HPGR Roll Assemblies with Superhard Stud Inserts

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Solution Overview

Problem

High Pressure Grinding Roll (HPGR) apparatuses face challenges in extending the useful life of their roll assemblies due to wear and tear, particularly in the stud elements that compress and crush materials, leading to reduced efficiency and increased maintenance costs.

Innovation Solution

The use of superhard stud elements, such as those made from polycrystalline diamond or tungsten carbide, secured to the roll body to form a crushing exterior, providing superior wear resistance and extending the operational life of the HPGR apparatuses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If conventional stud elements are used in HPGR roll assemblies, then the apparatus can perform basic crushing function, but the stud elements wear out quickly reducing useful life

Engineering Contradiction:

Improveuseful life of roll assemblyVSAvoidwear resistance of stud elements

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The patent applies composite materials by combining a base roll body material with superhard stud element material (such as cubic boron nitride or diamond). This composite structure allows the roll assembly to maintain both structural integrity and exceptional wear resistance, directly resolving the contradiction between useful life and wear resistance by using materials that are inherently more durable in the crushing environment.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the hardness parameter of the stud elements from conventional materials to superhard materials with significantly higher hardness values. This parameter change transforms the wear resistance characteristic, allowing the stud elements to withstand the crushing action and friction forces much longer, thereby extending the useful life of the roll assembly.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If superhard stud elements are secured to roll body, then wear resistance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvewear resistance of stud elementsVSAvoidmanufacturing complexity of roll assembly

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent segments the roll assembly into distinct components: the roll body and the stud elements. This segmentation allows each component to be manufactured separately using optimized processes, then assembled together. The stud elements can be pre-fabricated with their superhard coating or insertions, simplifying the overall manufacturing process while maintaining the wear resistance benefits.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces an intermediary layer or bonding mechanism between the roll body and the superhard stud elements. This intermediary (such as a bonding agent, mechanical interference fit, or intermediate substrate) facilitates the attachment of the superhard material to the roll body, making the manufacturing process more manageable while ensuring durable attachment that maintains wear resistance.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If stud elements are compressed and crushed to reduce material size, then productivity is improved, but the stud elements experience increased wear

Engineering Contradiction:

Improvecrushing efficiencyVSAvoidmaterial loss from stud element wear

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent uses composite materials where the stud elements are made from or coated with superhard materials like cubic boron nitride or diamond. These materials have hardness values significantly higher than conventional stud elements, allowing them to withstand the compressive and abrasive forces of crushing operations much longer, thereby reducing material loss from wear while maintaining high crushing efficiency.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the hardness parameter of the stud elements to superhard levels, which fundamentally alters their wear characteristics. This parameter change enables the stud elements to resist the material loss that would otherwise occur during high-productivity crushing operations, allowing continuous operation without frequent replacement.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9492827B2Roll assemblies including superhard inserts, high pressure grinder roll apparatuses using same, and methods of use

Publication Date: 2016.11.15 US SYNTHETIC CORP

AI summary

Embodiments of the invention are directed to roll assemblies configured to exhibit improved wear resistance of stud elements. Accordingly, the roll assemblies of may improve and/or increase the useful life of high pressure grinding roll apparatuses. In an embodiment, one or more stud elements may include superhard material, which may provide superior wear resistance characteristics and may increase the useful life of the rolls assemblies and high pressure grinding roll apparatuses.