Comminution Tool Wear Measurement Using Integrated Reference Surface
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Solution Overview
Problem
Existing comminution tools in rotor-stator or rotor-rotor systems suffer from inaccurate wear determination methods, leading to suboptimal end product quality and increased energy consumption due to mechanical stress and changing geometry, as visual checks and simple gap width measurements are prone to errors and do not account for wear on the stator or rotor surfaces.
Innovation Solution
A comminution tool with a reference surface integrated onto the tool itself, allowing for precise wear measurement by determining the distance between the effective edge and the reference surface, which is parallel to the main direction of wear, ensuring accurate wear assessment without stator or rotor surface interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual check or meter rule measurement is used to determine wear, then the measurement process is simple, but the measurement precision is low and results are inaccurate
Solution Approach 1:
A measuring gauge is introduced as an intermediary tool between the comminution tool and the measurement process. The gauge includes a reference surface that contacts the stator and a measuring element that contacts the comminution tool, mediating the measurement to eliminate direct contact between the stator surface wear and the measurement result.
Solution Approach 2:
The manual visual inspection and simple meter rule measurement are replaced by a mechanical measuring gauge system that provides automated, precise measurement through mechanical contact between the reference surface and the comminution tool, eliminating human error and subjectivity.
2Ease of operation
If gap width measurement using meter rule is performed, then the measurement is easy to perform, but measurement precision deteriorates due to stator surface wear changing the reference surface
Solution Approach 1:
The measuring gauge serves as an intermediary that decouples the measurement from the stator surface. The reference surface on the gauge contacts the stator while the measuring element contacts the comminution tool, creating a measurement chain where stator wear does not affect the reference.
Solution Approach 2:
The measurement system is segmented into distinct functional elements: a reference surface for stator contact, a measuring element for comminution tool contact, and a scale for reading. This segmentation allows each element to perform its specific function independently, isolating the measurement from stator surface variations.
3Productivity
If continuous operation of comminution devices is maintained, then productivity is high, but wear on comminution tools increases leading to decreased product quality and increased energy consumption
Solution Approach 1:
The precise wear measurement capability provides feedback on the actual wear state of comminution tools, enabling operators to monitor wear progression and schedule maintenance at optimal intervals. This feedback loop maintains product quality by ensuring tools are replaced before wear affects performance, while maximizing continuous operation time.
Solution Approach 2:
By implementing easy and precise wear measurement, maintenance actions can be planned in advance based on actual wear conditions rather than operating to fixed schedules. This preliminary planning allows optimization of maintenance timing to balance continuous operation with quality requirements.
Data Source
Figure 1a~2b
Figure 3a
Figure 3b
AI summary
The invention relates to determining the wear condition of comminution tools and thus comprises a comminution tool (1, 10, 20), a comminution device with such a comminution tool (1, 10, 20), and a corresponding method. The basic idea of the invention is to provide a reference surface (5, 15, 25) on the comminution tool (1, 10, 20) from which the distance A0, A1 to the effective edges (4, 14, 24) of the comminution tool (1, 10, 20) can be determined. The degree of wear is then obtained by comparing the original distance A0 of the unused comminution tool with the wear-related reduction in distance A1 after a certain period of use. This achieves the advantage that the wear condition can be determined independently of the general wear of the comminution device. Any resulting distortion of the measurement result is therefore excluded.