Segmented Grinding Roll Edge Ring to Prevent Material Build-Up
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Solution Overview
Problem
Existing flanged roller crushers experience material build-up in the corners between the grinding roll and flange, leading to local loads and deformation, necessitating frequent operational halts for maintenance.
Innovation Solution
The grinding roll features angled wear protecting surfaces and a flange ring with removable segments, preventing material build-up by providing increased pressure and allowing for efficient replacement of worn parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flange is provided at each end of the grinding roll to prevent material escape, then crushing result along the entire width is improved, but material build-up occurs in the corner between the roll and flange leading to local loads and deformation
Solution Approach 1:
The edge ring is divided into multiple segments that can be independently removed and replaced. This segmentation allows for easy maintenance and removal of material build-up without requiring complete disassembly of the grinding roll assembly, thus resolving the contradiction between maintaining crushing uniformity and preventing material accumulation damage.
Solution Approach 2:
The edge ring segments are designed to be removable and replaceable during operation. This dynamic design allows the system to adapt to material build-up conditions by enabling easy access for cleaning and maintenance, preventing the harmful local loads from developing while maintaining the flange's crushing uniformity function.
2Reliability
If material build-up is removed with a scraper to prevent deformation, then damage to the flange and roll edge is prevented, but frequent operational halts are required reducing productivity
Solution Approach 1:
By segmenting the edge ring into removable sections, the design allows for quick removal and replacement of segments without requiring complete disassembly or frequent operational halts. This maintains flange integrity while minimizing productivity loss.
Solution Approach 2:
The segmented edge ring design enables easy self-maintenance where segments can be quickly removed and replaced by operators without requiring specialized tools or extensive downtime, thus maintaining reliability while preserving operational continuity.
3Strength
If the entire edge ring is used as a single piece, then structural integrity is maintained, but replacement of worn parts requires complete replacement increasing maintenance complexity
Solution Approach 1:
The edge ring is segmented into multiple sections that can be independently replaced. Each segment maintains sufficient structural integrity for its function, while worn segments can be replaced individually without replacing the entire edge ring, reducing maintenance complexity and costs.
Solution Approach 2:
The segmented design allows worn segments to be discarded and replaced with new ones while retaining the functional segments. This selective replacement approach maintains overall structural integrity while simplifying maintenance operations and reducing waste.
Data Source
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AI summary
The present disclosure relates to a grinding roll comprising a roll body having a cylindrical outer surface extending axially between a pair of opposite ends, and a side groove formed at each end of the roll body, the side groove including a support shoulder recessed from the cylindrical outer surface and/or from surfaces of the opposite ends of the roll body. The grinding roll further comprises an edge ring including a plurality of spaced receiving cavities, and a plurality of wear members, each wear member being received and retained in at least one of the receiving cavities of the edge ring. The wear members are positioned along the edge ring to define an edge of the grinding roll, and the edge ring is received within each side groove. The plurality of wear members is arranged to provide a wear protecting surface which is angled in relation to the cylindrical outer surface of the roll body. Providing an angled wear protecting surface prevents excessive build-up of material on the grinding roll and reduces the need for maintenance. A grinding assembly and an edge ring segment providing improved wear protection are also disclosed.