Flanged Roller Crusher Scraper Spacing for Wear Control
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Solution Overview
Problem
Roller crushers with flanges experience excessive stress and wear on the flanges and edges due to material build-up, leading to reduced crushing efficiency and increased downtime from scraper malfunctions.
Innovation Solution
A roller crusher design with flanges and scrapers positioned to maintain a minimum gap of at least 45 mm, with scrapers placed at least 70% of the gap distance from the roller surface, and a movement blocking arrangement to prevent closer roller separation, combined with a mechanical scraper and remote material removal device for selective and controlled material removal.
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 due to material build-up
Solution Approach 1:
The harmful material build-up is extracted or removed from the flange area using scrapers positioned at the roller ends. This prevents the build-up from causing excessive stress and wear on the flanges while maintaining the crushing efficiency provided by the flange structure.
Solution Approach 2:
Scrapers are introduced as intermediary elements between the material build-up and the flanges. These scrapers continuously remove material accumulation, acting as a mediator that protects the flanges from the harmful effects of material build-up while allowing the flanges to maintain their crushing function.
2Object-generated harmful factors
If scrapers are positioned close to roller surface for effective material removal, then material build-up is reduced, but scraper wear and malfunction increases
Solution Approach 1:
The scrapers are positioned to perform partial material removal rather than complete contact scraping. By removing material build-up without requiring intense contact pressure, the scrapers effectively reduce build-up while experiencing less wear and malfunction.
3Manufacturing precision
If flanges extend further radially to prevent material escape, then edge effect is reduced, but stress on flanges and scraper malfunction increases
Solution Approach 1:
Material build-up that causes excessive stress is extracted or removed by the scrapers. This allows the flanges to maintain their extended radial position for preventing material escape and ensuring crushing uniformity, without suffering from the harmful effects of material accumulation.
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, and a movement blocking arrangement structured and arranged to limit the gap between the rollers to a minimum gap of at least 45 mm, wherein the roller crusher further comprises at least one scraper positioned at an end of the roller with a flange, and wherein the scraper is positioned such that a minimum roller surface distance between each scraping surface of the at least one scraper and the outer surface of the roller is at least 70% of the minimum gap. The disclosure further relates to a method for arrangement of a roller crusher.