Rock Crusher Flap Clamping Segments
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Solution Overview
Problem
The existing rock crushers face issues with the accumulation of fine material on the flap surface, leading to jamming and uncontrolled discharge, and the bearing segments of the adjustable flap wear out due to vibrations, causing instability and safety concerns during operation.
Innovation Solution
The introduction of detachable clamping segments that secure the bearing segments in place, preventing rotation and wear, combined with a support structure and adjustable design to maintain the flap in swivel positions, and the use of a floppy material to prevent material accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the flap is excited by the vibration generator in conjunction with the screening unit to oscillate, then the fine material accumulation on the flap surface is prevented, but the bearing segments wear out due to vibrations and the flap cannot be securely positioned in swivel positions
Solution Approach 1:
The bearing support structure is segmented into modular components: bearing segments that rotate with the flap, and clamping segments that are secured to the conveyor unit. This segmentation allows the bearing segments to oscillate with the flap while the clamping segments remain stationary, preventing wear and maintaining positioning reliability during vibration operation
Solution Approach 2:
The clamping segments are pre-secured to the conveyor unit before operation, creating a stable reference frame. This preliminary securing action ensures that when vibrations occur during operation, the bearing segments can rotate freely without the clamping segments moving or loosening, thus preventing wear and maintaining secure positioning
2Ease of operation
If the bearing has clearance in the range of one or several 1/10 mm to allow rotation, then the flap can be adjusted between swivel positions, but the bearings wear out over time due to vibrations
Solution Approach 1:
The bearing system is divided into rotating bearing segments and stationary clamping segments. The bearing segments have the necessary clearance for rotation and adjustment, while the clamping segments remain fixed to the conveyor unit. This segmentation isolates the wear-prone rotating parts from the stationary mounting structure, extending overall bearing service life
Solution Approach 2:
The bearing segments are designed as replaceable components that can be worn and discarded, while the clamping segments secured to the conveyor unit are durable and reusable. This allows easy replacement of worn bearing segments without replacing the entire bearing assembly or resecuring the clamping segments
3Stability of the object's composition
If bolted connections are used to lock the flap in swivel positions, then the flap can be secured in position, but the oscillations and vibrations cause the bolted connections to unbolt
Solution Approach 1:
The connection system is segmented into clamping segments with frictional locking surfaces that contact the bearing segments. This segmentation creates a friction-based locking mechanism that is more resistant to vibration-induced loosening compared to bolted connections, while still maintaining secure positioning of the flap in swivel positions
Solution Approach 2:
The bolted mechanical connection system is replaced with a friction-based clamping system. The clamping segments apply radial clamping force to the bearing segments, creating frictional locking that secures the flap position without requiring bolts that can loosen under vibration. This substitution eliminates the reliability issue of bolted connections while maintaining positioning stability
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
Enhances the operational safety and availability of the processing plant by preventing flap jamming and wear, ensuring reliable operation and secure positioning of the flap during vibrations.
Implementation Method 1
the clamping segment or segments assigned to a bearing segment form a bearing support for the bearing segment. the at least one bearing segment can be rotated therein from one swivel position to the other. If the clamping segment acts in a clamping manner on the at least one bearing segment, the bearing segment is held therein secured against co-rotation by means of frictional locking
Implementation Method 2
a screening unit, which can be oscillated by means of a vibration exciter. During operation, the flap then oscillates in conjunction with the screening unit, which is advantageous in preventing the fine material from accumulating on the surface of the flap
Data Source
AI summary
The invention relates to a processing plant, in particular a rock crusher (10), having a filler unit (20,), which can be filled with a material to be crushed, wherein a screening unit (30) is arranged downstream of the filler unit (20) in the conveying direction or in the filler unit (20), which screening unit can be oscillated by means of a vibration exciter (38), wherein the screening unit (30) is used to feed a first part of the supplied material to a process unit, in particular a crusher unit (40) and another part of the supplied material is screened-out in the screening unit (30), wherein a flap (72) of a conveyor unit (70) adjustable about a swivel axis (74.1) is used in a bypass position to feed the screened-out part of the material either onto a conveyor device, in particular a crusher discharge conveyor (60), bypassing the process unit, in particular the crusher unit (40), or, in a conveying position, to discharge the screened-out part of the material from a working area of the processing plant by means of a conveyor device (50), wherein bearing segments (75.1) of a bearing (75) are coupled to opposite sides of the flap (72), which are rotatably installed on the conveyor unit (70). It is suggested that at least one detachable clamping segment (80.1, 80.2) is assigned to at least one of the bearing segments (75.1), which acts in a clamping manner on the assigned bearing segment (75.1) and secures the latter in a swivel position of the flap (72) relative to the conveyor unit (70), such that in the swivel position the flap (72) is secured against rotation relative to the conveyor unit (70).