Roller Crusher Flange Design for Edge Material Containment
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Solution Overview
Problem
Existing high pressure grinding rollers face a significant edge effect, where material escapes over the edges, reducing crushing pressure and limiting the variability of roller diameter and width without compromising crushing results.
Innovation Solution
The introduction of a flange with a wear-resistant structure extending radially from the roller ends, featuring a feeding structure on its inside to maintain material within the crushing gap, preventing edge escape and allowing for greater variability in roller dimensions without reducing crushing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the roller diameter and roller width are increased to improve crushing capacity, then the crushing result is reduced at the edges due to material escape over the edges
Solution Approach 1:
The roller is segmented into a central crushing zone and edge zones with flanges. The flanges divide the roller surface into functional segments, with the central area performing primary crushing and the flange areas performing material containment and secondary compression, thereby maintaining uniform crushing results across different roller dimensions.
Solution Approach 2:
The solution transitions from a two-dimensional roller surface to a three-dimensional structure by adding flanges that extend radially outward. This dimensional change creates vertical barriers at the edges, preventing material escape and enabling larger roller widths without compromising edge crushing effectiveness.
2Quantity of substance
If the roller width is increased to handle larger material volumes, then material escape over the edges increases, reducing crushing pressure
Solution Approach 1:
The flanges perform preliminary containment of material before the main crushing action occurs. By preventing material from reaching the edges in the first place, the flanges ensure that crushing pressure is maintained across the entire roller width, allowing larger material volumes to be processed without pressure loss.
Solution Approach 2:
The flanges act as intermediary structures between the material feed and the crushing zone. They mediate material flow by directing it toward the central crushing area and preventing edge escape, thereby maintaining consistent crushing pressure regardless of roller width or material volume.
3Productivity
If the roller diameter is varied to optimize crushing performance, then the edge effect becomes more significant, reducing overall crushing efficiency
Solution Approach 1:
The flanges convert the harmful edge effect into a beneficial feature by using the roller edges as containment barriers. Instead of allowing material escape at the edges, the flanges utilize the edge locations to prevent escape and create additional compression zones, thereby transforming the edge effect from a disadvantage into an advantage for maintaining crushing efficiency.
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 flange enhances material engagement and pressure at the edges, enabling increased roller diameter and width variability while maintaining crushing effectiveness by preventing material from falling over the edges and facilitating an autogenous protection layer.
Implementation Method 1
The flange extends in a radial direction of the roller, and has a height above an outer surface of the roller... the flange comprises a wear-resistant structure to protect the flange from wear
Implementation Method 2
the structure comprises a feeding structure on the inside of the flange arranged to increase pressure on material towards the gap between the rollers
Implementation Method 3
the flange comprises a wear-resistant structure to protect the flange from wear
Data Source
Figure 1
Figure 2a~3b
Figure 4a~4b
AI summary
The invention relates to a roller crusher (1) having two generally parallel rollers (2) arranged to rotate in opposite directions, towards each other, and separated by a gap, each roller (2) having a first end (3) and a second end (4). The roller crusher (1) comprises a flange (5) attached to at least one of said ends (3, 4) of one of said rollers (2). The flange (5) extending in a radial direction of said roller (2), and has a height (H) above an outer surface (6) of said roller (2) which is sufficient to extend across said gap substantially along a nip angle (α) of said roller crusher (1).