Segmented Roller Shaft Radial Clamping for Fast Maintenance
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Solution Overview
Problem
Existing segmented rollers for crushing or compacting bulk material face challenges with complex and costly manufacturing processes, inadequate contact, and increased disassembly efforts due to axial fastening methods, leading to longer downtimes and high replacement costs.
Innovation Solution
A method for mounting and dismounting segments on a roller shaft using a n-cornered design with radially arranged clamping elements, providing a positive and non-positive connection, and utilizing assembly means like screws and mounting collars for efficient alignment and bracing, allowing for radial disassembly without removing the entire roller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If axial fastening methods with tie rods and clamping elements are used to secure segments on the roller shaft, then the segments are firmly fixed, but the disassembly process becomes complex and time-consuming requiring removal of the entire roller
Solution Approach 1:
The roller shell is divided into multiple replaceable segments that can be independently removed and replaced. Each segment can be detached without affecting the other segments or the roller shaft, enabling quick maintenance and replacement while maintaining strong fixation during operation.
Solution Approach 2:
The clamping elements are extracted from the axial direction and repositioned to act radially on the segments. This allows the clamping force to be applied perpendicular to the segment faces, securing them firmly to the roller shaft while enabling simple radial removal for replacement.
2Loss of time
If radial disassembly is implemented to allow segment removal without removing the entire roller, then downtime is reduced, but manufacturing tolerances and assembly complexity increase
Solution Approach 1:
The system transitions from a static fixed assembly to a dynamic configuration where segments can be easily inserted and removed radially. The clamping elements are designed to accommodate slight variations in positioning while maintaining secure fixation, reducing the stringency of manufacturing tolerances required.
Solution Approach 2:
Clamping elements serve as intermediaries between the segments and the roller shaft. These elements provide a forgiving interface that absorbs manufacturing tolerances and alignment variations, allowing segments to be securely attached without requiring extremely precise radial alignment.
3Strength
If the roller shell is made as a single piece or with minimal segmentation, then structural integrity is maintained, but replacement of worn surfaces requires removing the entire roller
Solution Approach 1:
The roller shell is segmented into multiple independent sections that can be separately removed and replaced. Each segment can be individually exchanged when worn, allowing maintenance without removing the entire roller assembly while preserving the structural integrity of the remaining segments during operation.
Solution Approach 2:
Worn segments are discarded and replaced with new or reconditioned segments, while the roller shaft and other components are retained and reused. This approach optimizes maintenance efficiency by replacing only the worn portions rather than the entire roller assembly.
4Reliability
If complex clamping mechanisms with multiple tie rods and axial fastening elements are used, then secure fixation is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The clamping mechanism is simplified by extracting the fastening action from the axial direction and relocating it to the radial direction. This eliminates the need for complex axial tie rods and multiple fastening points, reducing the number of components while maintaining secure fixation through radial clamping force.
Solution Approach 2:
Instead of applying clamping force axially through tie rods as in conventional designs, the clamping force is applied radially perpendicular to the segment faces. This inverted approach simplifies the mechanism by using direct radial pressure rather than complex axial tension members, reducing overall device complexity.
Data Source
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AI summary
The invention relates to a method for mounting and dismounting segments on a roller shaft. These segments are clamped to the roller shaft in a designated receptacle by means of at least one clamping element and are thus connected in their position by friction and form locking.