Impact Shield Removable Part for Crusher Armor Replacement
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Solution Overview
Problem
The existing impact grinding mills face challenges in efficiently and safely replacing the armor bodies on the impact shields due to their heavy mass and the need for individual removal within a limited and inaccessible grinding chamber, leading to prolonged downtime and increased operational risks.
Innovation Solution
The impact shield design incorporates a fixed part connected to the frame and a removable part carrying the armor bodies, allowing for simultaneous removal of all armor bodies outside the grinding chamber, facilitated by hook forming elements, fixing screws, and lifting eyelets, which simplifies and speeds up the replacement process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If armor bodies are fixed individually on the impact shield, then they can be replaced one by one inside the grinding chamber, but the replacement process becomes complicated and time-consuming
Solution Approach 1:
The impact shield is divided into a fixed part and a removable part. The removable part carries multiple armor bodies and can be detached as a single unit from the fixed part, allowing all armor bodies to be replaced simultaneously rather than individually. This segmentation resolves the contradiction by enabling quick replacement (reducing downtime) while maintaining the ability to service armor bodies inside the grinding chamber.
Solution Approach 2:
Multiple armor bodies are combined on a single removable part of the impact shield. This merging allows all armor bodies to be handled as one assembly, simplifying the replacement operation to a single detachment and attachment action, thereby reducing replacement time and operational complexity.
2Ease of operation
If armor bodies are removed one by one inside the grinding chamber, then replacement can be performed, but the operation becomes complicated due to limited space
Solution Approach 1:
The impact shield is segmented into fixed and removable parts. The removable part containing all armor bodies can be detached as a single unit, transforming a complex multi-step individual replacement process into a simple single-step operation, thereby reducing operational complexity.
Solution Approach 2:
The removable part with armor bodies is extracted from the fixed part of the impact shield. This extraction allows the armor bodies to be serviced as a separate assembly, simplifying the replacement operation and reducing the complexity of working within the limited grinding chamber space.
3Productivity
If armor bodies are removed inside the grinding chamber, then replacement can be performed, but it takes a lot of time and the mill remains unproductive
Solution Approach 1:
By segmenting the impact shield into fixed and removable parts, the armor bodies can be replaced as a single unit quickly inside the grinding chamber. This significantly reduces the time the mill remains unproductive, thereby improving overall productivity during maintenance operations.
Solution Approach 2:
The armor bodies are pre-assembled on the removable part of the impact shield. This preliminary assembly allows for quick replacement by simply detaching and reattaching the entire removable part, minimizing the time the mill is down and maximizing productivity.
4Reliability
If armor bodies are made of highly wear-resistant material, then they provide effective protection, but their considerable mass creates operational risks
Solution Approach 1:
The heavy armor bodies are segmented by mounting them on a removable part that can be easily detached. This allows the entire assembly to be quickly removed and replaced as one unit, reducing operational risks associated with handling heavy individual components and minimizing downtime during maintenance.
Solution Approach 2:
Multiple heavy armor bodies are merged onto a single removable part with connection means. This merging allows all armor bodies to be handled as one assembly, reducing the operational risk of handling individual heavy components while maintaining the protective function of the wear-resistant materials.
Data Source
AI summary
The impact shield (9, 10) carries a plurality of armor bodies (16) of a strongly wear resisting material. The armor bodies (16) are fixed horizontally in succession on a front side of the impact shield by a fixing element making it possible to detach them from the impact shield (9, 10) for their replacement. The impact shield (9, 10) is composed of a fixed part (21) connected to the frame (2), and a removable part (22) carrying the armor bodies (16) and making it possible to remove simultaneously all the armor bodies, fixed on the same, out of the grinding chamber (3). At least one such impact shield (9, 10) is arranged in a grinding chamber (3) of an impact grinding mill including a frame (2) further including a horizontal-axis rotor (6) provided with impactors (7) arranged regularly around its periphery.