Roll Crusher Teeth Staggering for Load Leveling
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Solution Overview
Problem
The existing roll crusher designs for cement clinker cooling in cooler apparatuses experience extreme load fluctuations, requiring powerful rotating units with large external dimensions and high power consumption, which is undesirable for size and energy efficiency.
Innovation Solution
The arrangement of crushing teeth on the rolls is shifted in the circumferential direction to distribute load evenly, using multiple types of teeth with different heights and staggered configurations, allowing for alternating high and low teeth to manage load distribution and reduce manufacturing costs by using fewer types of molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple crushing teeth are arranged on the rolls to crush clinker more efficiently, then crushing efficiency is improved, but roll load increases extremely in a particular period
Solution Approach 1:
The crushing teeth are segmented into multiple groups with different circumferential positions. Specifically, crushing teeth are arranged at multiple circumferential locations on the roll surface, so that not all teeth engage simultaneously. This segmentation distributes the crushing load across different time periods as the roll rotates, preventing extreme load concentration while maintaining effective crushing capability.
Solution Approach 2:
The roll rotates continuously, creating a periodic action where different sets of crushing teeth engage with the clinker at different times. By arranging teeth at multiple circumferential positions, the system creates a periodic distribution of loading, where the load on any single tooth or local area varies over time, thereby reducing peak loads while maintaining overall crushing efficiency.
2Reliability
If a rotating unit capable of generating great driving force is used to handle peak roll load, then reliability is improved, but external dimensions and power consumption increase
Solution Approach 1:
By segmenting the crushing teeth into multiple groups at different circumferential positions, the peak load on the roll is reduced. This segmentation allows the use of a smaller, more energy-efficient rotating unit that does not need to generate excessive driving force to handle maximum peak loads, while still maintaining reliable operation throughout the rotation cycle.
Solution Approach 2:
The arrangement parameters of the crushing teeth are optimized by changing their circumferential distribution. By adjusting the angular positions and spacing of teeth, the load profile over time is modified to reduce peak values. This parameter optimization allows the rotating unit to operate with lower power consumption while maintaining sufficient driving force for the actual operating conditions.
Data Source
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AI summary
Provided is a roll crusher of a cooler apparatus, the roll crusher being capable of leveling out temporal changes in the roll load. A roll crusher 15 of a cooler apparatus 1 includes a plurality of load-reducing rolls 15a and 15b. The load-reducing rolls 15a and 15b are arranged side by side in a conveying direction such that a gap S1 is formed therebetween, and are rotated about respective rotational axes L1 and L2 by corresponding rotating units to crush cement. The load-reducing rolls 15a and 15b include a plurality of crushing rings 22 and 23 and a plurality of crushing rings 32 and 33, respectively. Crushing teeth 24 and 27 are formed on outer peripheral surfaces of the crushing rings 22 and 23 at a regular pitch p1, and crushing teeth 34 and 35 are formed on outer peripheral surfaces of the crushing rings 32 and 33 at a regular pitch p2. The crushing teeth 27 and 35 are arranged such that they are shifted relative to the adjacent crushing teeth 24 and 34 in a circumferential direction.