion 212 and is threadably received by a nut 235. In some constructions, the nut 235 is T-shaped. The nut 235 is disposed below both the first wedge portion 208 and the second wedge portion 212. The wedging cavity 130 may have a protrusion 236 that separates the wedges 208, 212 from the nut 235 and limits the axial movement of the nut 235. In other embodiments, the nut 235 may be a hex nut or a square nut.

[0034] When the fastener 214 is tightened into the nut 235, it engages the first wedge 208 with the second wedge 212. More specifically, tightening the fastener 214 pushes the first wedge 208 downward (e.g., toward the inner cavity 78) and engages the angled contact surface 232 of the first wedge 208 with the angled contact surface 232 of the second wedge 212. The first wedge 208 presses the wedge surface 234 of the second wedge 212 laterally against the hammer 58, so that the hammer is fixed (wedge-locked or pinched) within the first collar 106a and cannot be removed. When the fastener 214 is loosened, it allows the first wedge 208 and the second wedge 212 to disengage. The first wedge portion 208 is relaxed so that it can exert less force on the second wedge 212. The hammer 58 is no longer secured so that it can be removed from the first collar 106a.

[0035] The wedging side 110 may also include an extension 134. The extension 134 extends past the support side 114. The extension 134 includes a cap 238 and a spacer 242 that extend the length of the wedging cavity 130. The cap 238 is configured to cover the wedging cavity 130 and prevent the nut 235 from falling into the inner cavity 78 of the drum 52. The spacer 242 allows the fastener 214 and nut 235 to be positioned within the wedging cavity 130 while allowing room for the fastener 214 to move downwardly.

[0036] Spacer 242 is welded to the distal end of wedging side 110 by weld 246. Cap 238 is welded to spacer 242 by weld 250. In some embodiments, spacer 242 and cap 238 are one piece. In some embodiments, spacer 242 and cap 238 are included within a monolithic forging of first collar 106a.

[0037] The support side 114 provides strength to the first collar 106a. The support side 114 is a generally solid structure and does not have any openings. The support side 114 does not have any removable parts or elements.

[0038] 20-27, the volume reduction rotor system 50 may include a sleeve 174 coupled to the first collar 106a and the second collar 106b. More specifically, the sleeve 174 may be press-fit into the inner profile 142 of the first collar 106a and the second collar 106b. The sleeve 174 is a rectangular extension configured to receive a hammer. The sleeve 174 has a constant rectangular cross-section. The sleeve 174 extends at least partially between the first opening 82a and the second opening 82b through the drum inner cavity 78. More specifically, the sleeve 174 extends between the first collar 106a and the second collar 106b. The sleeve 174 prevents objects (e.g., hammers, dirt, cut material, etc.) from accidentally falling into the inner cavity 78 of the drum 52 that may be inaccessible when assembled in the material reduction machine.

[0039] Additionally, the sleeve 174 may be used to create a clearance gap between the collars 106a, 106b and the outer surface 74 of the drum 58 during assembly of the rotor weldment 56. More specifically, the length of the sleeve 174 may be selected to create and control the size of the gap between the collars 106a, 106b and the outer surface 74. A first end of the sleeve 174 is received within the inner profile 142 of the first collar 106a and a second end of the sleeve 174 is received within the inner profile 142 of the second collar 106b. The length of the sleeve 174 separates the first collar 106a and the second collar 106b from each other. To set an increased distance between the first collar 106a and the second collar 106b, the sleeve 174 may be increased in length. To set a decreased distance between the first collar 106a and the second collar 106b, the sleeve 174 may be decreased in length. The length of the sleeve 174 is selected to achieve a desired gap between the first collar 106a and the exterior surface 72 and a desired gap between the second collar 106b and the exterior surface 72. The desired gap allows for a more controlled and consistent weld point (discussed in more detail below).

[0040] 6, 10, 11, and 20, the rotor weldment 56 may include a plurality of caul plates 90 (e.g., platings or shells) extending along the outer surface 74 of the drum 52. The plurality of caul plates 90 are secured to the outer surface 74 of the drum 52. More specifically, the plurality of caul plates 90 are welded to the outer surface 74 of the drum 52. The plurality of caul plates 90 may be formed from a harder material than the outer surface 74. The material of the caul plates 90 may be Hardox® 500 wear-resistant steel. Alternatively, the caul plates 90 may be constructed of another suitable wear-resistant steel. The plurality of caul plates 90 increase the strength and wear resistance of the rotor weldment 56 as compared to the drum 52 alone.

