Roller Crusher Deflection Distributor for Uneven Feed Loads
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Solution Overview
Problem
Roller crushers experience skewing due to uneven material feed, leading to unproportioned wear, jamming, and premature failure of mechanical components, particularly when handling high compression forces and varying material properties.
Innovation Solution
A deflection distributor refitting kit with a deflection distributing shaft, thrust rods, and a preload arrangement to maintain parallel movement of crusher rolls, reducing mechanical wear and compensating for uneven loads, and incorporating flanges to ensure uniform material feed and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hydraulic systems with accumulators are used to handle gap width variations, then the system can accommodate varied material feed characteristics, but the system complexity increases
Solution Approach 1:
The deflection distributor enables the crusher rolls to self-adjust to uneven material feed distribution automatically. The mechanical linkage allows the rolls to compensate for feed variations without requiring complex hydraulic control systems, making the system self-regulating and simpler
2Productivity
If high compression forces are applied to achieve interparticle crushing, then throughput and energy efficiency improve, but mechanical component wear and jamming increase
Solution Approach 1:
The deflection distributor acts as a cushioning mechanism that absorbs and distributes uneven loads before they reach the mechanical components. By allowing controlled deflection and distributing the load evenly across the roll length, it prevents sudden shocks and jamming that would otherwise occur under high compression forces
Solution Approach 2:
The deflection distributor serves as an intermediary between the feed material and the crusher rolls. It mediates the interaction by distributing uneven material feeds and loads evenly across the rolls, protecting the mechanical components from direct exposure to shock loads and jamming conditions
3Productivity
If choke feeding is used to maintain particle-on-particle compression, then comminution efficiency improves, but the risk of jamming and unproportioned wear increases
Solution Approach 1:
The deflection distributor acts as an intermediary that protects the crusher rolls from the harmful effects of choke feeding. It distributes the concentrated material load evenly across the roll length, preventing localized jamming and unproportioned wear while maintaining the high compression conditions necessary for efficient comminution
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
The solution effectively maintains parallel movement of crusher rolls, reducing wear, preventing jamming, and optimizing crushing efficiency by ensuring uniform material pressure, thereby increasing the crusher's capacity and uptime.
Implementation Method 1
a hydraulic system configured to adjust the position of the second crusher roll and the crushing pressure between the two crusher rolls
Implementation Method 2
hydraulic cylinders and accumulators, which accumulators provide a spring action to handle varied material feed characteristics
Data Source
AI summary
A deflection distributor refitting kit for a roller crusher. The deflection distributor refitting kit includes a deflection distributing shaft, thrust rods each having first and second ends and mounts for attachment of the deflection distributing shaft at a frame of the roller crusher. A first end of each of the thrust rods is attached to the deflection distributing shaft via a lever. A second end of each of the thrust rods is arranged to be attached to a movable bearing housing of the roller crusher. The deflection distributor refitting kit further includes a preload arrangement which induces a bias to parts of the deflection distributor refitting kit. A method for mounting the deflection distributor refitting kit, as well as a roller crusher including the deflection distributor, is disclosed.