Segmented Stator Tools for Grinding Feedstock
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Solution Overview
Problem
Existing mechanical process engineering devices, such as disk mills and impact crushers, face challenges with lengthy tool change times and limited flexibility in adapting stator tool geometry to suit different feed materials and processing outcomes, leading to inefficient operation and suboptimal comminution results.
Innovation Solution
The design of stator tools into segments allows for different corrugations between consecutive segments, enabling control over comminution intensity and residence time, with simple assembly and fixation using clamping elements, thereby reducing tool change downtimes and enhancing adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If rotor and stator tools are formed by segments and screwed to the carrier disk or housing wall, then tool adaptability and comminution performance are improved, but assembly effort and downtime increase significantly
Solution Approach 1:
The stator tools are divided into multiple segments that can be independently replaced. Each segment can be removed and replaced separately from the housing, allowing for targeted tool changes without replacing the entire stator assembly. This segmentation reduces the time required for tool changes while maintaining the adaptability of having different corrugation profiles on different segments.
2Loss of time
If rotor and stator tools are replaced as complete rings, then tool change time is reduced, but the profile of grinding tools is limited to substantially radial corrugation only
Solution Approach 1:
The stator is segmented into multiple replaceable segments that can be individually configured with different corrugation profiles. This allows the system to maintain fast tool change times (by replacing only the worn segment rather than the entire ring) while enabling diverse tool profiles including radial corrugations, axial corrugations, or combinations thereof, depending on the specific application requirements.
Solution Approach 2:
Different segments of the stator can have different corrugation profiles tailored to specific local requirements. For example, certain segments can feature radial corrugations for intensive comminution while others have axial corrugations for different processing needs. This local differentiation enables the system to optimize performance for specific feed materials and processing stages without compromising the entire stator assembly.
3Device complexity
If monolithic grinding track insert is used, then structural simplicity is maintained, but flexibility in adapting stator tools to specific feed material is lost
Solution Approach 1:
The grinding track insert is divided into multiple segments that can be independently replaced and configured. This segmentation maintains relative structural simplicity (each segment is a straightforward component) while enabling high flexibility in adapting the stator tools to different feed materials. The segments can be replaced with different corrugation profiles as needed, providing adaptability without requiring a completely complex monolithic structure.
Solution Approach 2:
The stator tool configuration is made dynamic and adjustable rather than fixed. The segmented design allows the system to adapt its tooling configuration based on the specific feed material and processing requirements. Different segments can be installed or replaced to change the corrugation profile, enabling the system to respond dynamically to different processing needs while maintaining a relatively simple overall structure.
Data Source
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AI summary
The feedstock comminuting device comprises stator tools, which are formed by segments (21), formed a comminuting surface rest on a stator with their rear side and lie with their long sides against one another. Segments are attachable to the stator with their first short side and second short side by a positive fit. The stator has a clamping element that works together with the first short side and the second short side to clamp the segments against the stator.