Roller Crusher Deflection Distributor for Skewing and Uneven Loads
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Solution Overview
Problem
Roller crushers experience skewing and uneven feed distribution due to non-uniform material characteristics, leading to unbalanced loads, wear, and premature failure of mechanical components, particularly in high-pressure grinding applications.
Innovation Solution
A deflection distributor refitting kit with a deflection distributing shaft, thrust rods, and a preload arrangement to maintain parallel movement of crusher rolls, reducing mechanical wear and compensating for uneven loads, and incorporating flanges to ensure uniform material feed and pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high compression forces are applied to achieve interparticle crushing, then productivity and energy efficiency are improved, but mechanical components experience increased wear and premature failure
Solution Approach 1:
The patent applies beforehand cushioning by introducing a deflection distributor with spring elements that anticipate and absorb uneven load distributions before they can cause damage. The spring elements act as preemptive shock absorbers that cushion the mechanical components against the high compression forces and uneven feeds, allowing the system to operate at high productivity while protecting components from premature failure due to unbalanced loads
2Adaptability or versatility
If the gap width is adjusted to handle varied material feed characteristics, then adaptability is improved, but skewing occurs leading to unbalanced loads
Solution Approach 1:
The patent implements feedback through the deflection distributor system that continuously monitors and responds to uneven load distributions on the crusher rolls. When skewing occurs due to varied material characteristics, the spring elements detect the deflection and automatically adjust the gap width distribution along the roll length, providing real-time feedback control that maintains parallelism while preserving adaptability to different material feeds
3Productivity
If choke feeding is applied to maintain particle-on-particle compression, then productivity is improved, but unbalanced feeds cause skewing and unbalanced loads
Solution Approach 1:
The patent introduces the deflection distributor as an intermediary element between the feed material and the crusher rolls. This intermediary system with spring elements absorbs and redistributes the uneven forces generated by non-uniform choke feeding, allowing high productivity through continuous feeding while mediating the negative effects of feed unbalance that would otherwise cause skewing and unbalanced loads on the mechanical components
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 solution effectively maintains parallel movement of crusher rolls, reducing mechanical wear, enhancing efficiency, and increasing uptime by up to 20%, while minimizing vibrations and shock loads, and optimizing wear profiles.
Implementation Method 1
a hydraulic system configured to adjust the position of the second crusher roll and the crushing pressure between the two crusher rolls
Implementation Method 2
spring elements arranged to compensate for unbalanced loads on the crusher rolls
Data Source
AI summary
Disclosed is a deflection distributor refitting kit for a roller crusher. According to the disclosure the deflection distributor refitting kit comprises a deflection distributing shaft, thrust rods each having first and second ends and mounts for attachment of the deflection distributing shaft at a frame of the roller crusher, wherein a first end of each of said thrust rods is attached to the deflection distributing shaft via a lever, wherein a second end of each of the thrust rods is arranged to be attached to a movable bearing housing of the roller crusher, and wherein the deflection distributor refitting kit further comprises a preload arrangement which induces a bias to parts of the deflection distributor refitting kit. Also disclosed is a method for mounting the deflection distributor refitting kit, as well as a roller crusher comprising a deflection distributor.