[0041] In the illustrated embodiment, the plurality of backing plates 90 includes a first backing plate 90a, a second backing plate 90b, a third backing plate 90c, and a fourth backing plate 90d. The first backing plate 90a is circumferentially adjacent to the second backing plate 90c, and the third backing plate 90c is circumferentially adjacent to the fourth backing plate 90d. The first backing plate 90a is axially adjacent to the third backing plate 90c, and the second backing plate 90d is axially adjacent to the fourth backing plate 90d. In the illustrated embodiment, the backing plates 90a-90d are all similar, and therefore only the first backing plate 90a will be described in detail.

[0042] The first backing plate 90a includes an inner surface 94, an outer surface 98, and at least one curved edge 102. When the first backing plate 90a is placed on the drum 52, the inner surface 94 of the first backing plate 90a abuts and flush against the outer surface 74 of the drum 52. The first backing plate 90a defines a curved inner surface 94. In the illustrated embodiment, the inner surface 94 has a semicircular shape. The second backing plate 90b is positioned circumferentially adjacent to the first backing plate 90a to cover the circumference of the drum 52. Circumferentially adjacent backing plates (e.g., the first backing plate 90a and the second backing plate 90b) may abut one another or there may be a gap defined between the backing plates 90a, 90b. In other embodiments, the backing plates may be smaller such that three or more backing plates may be used to cover the circumference of the drum 52. Similar to the opening 82, the first and second backing plates 90a, 90b are angularly offset from the third and fourth backing plates 90c, 90d, as shown in Figure 20. In the embodiment shown, the set of backing plates are offset by 60 degrees. In some embodiments, the angular offset may be greater or less than this amount.

[0043] The first caul plate 90a has two curved edges 102. When the first caul plate 90a is placed on the drum 52, the curved edges 102 are positioned adjacent to a corresponding portion of the opening 82 of the drum 52. In other words, the edges 102 follow the contour of a portion of the opening 82. In the illustrated embodiment, the edges 102 have a semi-elliptical shape, whereby the two caul plates form an elliptical opening that follows the contour of one of the openings 82 or follows the contour of one of the collars 106. For example, referring to FIG. 6, an elliptical opening is formed between the first caul plate 90a having the edge 102a and the fourth caul plate 90d having the edge 102d. In some embodiments, the first caul plate 90a has an elliptical shaped opening, whereby only one caul plate (e.g., the first caul plate 90a) is needed to create an opening corresponding to the opening 82. In some embodiments, the caul plate 90 may have weld tabs that extend from the caul plate 90 to allow for welding on the tabs.

[0044] The caul plate 90 may be positioned adjacent to the collar 106 while allowing a gap for welding between the caul plate 90 and the collar 106. For example, in the illustrated embodiment, the first caul plate 90a is positioned adjacent to the first collar 106a. More specifically, the edge 102 of the first caul plate 90a is adjacent to the outer portion 122 of the first collar 106a. The edge 102 may be offset from the outer portion 122 such that a weld gap 152 ( FIG. 27 ) is defined between the edge 102 and the outer portion 122. At the weld gap 152, the outer surface 74 of the drum 52 is exposed. The weld gap 152 may extend along the entire perimeter of the outer portion 122, or the weld gap 152 may extend only partially along the perimeter of the outer portion 122. In some embodiments, the first backing plate 90a is immediately adjacent to the first collar 106a, and there is no weld gap defined between the first backing plate 90a and the first collar 106a.

