Gyratory Crusher Bottomshell Hatch Assembly Design
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Solution Overview
Problem
Conventional gyratory crusher bottomshells with oversized hatch openings require machining, leading to increased processing time, energy use, and potential porosity, while also limiting strength due to stress concentrations and restricted material flow.
Innovation Solution
A bottomshell design with a uniform wall thickness and tapered border region around hatch openings, allowing for attachment via liner wear plates instead of direct mounting to the shell, reducing machining needs and stress concentrations, and facilitating casting by eliminating oversized walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bottomshell wall around the hatch opening is oversized and machined to provide a planar surface, then the hatch assembly can be mounted securely, but the manufacturing complexity increases, processing time increases, energy consumption increases, and porosity risk increases
Solution Approach 1:
The hatch assembly is separated from the bottomshell structure, allowing the bottomshell to be cast with uniform wall thickness without requiring oversized or machined regions. The hatch assembly becomes an independent component that can be mounted without compromising the casting integrity.
Solution Approach 2:
The wall thickness parameter around the hatch opening is changed from oversized to uniform, matching the rest of the bottomshell. This eliminates the need for machining while maintaining sufficient material for secure hatch mounting.
2Reliability
If the bottomshell wall around the hatch opening is oversized, then the hatch assembly can be mounted, but the material flow during casting is restricted leading to porosity
Solution Approach 1:
The wall thickness parameter is optimized to be uniform throughout the bottomshell, eliminating oversized regions that restrict material flow during casting. This improves casting quality by ensuring proper material flow and reducing porosity risk.
3Reliability
If the wall thickness at the hatch opening is increased, then the hatch assembly can be mounted, but the maximum wall thickness of the bottomshell is limited accordingly
Solution Approach 1:
The hatch assembly is made into a separate component rather than being integrated into the bottomshell wall structure. This allows the bottomshell to maintain its optimal uniform wall thickness for maximum strength while the hatch assembly is mounted independently.
4Manufacturing precision
If machining is performed on the bottomshell wall at the hatch opening region, then the hatch assembly can be mounted precisely, but additional processing time, tooling, personnel and energy use are required
Solution Approach 1:
The surface finish parameter of the bottomshell wall at the hatch opening is changed from requiring machined precision to accepting cast surface precision. This eliminates machining operations while maintaining sufficient mounting precision through the use of wear plates and flexible mounting mechanisms.
Data Source
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AI summary
A gyratory crusher bottomshell and inspection hatch assembly attachable exclusively to the bottomshell via a wear plate positioned at an internal region of the bottomshell. A wall thickness of the bottomshell at a border region immediately surrounding the hatch opening is generally equal to or less than a wall thickness over a remainder region of the wall at the same axial height position of the hatch opening.