External Rotor Positioning Device for Horizontal Shaft Impact Crushers
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Solution Overview
Problem
Existing rotor positioning devices for horizontal shaft impact crushers are either heavy, complex, and require internal access for maintenance, posing safety risks and increasing maintenance challenges.
Innovation Solution
An externally mounted rotor positioning device that allows for manual adjustment and locking of the rotor's rotational position without requiring internal access, using a shaft engager with a multi-toothed configuration and a gearbox for rotational drive, and an alignable indicator for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If an internally mounted powered positioning device is used, then the rotor can be adjusted automatically, but the device adds weight and increases complexity requiring internal access for maintenance
Solution Approach 1:
The positioning device is extracted from the internal mounting location and relocated to an external mounting position on the crusher frame. This allows the device to remain accessible for maintenance while still achieving the positioning function, thereby reducing internal construction complexity and eliminating the need for internal access during servicing.
Solution Approach 2:
The positioning device is designed as a separate, modular unit that can be independently mounted and removed from the crusher frame. This segmentation allows the positioning function to be separated from the main crusher structure, reducing overall system complexity and enabling easy maintenance without disassembling internal components.
2Reliability
If an internally mounted positioning device is used, then rotor positioning can be achieved, but access is required for servicing and maintenance
Solution Approach 1:
The positioning device is extracted from internal locations where it would require disassembly for maintenance, and relocated to an external position on the crusher frame. This external positioning maintains full rotor positioning capability while allowing direct access to the device for servicing without requiring internal access or disassembly of crusher components.
3Ease of operation
If manual adjustment by operator leaning into chamber is used, then rotor positioning is possible, but health and safety risks arise
Solution Approach 1:
The positioning device acts as an intermediary mechanism between the operator and the rotor. Instead of the operator directly accessing the rotor within the crushing chamber, the device provides a remote interface that transmits positioning commands to the rotor, thereby eliminating the need for personnel to enter the hazardous chamber while maintaining manual positioning capability.
Solution Approach 2:
The direct manual mechanical adjustment method is replaced with an externally mounted positioning device that uses a rod and indexing mechanism. This substitution eliminates the need for operators to physically lean into the crushing chamber, removing them from the hazardous environment while still enabling precise manual rotor positioning through the external device interface.
Data Source
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AI summary
A rotor positioning device (113) in a crusher (1) for adjusting a rotational position of a rotor shaft (6). A shaft engager (105) includes a female toothed mating surface (120) for coaxial engagement with a male mating surface (121) at an end of the rotor shaft (6), so they become rotationally interlocked. The shaft engager (105) includes alignable indicator slots (128) that are, in use, alignable with markings (129) associated with an end of the rotor shaft (6), such that said markings become visible through the slots (128) as the rod (104) is rotationally driven by a drive component (107, 108). The markings (129) correspond to hammer positions within the crusher, such that these can be manoeuvred for maintenance (e.g. to top dead-centre positions) before access to the crusher chamber is gained.