Modular Agitator Shaft for Ball Mill Wear Reduction
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Solution Overview
Problem
Agitator shafts in agitator ball mills experience high wear, leading to frequent replacements and significant maintenance costs, as they activate grinding aids that cause wear on both the agitator and grinding container.
Innovation Solution
A modular agitator shaft with releasably connected modules, featuring a base plate and segments with positive and non-positive connections, allowing for easy detachment and replacement of worn grinding elements, thereby extending the service life and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the agitator shaft is designed as a solid integrated component, then it has high structural strength and reliability, but it cannot be easily replaced or maintained, leading to high maintenance costs and downtime
Solution Approach 1:
The agitator shaft is divided into modular segments (first module, second module, etc.) that can be independently removed and replaced. Each module contains grinding elements that can be separately maintained, allowing partial replacement without dismantling the entire shaft structure.
Solution Approach 2:
The connection between modules and the agitator shaft is designed to be dynamically changeable - modules can be attached during operation and detached for maintenance. The claw-like connection elements enable quick attachment/detachment without permanent fastening.
2Productivity
If grinding elements are permanently fixed on the agitator shaft, then they provide consistent grinding performance, but worn elements cannot be replaced without replacing the entire agitator
Solution Approach 1:
Grinding elements are segmented and arranged on separate modular sections of the agitator shaft. This allows individual modules with worn grinding elements to be identified and replaced independently, maintaining consistent grinding performance while reducing maintenance frequency through targeted replacement.
Solution Approach 2:
Worn grinding elements on removable modules can be discarded and replaced with new modules, while the remaining functional modules are retained and reused. This recovers valuable components and reduces overall maintenance costs and frequency.
3Duration of action of stationary object
If the agitator shaft is designed with replaceable modules, then maintenance becomes easier and service life extends, but the connection mechanisms add complexity and potential failure points
Solution Approach 1:
Multiple connection functions (positive locking, force fitting, alignment) are merged into a single integrated claw-like connection element. This reduces the number of separate connection components and potential failure points while maintaining high connection reliability and enabling easy module replacement.
Solution Approach 2:
The claw-like connection elements serve multiple functions simultaneously: providing positive locking engagement, allowing force-fit attachment during operation, ensuring proper module alignment, and enabling quick release for maintenance. This multi-functionality reduces complexity while extending service life.
Data Source
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AI summary
The present invention relates to the agitator shaft for a stirred ball mill of modular construction. This modular agitator shaft consists of a rotor and a solid shaft. At least two grinding elements are arranged on the rotor and on the solid shaft. The at least two grinding elements are arranged on at least two modules, at least in the region of the solid shaft. The at least two modules are detachably connected to the agitator shaft in the region of the solid shaft by a positive-locking and/or force-locking connection.