Impact Crusher Anvil Wear Inserts Bonded With Adhesive

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Solution Overview

Problem

Existing impact crusher components, such as anvils and impellers, suffer from wear and tear due to abrasive materials, leading to costly replacements and inefficiencies, as previous solutions like using hardened materials for only exposed surfaces leave gaps that result in 'wash out' and uneven wear.

Innovation Solution

The use of an array of wear-resistant inserts, such as cemented tungsten carbide, bonded within a depression on the anvil's wear surface using a bonding material like epoxy adhesive, reduces the need for expensive alloys and minimizes gaps, thereby enhancing durability and preventing 'wash out'.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hardened material inserts are used to protect wear surfaces, then wear resistance is improved, but gaps between inserts allow base material to be exposed to abrasion causing wash out

Engineering Contradiction:

Improvewear resistanceVSAvoidwash out

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A bonding material acts as an intermediary substance that fills the gaps between hardened material inserts and the base component, preventing abrasive materials from reaching and eroding the softer base material, thereby eliminating the wash out problem while maintaining wear resistance

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The wear-resistant surface is segmented into multiple discrete hardened inserts rather than a continuous layer, allowing for cost-effective manufacturing while the bonding material ensures these segments work together as a unified protective surface by filling interstitial gaps

Inventive Principle:

Principle #1Segmentation

2Reliability

If entire anvil or impeller is made from hard material like tungsten carbide, then wear resistance is improved, but manufacturing cost becomes prohibitive

Engineering Contradiction:

Improvewear resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Hardened material inserts are applied only to the specific localized areas where wear occurs (the wear surfaces), while the remainder of the component is made from less expensive base material, achieving wear resistance where needed without the prohibitive cost of making the entire component from hard material

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The component is constructed as a composite structure combining hardened material inserts with a softer base material, leveraging the wear resistance of the hard inserts and the cost-effectiveness and toughness of the base material to create an economically viable solution

Inventive Principle:

Principle #40Composite materials

3Duration of action of stationary object

If wear resistant pieces are used to protect base material, then durability is improved, but the softer base material is quickly abraded when wear resistant piece is dislodged

Engineering Contradiction:

Improveservice lifeVSAvoidquick abrasion

Core Design Contradiction:

Duration of action of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The bonding material serves as a protective cushioning layer applied beforehand that prevents abrasive materials from directly contacting and eroding the softer base material, even when wear resistant inserts become dislodged, thereby maintaining protection and preventing quick abrasion

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design extends the lifespan of crusher components by distributing wear evenly, reducing the likelihood of 'wash out' and maintaining consistent aggregate size and distribution, while allowing for cost-effective manufacturing using less expensive metals.

Implementation Method 1

a bonding material attaching the wear resistant inserts to the forward depression of the base

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS8016219B2Impact crusher wear components including wear resistant inserts bonded therein

Publication Date: 2011.09.13 KENNAMETAL INC

AI summary

A wear component for use in an impact crusher having a forward depression on the face of the wear component which is exposed to aggregate wear. Wear resistant inserts, for example cemented tungsten carbide inserts, are bonded within the forward depression to prevent rapid abrasion of the wear component. Joints are formed between wear resistant inserts and joints are also formed between wear resistant inserts and the wear component. Bonding material fills the joints to further secure the wear resistant inserts and to prevent crack propagation.