Impact Bar Trapezoidal Ribs Utilization Factor
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Solution Overview
Problem
Impact bars in impact crushers face high stress and wear issues due to suboptimal holding and utilization factors, leading to premature failure and economic inefficiencies, as the holding region is either too small, causing stress, or too large, resulting in unused material.
Innovation Solution
The impact bar design features trapezoidal longitudinal ribs with specific flank angles and a wider central region for secure anchoring, allowing for reversible operation and high utilization, with the inner flanks supporting forces and torque transmission, reducing stress and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the holding region of the impact bar is made small to increase utilization factor, then the utilization factor is improved, but the impact bar is exposed to high stress and may break
Solution Approach 1:
The impact bar features a non-uniform cross-section with a wider holding region (greater width in x-direction) and a narrower impact region. This local variation in geometry concentrates material where needed for strength (holding region) while minimizing material where wear occurs (impact region), thereby increasing utilization factor without compromising overall reliability.
2Reliability
If the holding region of the impact bar is made large to reduce stress, then the reliability is improved, but significant material parts are not used for contact with material
Solution Approach 1:
The impact bar features a non-uniform cross-section with a wider holding region (greater width in x-direction) and a narrower impact region. This local variation in geometry concentrates material where needed for strength (holding region) while minimizing material where wear occurs (impact region), thereby increasing utilization factor without compromising overall reliability.
3Ease of operation
If the impact bar is designed with symmetric longitudinal ribs for secure mounting, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The impact bar features longitudinal ribs with asymmetric cross-sections: the inner flanks have a specific inclination angle (20°-27°) relative to the x-direction, while the outer flanks have a different geometry. This asymmetric design provides secure mounting through form-fit engagement with the rotor while maintaining manufacturing simplicity through symmetric arrangement of the ribs themselves.
Data Source
AI summary
An impact bar for installation in an axis-parallel impact bar mount of a rotor of an impact crusher includes front-side and backside holding regions between end faces, and longitudinal ribs projecting beyond the end faces. Each holding region is bordered by two longitudinal ribs which have a trapezoidal cross section to define a base and a topside at a distance to the base, with the base being wider than the topside. The longitudinal ribs have each an inner inclined flank and an outer flank, with the inner and outer flanks extending between the base and the topside and with the inner flank extending at a flank angle of 20° to 27° in relation to the x direction and configured such that only the inner flank is supportable in the installation position for transmission of a force into the impact bar mount at the rotor.