Interlocking Liner Segments for Tumbling Units
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Solution Overview
Problem
Existing interlocking liners for tumbling units require frequent re-tightening and replacement due to bolt wear and loosening, leading to significant downtime and maintenance costs, especially in continuously operated units.
Innovation Solution
An interlocking liner system with lifter portions, rifling, and locking pins that allows segments to securely fit together without bolts, enabling continuous operation and extended lifespan by maintaining tightness and preventing segment separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bolts are used to secure liner segments to the drum shell, then the liner can be easily installed and segments can be replaced, but the bolts wear down and loosen over time requiring frequent re-tightening and replacement
Solution Approach 1:
The liner is divided into multiple replaceable segments that can be independently installed and removed. Each segment has integrated locking features that eliminate the need for separate fasteners, allowing easy replacement while maintaining secure retention during operation.
Solution Approach 2:
The locking mechanism is merged directly into the liner segment structure itself. The segments incorporate integrated locking features such as protrusions, recesses, or interference-fit elements that combine the functions of the liner body and fastening components into a single unified structure.
2Reliability
If bolts are used to secure the liner, then the liner can be retained on the drum, but the constant re-tightening causes significant downtime in continuously operated units
Solution Approach 1:
The locking mechanism is pre-configured during liner manufacturing with precision-machined locking features. This preliminary action ensures proper alignment and engagement geometry, allowing the segments to lock automatically upon installation without requiring operational adjustments or re-tightening during continuous operation.
Solution Approach 2:
The liner segments perform self-locking through their integrated locking features. The design includes self-aligning protrusions and recesses, or interference-fit elements, that automatically engage when segments are assembled, eliminating the need for external fasteners or operational re-tightening by maintenance personnel.
3Duration of action of stationary object
If bolts are recessed to protect them, then they are less exposed to wear, but once the liner wears to the recess level, the bolt heads are worn away requiring complete liner replacement
Solution Approach 1:
The liner segments are designed as disposable or limited-life components with integrated locking features. Rather than attempting to protect and extend the life of fasteners, the entire segment is designed to be replaced after a predetermined service life, at which point both the liner and its locking features are renewed together as a single unit.
Solution Approach 2:
The locking mechanism is merged directly into the liner segment structure itself. The segments incorporate integrated locking features such as protrusions, recesses, or interference-fit elements that combine the functions of the liner body and fastening components into a single unified structure that is replaced as one unit.
Data Source
AI summary
An interlocking liner segment for a tumbling unit is disclosed which comprises a body having an inner surface having a first end and a second end, an outer surface, a first side edge, a second side edge opposite the first side edge, a front edge, and a back edge, a first lifter portion at the first end having a first aperture; a second lifter portion at the second end having a second aperture; and a rifling portion on the inner surface intermediate the first lifter portion and the second lifter portion.