[0045] 27, at the weld gap 152, the first back plate 90a, the first collar 106a, and the outer surface 74 of the drum 52 may be welded together to form the rotor weldment 56. The weld may be made with at least one weld spot to span the weld gap 152. In the illustrated embodiment, the weld gap 152 is filled with a plurality of weld spots 154. The plurality of weld spots 154 may include a first weld beam 158, a second weld bead 162, and a third weld bead 166. The first weld bead 158 is applied between the outer portion 122 of the first collar 106a and the outer surface 74 to secure the first collar 106a to the outer surface 74. The second weld bead 162 is applied between the first back plate 90a and the outer surface 74 to secure the first back plate 90 to the outer surface 74. A third weld bead 166 is applied between the first weld bead 158 and the second weld bead 162 to secure the first collar 106a, the first backing plate 90a, and the outer surface 74 together. The first weld bead 158 and the second weld bead 162 may each be formed from multiple weld passes (e.g., weld layers). For example, the first weld bead 158 and the second weld bead 162 may each be formed from three weld passes. The weld passes may be continuous welds extending along the entire outer perimeter of the first collar 106a and the edge 102 of the first backing plate 90a. In some embodiments, the weld passes may be discontinuous passes extending along the outer perimeter of the first collar 106a and the edge 102 of the first backing plate 90a. In some embodiments, the weld beads 158, 162, 166 may be applied in a different order. In some embodiments, the plurality of welds 154 may include more welds. In some embodiments, the backing plate 90 may be welded directly to the collar 106 with minimal or no welds connecting the backing plate 90 to the exterior surface 74 of the drum 52.

[0046] 28 illustrates a rotor weldment 56' according to another embodiment. The rotor weldment 56' is similar to the rotor weldment 56, except that the rotor weldment 56' includes a different weld pattern. The flange of the first collar 106a, the outer surface 74 of the drum 52, and the backing plate 90 of the rotor weldment 56' are secured or fused together by a single weld spot 154'. The single weld spot 154' is a single weld bead formed in a single weld pass that fills the entire weld gap 152. The single weld spot 154' may be achieved by applying a single weld bead on the outer surface 74 of the drum 52, the flange of the first collar 106a, and the backing plate 90 by submerged arc welding.

[0047] 27 and 28 show the welds 154, 154' as extending along the surface of the drum 52, 52', the first collar 106, 106', and the backing plate 90, 90'. However, those skilled in the art of welding will recognize that the welds 154, 154' penetrate into and fuse with the base material of the drum 52, 52', the first collar 106, 106', and the backing plate 90, 90'.

[0048] 20 and 21 , the drum 52, collar 106, backing plate 90, and welds 154 form the rotor weldment 56. The welds 154 fuse the drum 52, collar 106, and backing plate 90 to form the rotor weldment 56. The rotor weldment 56 is permanently bonded together. The hammer 58 is removably bonded to the rotor weldment 56.

[0049] The collar 106 and welds 154, 154' increase the strength of the drum 52. More specifically, the collar 106 and welds 154, 154' reduce the amount of stress along the outer surface 74 of the drum 52 and around the opening 82. The collar 106 prevents excessive stress on the trailing edge of the opening 82 (e.g., the edge adjacent the support side 114 of the collar 106) as the reducer 62 repeatedly impacts the material. The rotor weldments 56 create a load path that transfers some or most of the loads (e.g., stresses) experienced during reduction from the reducer 62 and hammer 58 through the collar 106 (via the flange 150) to the drum 52 and / or backing plate 90. The load path distributes the loads to the rotor weldments 56 rather than concentrating the loads around the opening 82.

[0050] 24, the hammer 58 includes a first end 182 and a second end 186 opposite the first end 182. In the illustrated embodiment, the hammer 58 has a generally rectangular shape. More specifically, the ends 182, 186 may be wider than a central portion of the hammer 58.

[0051] During assembly, the hammer 58 is placed in the sleeve 174, which extends into the inner cavity 78 of the drum 52 and is removably coupled to the first collar 106a and the second collar 106b. More specifically, a first end 182 of the hammer 58 is received in the first collar 106a, and the hammer 58 extends lengthwise across the axis of rotation 54 to the second collar 106b such that a second end 186 of the hammer 58 is received in the second collar 106b. In configurations in which the hammer has a volume reduction device on the first end 182 and / or the second end 186, a portion of the hammer 58 may be exposed (e.g., outside the drum 52 and the collars 106a, 106b). The exposed portion may have a cutout shape or may act as a support or mount for the volume reduction device 62. In some embodiments, the hammers 58 have a shorter length and do not extend across the axis of rotation 54 such that a first hammer is received within the first collar 106a and a second hammer is received within the second collar 106b.

