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, which affects the crushing efficiency.

Innovation Solution

The implementation of flanges extending radially from the rollers' ends, with a height sufficient to cover the gap along the nip angle, prevents material from falling off and allows for increased pressure and the formation of an autogenous protection layer, enabling the rollers' diameter and width to be varied without reducing crushing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the roller diameter and roller width are varied to optimize crushing performance, then crushing efficiency can be improved, but material escapes over the edges reducing crushing pressure at the edges

Engineering Contradiction:

Improvecrushing efficiencyVSAvoidmaterial escape at edges

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The roller is segmented into a central crushing zone and edge zones, with the flange providing a separate structural element at the edges to contain material while the central zone performs crushing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flange acts as an intermediary element between the roller and the material, providing a containing structure that prevents material escape while allowing the roller to maintain its crushing function

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the roller width is increased to handle wider material feeds, then processing capacity increases, but edge effects become more significant reducing overall crushing pressure

Engineering Contradiction:

Improveprocessing capacityVSAvoidcrushing pressure at edges

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The roller system is segmented into active crushing surface and edge containment zones, allowing the crushing pressure to be maintained in the central region while the flange handles edge containment

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different parts of the roller system have different functions: the central roller surface provides crushing pressure while the flange provides edge containment, allowing each part to be optimized for its specific function

Inventive Principle:

Principle #3Local quality

3Volume of moving object

If the roller diameter is reduced to achieve compact design, then space requirements decrease, but the edge effect becomes more pronounced reducing crushing effectiveness

Engineering Contradiction:

Improveroller sizeVSAvoidcrushing effectiveness

Core Design Contradiction:

Volume of moving objectVSProductivity

Solution Approach 1:

The solution moves from a two-dimensional roller surface problem to a three-dimensional structure by adding the flange dimension, which provides edge containment without requiring a larger roller diameter

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10493460B2Roller crusher having at least one roller comprising a flange

Publication Date: 2019.12.03 METSO OUTOTEC USA INC

AI summary

The invention 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 a first end and a second end. The roller crusher comprises a flange attached to at least one of said ends of one of said rollers. The flange extending in a radial direction of said roller, and has a height above an outer surface of said roller which is sufficient to extend across said gap substantially along a nip angle of said roller crusher.