Roller Crusher Wedge Adjustment for Overload Protection
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Solution Overview
Problem
Eccentric roll crushers face challenges with clogging and damage due to hard foreign substances, requiring large and complex overload protection systems, which are difficult to adjust and can lead to undefined operating states and incorrect grain sizes.
Innovation Solution
A wedge-based adjustment device that transmits force to a stationary abutment, allowing for precise adjustment of the crushing gap and incorporating an overload protection mechanism where the wedge moves to expand the crushing space upon overload, using a combination of mechanical and hydraulic components for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large stable springs are used for overload protection, then the rocker can withstand normal breaking stress, but the device becomes complex and difficult to adjust
Solution Approach 1:
The patent replaces the traditional spring-based mechanical overload protection system with a hydraulic support system. The hydraulic cylinder provides the necessary support force through fluid pressure, eliminating the need for large stable springs and their associated adjustment mechanisms, thus reducing device complexity while maintaining reliability.
Solution Approach 2:
The patent introduces a hydraulic support system using a hydraulic cylinder to replace the mechanical spring support. The hydraulic system provides controlled support force and enables easier adjustment of the rocker position, solving the contradiction between reliability and device complexity by using fluid mechanics instead of mechanical springs.
2Reliability
If springs are used for overload protection, then the rocker can expand the crushing chamber, but large spring forces continue to act during springing back causing potential damage
Solution Approach 1:
The patent replaces the spring-based mechanical system with a hydraulic support system. The hydraulic cylinder can control the support force more precisely and release it smoothly, preventing the excessive forces during retreat that occur with spring systems, thus eliminating the harmful effects while maintaining the overload protection function.
3Reliability
If springs are used for support, then the rocker can be supported, but an undefined transitional area occurs where springs are only partially compressed leading to incorrect grain size
Solution Approach 1:
The patent uses a hydraulic support system instead of springs. The hydraulic cylinder provides controlled and consistent support force through fluid pressure, eliminating the undefined transitional areas that occur with partially compressed springs. This ensures consistent crushing gap and correct grain size production while maintaining rocker support stability.
4Ease of operation
If electromagnets are used for overload protection, then the rocker can be released without significant counterforce, but large currents are required and the electromagnet must be dimensioned accordingly
Solution Approach 1:
The patent replaces the electromagnet-based release mechanism with a hydraulic support system. The hydraulic cylinder can be controlled to release the rocker smoothly without requiring large currents, as the hydraulic fluid can be diverted or pressure reduced easily. This maintains ease of operation while significantly reducing energy consumption compared to large electromagnets.
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
Enables accurate adjustment of the crushing gap, reduces the need for large spring forces, and provides effective overload protection, minimizing damage and maintaining consistent grain size production.
Implementation Method 1
the wedge (8) which is arranged in a gap between a contact surface (9) formed on the rear side of the rocker (4) and a counter surface (10) assigned to the abutment (7)... a large part of the force acting on the rocker is transmitted via the wedge to the stationary abutment
Implementation Method 2
the wedge (8) is pushed in the direction of the second position by the forces acting on the rocker (4)... when a predetermined force is applied to the rocker arm, the wedge (8) is pushed in the direction of the second position by the forces acting on the rocker (4)
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The invention relates to a roller crusher comprising a housing frame (1), a rotatable roller (2), an oscillating arm (4) mounted on an oscillating arm axis (3) on a housing frame (1), a crusher chamber (5) between the roller (2) and the oscillating arm (4), and an adjustment device (6) which is arranged at a distance to the oscillating arm axis (3) between said oscillating arm (4) and an abutment (7) which is stationary with respect to the housing frame (1), in order to enable said oscillating arm (4) to rotate about the oscillating arm axis (3). According to the invention, the adjusting device (6) comprises a wedge (8) which is arranged between the oscillating arm (4) and the abutment (7), said wedge bridging a gap between a bearing surface (9) arranged on a rear side of oscillating arm and a counter surface (10) associated with the abutment (7). The distance between the oscillating arm (4) and the roller (2) is, in the second position (P2) of the wedge (8) in the gap, greater than in a first position (P1) of the wedge in the gap.