Multi-Roller Mill Segmentation for Wear Reduction
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Solution Overview
Problem
Existing grinding technologies, such as tube-ball mills and high-pressure roller presses, face inefficiencies due to asymmetrical grinding processes, high energy demands, and excessive wear-and-tear, which are not effectively addressed by existing multi-roller press designs.
Innovation Solution
A mill design featuring a main grinding roller with guide rings and at least three smaller grinding runners, equipped with compression devices and antifriction bearings, where the first runner has a drive and the others induce thrust through hydraulic or pneumatic cylinders, using abrasion-resistant materials to enhance grinding efficiency and reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If tube-ball mills are used for grinding materials, then grinding capability is achieved, but energy efficiency is low due to asymmetrical grinding process
Solution Approach 1:
The grinding process is segmented into multiple stages with three grinding rollers of different diameters working in sequence. Each roller handles a specific portion of the grinding task, creating a systematic approach that improves both energy efficiency and productivity compared to single-stage grinding methods.
Solution Approach 2:
The patent intentionally uses asymmetrical roller diameters (D1 > D2 > D3) to create optimal grinding conditions at each stage. The largest roller performs coarse grinding, medium roller handles intermediate grinding, and smallest roller completes fine grinding, resolving the contradiction between energy efficiency and grinding effectiveness.
2Productivity
If high-pressure roller presses are used to complete grinding in one pass, then productivity is improved, but wear-and-tear increases due to high thrust
Solution Approach 1:
Instead of applying high pressure in a single pass, the grinding process is divided into three sequential passes with progressively smaller rollers. This segmentation distributes the wear across multiple components and passes, reducing the thrust burden on each individual roller while maintaining high productivity.
Solution Approach 2:
Each grinding roller is designed with specific local characteristics (different diameters, positions, and thrust requirements) optimized for its specific grinding stage. The first roller handles coarse material with higher thrust, while subsequent rollers handle progressively finer material with reduced thrust, minimizing overall wear.
3Force
If high thrust is applied in high-pressure roller presses, then grinding effectiveness is improved, but manufacturing costs increase due to robust structure requirements
Solution Approach 1:
The total required thrust is segmented across three rollers rather than concentrated on one or two rollers. Each roller operates at lower thrust levels, allowing for lighter, less expensive structural support systems while maintaining overall grinding effectiveness through the cumulative action of all three rollers.
Solution Approach 2:
The system dynamically distributes the grinding load across multiple rollers with different characteristics. The variable thrust requirements of each roller (based on material stage and roller size) allow for optimized structural design that reduces manufacturing costs compared to uniformly high-thrust systems.
4Reliability
If grinding rollers are made smaller to reduce wear, then reliability is improved, but grinding capability decreases
Solution Approach 1:
Grinding capability is maintained by segmenting the process into three stages with rollers of progressively smaller sizes. The cumulative grinding action of all three rollers equals or exceeds that of a single large roller, while each smaller roller experiences reduced wear. The segmentation allows smaller rollers to collectively perform the work of larger rollers.
Solution Approach 2:
The system changes multiple parameters simultaneously: roller diameter (D1 > D2 > D3), roller position, and thrust force. These coordinated parameter changes ensure that smaller rollers maintain adequate grinding capability while experiencing reduced wear, resolving the contradiction between reliability and productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The mill achieves improved energy efficiency and reduced wear by ensuring symmetrical grinding, controlled material distribution, and adjustable thrust, leading to enhanced grinding performance and lower operational costs.
Implementation Method 1
Guide grooves are fitted with lubrication channels and lined along their circumference with sliding plates with lubrication grooves
Implementation Method 2
The first grinding runner is equipped with its own drive by means of extended ends of its shaft, protruding from bearing houses, accommodating said driven shaft in the antifriction bearings
Implementation Method 3
All grinding runners are equipped with devices providing their thrust to the main grinding roller
Data Source
Figure 1
Figure 2~5
Figure 6~7
AI summary
The mill for grinding of materials of different hardness and grain size comprises drives (8, 23) and the body (4), equipped with the hopper (5) and the discharge hopper (6), accommodating the main grinding roller (1), seated in a rotating manner and driven by the main drive (8), equipped with the replaceable abrasion-resistant tire and from both sides fitted with guide rings along the circumference, overlapping its diameter, arranged in a manner to prevent ground stock leakage from the grinding slot. In addition, at least three smaller grinding runners (2, 3, 33, are accommodated in the body (4) of the mill, in a rotating and sliding manner, whose axes are parallel to the axis of the main grinding roller (1), arranged in the direction of its rotation along its circumference between the hopper (5) and the discharge hopper 6. All grinding runners (2, 3, 3') are equipped with compression devices (7) providing their thrust to the main grinding roller (1) and the first grinding runner (2) is fitted with its own drive by means of extended ends of its shaft (9), protruding from bearing houses (11), where the driven shaft (9) is seated in antifriction bearings (12). Bearing houses (11) of grinding runners (2, 3, 3') are fitted with guide grooves (13), arranged to fit into the guide in sidewalls of the body (4) of the mill, whereas said guide grooves (13) are fitted with lubrication channels (16) and lined along their circumference with the sliding plates (14) with lubrication grooves (15), whereas bearing houses (11) of the first grinding runner (2) are coupled by the crossbeam (18), to which is leaned the push rod (17) of compression devices (7) via axial ball bearings (19).