[0052] The first end 182 of the hammer 58 may be a cutting end configured to be removably coupled to the volume reducer 62. The volume reducer 62 may be removably coupled to the first end 182 by fasteners 194 (e.g., bolts or screws). In the illustrated embodiment, the volume reducer 62 is coupled to the first end 182 by two fasteners 194. The fasteners 194 are inserted through the volume reducer 62 into the hammer 58 in a direction perpendicular to the length of the hammer 58. The volume reducer 62 includes a sharp tool face 66. The tool face 66 is above the wedging side 110 of the first collar 106a such that it faces forward relative to the direction of rotation 70. The volume reducer 62 can be replaced or removed from the hammer 58 by loosening the fasteners 194. The volume reducer 62 can be removed without having to remove the hammer 58 from the collar 106 and rotor weldment 56 .

[0053] 23, 25, and 26, the second end 186 of the hammer 58 may be a blank end that is not coupled to the volume reduction apparatus 62. The second end 186 is removably coupled to a cap 198 that covers the second end 186. The cap 198 is coupled to the second end 186 by fasteners 202 (e.g., bolts or screws). In the illustrated embodiment, the cap 198 is coupled to the second end 186 by two fasteners 202. The fasteners 202 are inserted through the cap 198 into the hammer 58 in a direction parallel to the hammer 58.

[0054] In some embodiments, both the first end 182 and the second end 186 may be cut ends. In some embodiments, both the first end 182 and the second end 186 may be blank ends.

[0055] Additionally, a detailed description of a hammer, which may be similar to hammer 58, is provided in U.S. Pat. No. 11,338,298 to Vermeer Mfg. Co., which is incorporated herein by reference in its entirety.

[0056] The volume reduction rotor system 50 is assembled by first providing the drum 52. The drum 52 includes at least a first opening 82a and a second opening 82b disposed in the outer surface 74 of the drum 52.

[0057] The first collar 106a is then inserted (e.g., assembled, positioned, or disposed) into the first opening 82a from outside the drum 52 until the inner portion 118 extends into the drum 52 and the outer portion 122, and more particularly the flange 150 of the outer portion 122, extends along the outer surface 74 of the drum 52 beyond the first opening 82a. The sleeve 174 is inserted into the inner profile 142 of the first collar 106a through the second opening 82b such that it is press-fit into the first collar 106a and extends between the first opening 82a and the second opening 82b. In some embodiments, the sleeve 174 may be press-fit into the first collar 106a before the first collar 106a is inserted into the first opening 82a, such that the sleeve 174 is inserted into the drum 52 when the first collar 106a is inserted into the drum 52.

[0058] Next, the second collar 106b is inserted (e.g., positioned) in the second opening 82b until the inner portion 118 extends into the drum 52 and the outer portion 122, and more particularly, the flange 150 of the outer portion 122, abuts the outer surface 74 of the drum 52. The second collar 106b is aligned with the first collar 106a and the sleeve 174 such that it is coupled to the sleeve 174. More particularly, while the second collar 106b is inserted into the second opening 82b, the sleeve 174 is aligned with the inner profile 142 of the second collar 106b such that the sleeve 174 can be press-fit into the inner profile 142 when the second collar 106b is fully inserted into the opening 82b. The second collar 106b is inserted into the second opening 82b such that the wedging side 110 of the second collar 106b is directionally aligned with the wedging side 110 of the first collar 106a relative to the intended direction of rotation 70.

[0059] When the first and second collars 106a, 106b are positioned within their respective openings 82a, 82b, the backing plates 90a-90d are positioned on the outer surface 74 of the drum 52. The backing plates 90a-90d are positioned such that their inner surfaces 94 abut the outer surface 74 of the drum 52 and the edges 102 are adjacent the outer portions 122 of the collars 106a, 106b, and more particularly, the flanges 150 of the outer portions 122. The backing plates 90a-90b are also positioned such that they are offset from the outer portions 122 of the collars 106a, 106b such that a weld gap 152 is formed between the collars 106a, 106b and the backing plates 90a-90d.

