Roller Crusher Scraper Layout for Flange Build-Up Removal
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Solution Overview
Problem
Roller crushers with flanges experience excessive stress and wear at the flanges and edges, leading to material build-up and potential damage, which existing scrapers fail to effectively manage, resulting in reduced efficiency and increased downtime.
Innovation Solution
A roller crusher design with at least two consecutively arranged scrapers and an optional remote material removal device to selectively remove material build-up on the flanges and outer surfaces, ensuring prolonged operational time and reduced downtime by distributing scraping responsibility and using mechanical and remote methods to manage build-up.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If flanges are attached to the ends of rollers to maintain crushing effect, then crushing uniformity is improved, but stress and wear on flanges increases leading to material build-up
Solution Approach 1:
The scraper system is segmented into multiple consecutively arranged scrapers (at least two) that work in sequence to remove material build-up from the flange and roller surface. This segmentation distributes the scraping function across multiple elements, preventing any single scraper from bearing excessive stress and wear, thereby addressing the durability issue while maintaining the crushing uniformity provided by the flanges.
Solution Approach 2:
The scrapers are positioned to remove material build-up before it accumulates to problematic levels that would compromise flange durability. By continuously scraping the flange and roller surface in the direction of rotation, the system performs preliminary removal of material that would otherwise build up and cause excessive stress and wear on the flanges.
2Ease of manufacture
If single scraper is used to remove material build-up, then maintenance is simplified, but scraper wear increases leading to more frequent replacements
Solution Approach 1:
The scraper system is divided into multiple consecutively arranged scrapers (at least two) that share the material removal task. Each scraper experiences reduced individual wear compared to a single scraper handling the entire load, thereby extending the operational life of each scraper element while maintaining effective build-up removal.
Solution Approach 2:
The scrapers are designed to be replaceable individual elements rather than a single integrated component. When one scraper becomes worn, it can be replaced independently while the other scrapers continue to function, extending the overall operational life of the scraper system and reducing downtime.
3Productivity
If flanges are used to prevent material escape at edges, then crushing efficiency is improved, but material build-up in transition zone increases stress and wear
Solution Approach 1:
The scrapers are positioned to continuously remove material build-up from the flange and roller surface in the direction of rotation, performing preliminary removal before the build-up can accumulate to levels that create excessive stress and wear on the flanges and roller edges.
Solution Approach 2:
The scraping action is locally applied at the critical transition zone between the roller surface and flange where material build-up occurs. By concentrating the material removal function at this specific location, the system maintains crushing efficiency provided by the flanges while preventing harmful stress accumulation from build-up in the transition 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, the flange extending in a radial direction of the roller, the flange having a height above an outer surface of the roller, wherein the roller crusher further comprises at least two scrapers 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.