Roller Crusher Hydraulic Synchronization to Prevent Skewing
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Solution Overview
Problem
Roller crushers experience skewing issues due to uneven material distribution and varying material properties, leading to compromised seals and unwanted contact between rollers and flanges, which complicates the use of flanged rollers.
Innovation Solution
A hydraulic system with synchronized main and synchronizing pistons and cylinders that maintain parallel movement of rollers, preventing skewing by fluidly connecting compression and rebound chambers to ensure synchronized movement of the movable bearing housings, thus maintaining optimal crushing pressure and reducing the need for external control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a hydraulic system with independent main cylinders is used to bias the movable roller, then sufficient crushing pressure is delivered, but skewing occurs due to unsynchronized movement of bearing housings
Solution Approach 1:
The patent combines the main cylinders and synchronizing cylinders into a single integrated hydraulic system. The main cylinders provide crushing force while the synchronizing cylinders ensure coordinated movement of both bearing housings. This merging of functions into one unified system resolves the contradiction by ensuring that both crushing pressure and parallelism are maintained simultaneously during operation.
Solution Approach 2:
The synchronizing cylinders act as intermediary components between the main cylinders and the bearing housings. These intermediate elements specifically address the parallelism issue by ensuring synchronized movement, while the main cylinders continue to provide the primary crushing force. This intermediary mechanism resolves the contradiction by separating the force application function from the synchronization function.
2Strength
If flanged rollers are used in the crusher, then structural integrity is improved, but skewing causes unwanted contact between rollers and flanges
Solution Approach 1:
The patent converts the potential harm of skewing into a benefit by using the hydraulic system with synchronizing cylinders to actively prevent skewing. The system monitors and corrects any tendency toward skewing by adjusting the position of bearing housings, thereby protecting the flanged rollers from unwanted contact while maintaining the structural integrity benefits of flanged design.
3Stability of the object's composition
If a complex hydraulic control system is implemented to prevent skewing, then roller parallelism is maintained, but device complexity increases
Solution Approach 1:
The hydraulic system is designed to be self-regulating through the interaction between main cylinders and synchronizing cylinders. The synchronizing cylinders automatically adjust bearing housing positions based on the operational state, without requiring complex external control systems. This self-service mechanism maintains parallelism while minimizing the need for complex external control infrastructure.
Solution Approach 2:
The system incorporates inherent feedback mechanisms where the movement of one bearing housing influences the other through the hydraulic fluid connection and synchronizing cylinder design. This passive feedback ensures that any deviation from parallelism is automatically corrected, maintaining stability without requiring complex active control systems with sensors and actuators.
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 hydraulic system effectively prevents skewing, ensuring consistent crushing pressure and reducing the risk of seal compromise and unwanted contact, while allowing for efficient retrofitting and minimizing manufacturing changes.
Implementation Method 1
a first main hydraulic chamber for controlling the force exerted by the first main piston, a second main hydraulic chamber for controlling the force exerted by the second main piston
Implementation Method 2
the first compression chamber is fluidly connected to the second rebound chamber and the first rebound chamber is fluidly connected to second compression chamber
Data Source
AI summary
A hydraulic system for a roller crusher including a first main cylinder connectable to a first movable bearing of the roller crusher, a second main cylinder connectable to a second movable bearing of the roller crusher, a first crossing cylinder to the first movable bearing of the roller crusher, a second crossing cylinder connectable to the second movable bearing of the roller crusher. A first compression chamber of the first crossing cylinder is fluidly connected to a second rebound chamber of the second crossing cylinder, and the first rebound chamber of the first crossing cylinder is fluidly connected to the second compression chamber of the second crossing cylinder.