[0060] The first collar 106a, the second collar 106b, and the backing plates 90a-90d are then secured to the outer surface 74 of the drum 52 to form the rotor weldment 56. More specifically, the first collar 106a, the second collar 106b, and the backing plates 90a-90d are welded to the outer surface 74 of the drum 52. Even more specifically, the flange 150 of the first collar 106a, the flange 150 of the second collar 106b, and the outer surfaces 98 of the backing plates 90a-90d are welded to the outer surface 74 of the drum 52. Welding the first collar 106a, the second collar 106b, and the backing plates 90a-90d may include depositing multiple passes within the weld gap 152. More specifically, the flange 150 of the first collar 106a is welded to the outer surface 74 of the drum 52 by depositing a first weld pass to form a first weld bead 158 in the weld gap 152 between the first collar 106a and the outer surface 74. The outer surface 98 of the back plate 90a is then welded to the outer surface 74 of the drum 52 by depositing a second weld pass to form a second weld bead 162 in the weld gap 152 between the back plate 90a and the outer surface 74. Finally, the first collar 106a, the back plate 90a, and the outer surface 74 are welded together by depositing a third weld pass to form a third weld bead 166 between the first weld bead 158 and the second weld bead 162 in the weld gap 152. A similar welding process may be repeated on the other side of the drum 52 to secure the second collar 106b and the second backing plate 90b to the outer surface 74 of the drum 52. As noted above, different welding configurations may be used in forming the rotor weldment 56.

[0061] Once the rotor weldment 56 is formed, the hammer 58 is inserted into the drum 52 through the first collar 106a. The hammer 58 is inserted through the first collar 106a and into the sleeve 174. The hammer 58 is inserted until the second end 186 of the hammer 58 is received within the second collar 106b, leaving a portion of the hammer 58 exposed.

[0062] The hammer 58 is then secured to the first collar 106a and the second collar 106b. The hammer 58 is secured to the first collar 106a by tightening the fastener 214 to compress the first wedge portion 208 and force the wedging surface 234 of the second wedge portion 212 against the wedging side 110 of the hammer 58. As the fastener 214 is tightened, it moves downward (e.g., toward the inner cavity 78) and pushes the first wedge portion 208 downward. The angled contact surface 221 of the first wedge 208 presses against and wedges the angled contact surface 232 of the second wedge portion 212, thereby securing and clamping the hammer 58 to the first collar 106a. A similar welding process may be repeated on the other side of the drum 52 to secure the hammer 58 to the second collar 106 b and the drum 52 .

[0063] Once the hammer 58 is secured to the first collar 106a and the second collar 106b, the volume reducer 62 is coupled to the first end 182 and the cap 198 is coupled to the second end 186. The volume reducer 62 is aligned with the hammer 58 such that its tool face 66 faces the direction of rotation 70. The volume reducer 62 is coupled to the hammer 58 by inserting a fastener 194 through the volume reducer 62 into the hammer 58 and tightening the fastener 194 to secure the volume reducer 62. The fastener 194 is inserted perpendicular to the hammer 58. On the second end 186, the cap 198 is coupled to the hammer 58 by inserting a fastener 202 through the cap 198 into the hammer 58 and tightening the fastener 202 to secure the cap 198. The fastener 202 is inserted in a parallel direction to the hammer 58.

[0064] Once the reduction device 62 and cap 198 are secured to the hammer 58, the first end cap 53 and the second end cap 55 may be secured to the ends of the rotor weldment 56. Once the end caps 53, 55 are secured to the rotor weldment 56, the reduction rotor system 50 may be placed in a material reduction machine, such as the rotary material reduction machine 20, such that the drum rotor weldment 56 and the reduction rotor system 50 may be driven to rotate about the axis of rotation 54 and the central axis 26. In some embodiments, the hammer 58, along with the reduction device 62 and cap 198, are secured to the rotor weldment 56 after the rotor weldment 56 is attached to the material reduction machine.

[0065] If one of the volume reducers 62 breaks or wears out, one of the volume reducers 62 can be easily replaced by loosening the fasteners 194 to decouple the volume reducer 62 from the hammer 58. Once the old volume reducer 62 is decoupled, a new volume reducer 62 can be coupled to the hammer 58 by the fasteners 194. During replacement of the volume reducer 62, the hammer 58 and collar 106 remain fixed within the drum 52.

[0066] If the hammer 58 becomes worn, broken, or needs to be inspected, it can be easily replaced by first removing any volume reducers 62 or caps 198 coupled to that hammer 58, and then loosening the fasteners 214 in the first and second collars 106a, 106b. Loosening the fasteners 214 disengages the hammer 58, thereby allowing the hammer 58 to then be easily slid out of the collars 106a, 106b and drum 52.

