Screen Cloths With Brazed Anti-Wear Tiles
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Solution Overview
Problem
Vibrating screens used in oil sand slurry processing experience rapid spalling and wear due to the abrasive nature of the slurry, leading to frequent maintenance interruptions, as larger gaps between anti-wear tiles on the screen cloths increase stress concentration and corrosion, causing fatigue cracking and failure.
Innovation Solution
The use of screen cloths with anti-wear tiles spaced less than 0.5 mm apart, where the brazing material fills the gaps through capillary action, connecting the tiles and reducing stress concentration, thereby enhancing wear resistance and preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If larger gaps (1-3 mm) are provided between anti-wear tiles, then the tiles are protected from compressive stresses and edge breakage, but stress concentration in the screen support structure increases and corrosion accelerates at gap locations
Solution Approach 1:
The patent introduces brazing material as an intermediary substance that fills the gaps between anti-wear tiles. This brazing material serves as a mediator that connects adjacent tiles and distributes stresses, preventing both tile edge breakage and stress concentration in the support structure. The brazing material creates a continuous load path that eliminates the harmful effects of large gaps while maintaining the protective function of the tiles.
Solution Approach 2:
The patent merges the previously separate elements (tiles and support structure) by using brazing material to create a unified, continuous structure. The brazing material bonds the tiles to each other and to the support structure, eliminating the discontinuities created by gaps. This merging creates a composite structure that distributes stresses evenly and prevents corrosion pathways.
2Strength
If anti-wear tiles are attached to screen support structure, then wear resistance is improved, but stress concentration and corrosion at tile gaps lead to fatigue cracking and failure
Solution Approach 1:
The brazing material acts as an intermediary that eliminates the discontinuities between tiles and the support structure. By filling the gaps, it prevents corrosion pathways and distributes cyclic stresses evenly, thereby preventing fatigue cracking while maintaining the wear resistance provided by the anti-wear tiles.
Solution Approach 2:
The patent creates a composite structure consisting of anti-wear tiles, brazing material, and screen support structure. This composite construction combines the wear resistance of the tiles with the structural integrity of the support structure, while the brazing material ensures strong bonding and stress distribution throughout the composite assembly.
3Productivity
If screen cloths are used in vibrating screens with 4-5 g acceleration, then all oil sand slurry material passes over and through the screen, but rapid spalling and hole-throughs occur leading to production interruption
Solution Approach 1:
The patent applies a composite material system consisting of anti-wear tiles bonded with brazing material to the screen support structure. This composite construction provides both the screening functionality and the wear resistance needed to withstand the harsh conditions of oil sand slurry processing at high acceleration, thereby extending screen cloth life while maintaining productivity.
Solution Approach 2:
The patent applies local quality enhancement by attaching anti-wear tiles only to the specific areas of the screen cloth that are subject to wear. The brazing material provides localized bonding strength at the tile-support structure interface, creating regions of enhanced durability where needed while maintaining the overall screening functionality of the cloth.
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
This configuration extends the operational life of vibrating screening devices by reducing stress concentration and corrosion, leading to fewer maintenance shutdowns and increased durability of the screen cloths.
Implementation Method 1
a brazing material used to attach the anti-wear tiles to the at least one support structure fills the gap between each anti-wear tile through capillary action
Data Source
AI summary
A screen cloth for use in a screening device for screening out oversize objects, including oil sands lumps and rocks present in an oil sands slurry is provided, comprising at least one screen segment having a top surface and having a plurality of openings therein; and a plurality of anti-wear tiles attached to the top surface of the at least one screen segment by brazing; whereby each anti-wear tile is separated from an adjacent anti-wear tile by a gap that is about 0.5 mm or less such that a brazing material used to attach the anti-wear tiles to the at least one support structure fills the gap between each anti-wear tile through capillary action thereby connecting each anti-wear tile to its adjacent anti-wear tile.