Roller Crusher Flange Cleaning to Reduce Edge Wear
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Solution Overview
Problem
Roller crushers with flanges experience excessive stress and wear at the flanges and edges due to material build-up, leading to reduced crushing efficiency and increased maintenance needs.
Innovation Solution
A combination of mechanical scrapers and remote material removal devices, such as fluid jet knives, are used to remove material build-up on the flanges and roller surfaces, with the scrapers operating continuously and the remote devices operating intermittently to minimize wear and maintain efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flanges are attached to roller ends to maintain crushing effect, then crushing efficiency is improved, but stress and wear on flanges increases
Solution Approach 1:
The patent extracts the harmful material build-up from the system by introducing scraping elements that continuously remove accumulated material from the flange surfaces and roller-end interfaces. This prevents the build-up from creating excessive stress concentrations and wear points, thereby maintaining flange strength while preserving the crushing efficiency provided by the flanges.
Solution Approach 2:
The scraping elements perform preliminary action by preventing material build-up before it can accumulate to harmful levels. By continuously scraping the flange surfaces and roller-end interfaces, the system maintains clean contact surfaces that distribute stress more evenly, preventing the development of high-stress zones that would lead to accelerated wear and potential flange failure.
2Strength
If mechanical scrapers are used to remove material build-up, then stress and wear on flanges is reduced, but scraper wear increases
Solution Approach 1:
The patent replaces purely mechanical scraping action with a hybrid system that incorporates high-pressure fluid jets (water or air). This substitution reduces the mechanical wear on scrapers by using fluid impact to loosen and remove material build-up, thereby extending scraper operational life while still effectively protecting the flanges from excessive stress and wear.
Solution Approach 2:
The patent introduces pneumatic (compressed air) or hydraulic (high-pressure water) systems to assist the mechanical scrapers. These fluid jets are directed at the material build-up on flanges and roller ends, where the high-velocity fluid impact breaks down and removes accumulated material, reducing the mechanical load and wear on the scraper elements themselves.
3Duration of action of moving object
If remote material removal devices are used intermittently, then scraper wear is minimized, but material build-up may accumulate between removal cycles
Solution Approach 1:
The patent implements continuous material removal action by combining always-active mechanical scrapers with periodically activated remote material removal devices. The mechanical scrapers provide continuous scraping action to prevent significant build-up accumulation, while the remote devices operate intermittently to perform deeper cleaning and reset the system, ensuring both extended scraper life and prevention of harmful material accumulation.
Solution Approach 2:
The patent employs periodic action through the remote material removal devices (high-pressure fluid jets) that operate at scheduled intervals. These periodic pulses of intense material removal complement the continuous mechanical scraping, creating a rhythm of maintenance that prevents harmful build-up accumulation while allowing scrapers to operate with reduced wear between intensive cleaning cycles.
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 system effectively reduces stress and wear on flanges and edges, enhances crushing efficiency, and prolongs the operational life of the scrapers by selectively removing material build-up, thereby improving the overall performance and reducing maintenance intervals.
Implementation Method 1
a remote material removal device configured to output a material removing beam towards a target area
Data Source
Figure 1~2B
Figure 3A~3C
Figure 4A~4D
AI summary
The disclosure relates to a roller crusher having two generally parallel rollers arranged to rotate in opposite directions, towards each other, and separated by a gap, each roller having two ends, the roller crusher comprising: a flange attached to at least one of the ends of one of the rollers, wherein the roller crusher further comprises at least one mechanical scraper and a remote material removal device configured to output a material removing beam towards a target area, wherein the at least one mechanical scraper and the remote material removal device are arranged consecutive to each other at an end of the roller with a flange for at least partially removing material accumulated on the flange and/or on the outer surface at the end of the roller. The disclosure further relates to a method for operating a roller crusher.