[0067] Although the method of assembling the reduced volume rotor system 50 is described in sequential steps, it will be understood that some of the steps may be completed in a different order, some of the steps may be completed simultaneously, and some of the steps may be omitted.

[0068] In addition, the articles "a" and "an" shall not be construed as meaning "one" or "only one" unless the context of their usage clearly indicates otherwise. Instead, these articles shall be construed as meaning "at least one" or "one or more."

[0069] While particular embodiments, examples, features, and aspects have been described and illustrated, variations and modifications exist within the scope and spirit of the subject matter described and illustrated.

Claims

1. 1. A method of assembling a rotary material reduction tool, comprising: providing a drum having an outer surface extending about an axis of rotation of the drum; assembling the collar into the first opening in the outer surface of the drum from outside the drum until a portion of the collar extends into the drum and a flange of the collar extends along the outer surface of the drum beyond the first opening; welding the flange of the collar and the outer surface of the drum together; inserting a hammer through the collar such that a portion of the hammer remains exposed; and securing the hammer to the collar.

2. The method of claim 1 , wherein welding the flange of the collar and the outer surface of the drum together comprises depositing multiple weld passes.

3. 2. The method of claim 1, further comprising positioning the second collar at a second opening in the outer surface of the drum until a portion of the second collar extends into the drum and a flange of the second collar extends along the outer surface of the drum beyond the first opening, the second opening being opposite the first opening.

4. The method of claim 3 further comprising press-fitting a sleeve into the collar, the sleeve extending between the collar and the second collar.

5. The method of claim 1 , wherein the hammer is secured to the collar by tightening a fastener into one side of the collar to wedge the hammer into the collar.

6. The method of claim 1 further comprising the step of securing a caul plate to the outer surface of the drum.

7. The method of claim 6 , wherein the caul plate is secured to the outer surface of the drum by welding.

8. 8. The method of claim 7, wherein the step of welding the flange of the collar and the outer surface of the drum together comprises depositing a first weld pass, and the step of welding the backing plate and the outer surface of the drum together comprises depositing a second weld pass, the method further comprising depositing at least one additional weld pass between the first weld pass and the second weld pass.

9. 8. The method of claim 7, wherein the steps of welding the flange of the collar and the outer surface of the drum together and the steps of welding the backing plate and the outer surface of the drum together include applying a single weld pass between the flange of the collar, the outer surface of the drum, and the backing plate.

10. In a rotary material reduction tool, a drum having an outer surface extending about an axis of rotation of the drum, the drum having a first opening defined in the outer surface of the drum; a collar received within the first opening, a first portion of the collar extending into the drum and a flange of the collar extending along the outer surface of the drum beyond the first opening; a hammer extending through the collar into the drum, the hammer having an exposed portion; A rotary material reduction tool, wherein the flange of the collar and the outer surface of the drum are welded together.

11. 11. The rotary material reduction tool of claim 10, further comprising a second collar coupled to a second opening in the outer surface of the drum, the second opening being opposite the first opening, a first portion of the second collar extending into the drum, and a flange of the second collar extending outside the drum.

12. The rotary material reduction tool of claim 10 further comprising a backing plate secured onto the outer surface of the drum.

13. The rotary material reduction tool of claim 12 , wherein the collar, the backing plate, and the outer surface of the drum are welded together.

14. The rotary material reduction tool of claim 10 , wherein an outer periphery of the collar defines a curved surface.

15. The rotary material reduction tool of claim 10 , wherein the flange extends beyond the entire perimeter of the first opening.

16. 11. The rotary material reduction tool of claim 10, further comprising a sleeve extending at least partially between the first and second openings in the outer surface, the second opening being opposite the first opening, and the hammer being at least partially disposed within the sleeve.

17. 11. The rotary material reduction tool of claim 10, wherein the collar includes a wedging side and a support side, the wedging side including a fastener and a wedging assembly, the wedging assembly securing the hammer to the collar when the fastener is secured.

18. 20. The rotary material reduction tool of claim 17, wherein the support side is a generally solid structure without any openings.

19. The rotary material reduction tool of claim 10 , wherein the collar is a monolithic forging.

20. The rotary material reduction tool of claim 10 , wherein the hammer extends transverse to the axis of rotation.

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