This invention relates to crushing, grinding, and comminution equipment, and more particularly to high pressure grinding roller (HPGR) press systems used, for instance, in the mining, cement, coal, and minerals processing industries.
In such configurations, the hole having female threads 924 is positioned well below wear insert pockets 922 in order to avoid interferences between the wear inserts 930 and the fastener 940. This lower fastening position makes the edge wear component 950 more susceptible to premature “pull-off” due to larger moment forces, which are created, for instance, when feed and/or autogenous layer material pushes against upper regions of the edge wear component 950.
Currently, when a roller edge 910 erodes, it is repaired by filling gaps, holes, and worn-away material on the roller sleeve 920 with hardface weld material. Subsequent grinding and machining processes on the roller sleeve 920 may be necessary after hardface welding, in order to bring the roller 900 back to original specifications. Such methods are time-consuming, inefficient, and costly. Moreover, with the aforementioned prior art designs, if female threads 924 in the roller shell 920 become stripped by the fastener 940, the roller sleeve 920 needs to be reworked.
Recent attempts have been made to prevent premature edge wear grinding rollers. For instance, KHD and Polysius have pursued roller designs which incorporate the fastening of removable hard bodies to the roller edges (see U.S. Pat. Nos. 7,497,396 and 7,510,135). However, these designs are susceptible to “washout”, where roller sleeve substrate material begins to erode due to the migration of abrasive particles forming the autogenous layer.
It is, therefore, an object of the invention to provide a mechanically-robust edge wear component system.
It is also an object of the invention to provide edge wear components having adequate support, stability, and resistance to “pull off”.
It is yet another object of the invention to provide a means for quickly repairing stripped or damaged female threads which would otherwise require the reworking of a roller or sleeve portion thereof.
These and other objects of the invention will be apparent from the drawings and description herein. Although every object of the invention is believed to be attained by at least one embodiment of the invention, there is not necessarily any one embodiment of the invention that achieves all of the objects of the invention.
A roller press is disclosed. The roller press comprises a roller having a roller edge formed by the intersection of a roller end and an outer surface. An edge wear component is provided adjacent said roller edge, and a mounting insert is provided within a mounting insert pocket which is located inland of said roller end and spaced from said roller edge. A fastener extends between the edge wear component and the mounting insert to keep the edge wear component attached to the roller. The fastener threadedly engages female threads which are provided within the mounting insert. In some embodiments, the edge wear component may comprise at least one of an end face liner and an outer face liner. In some embodiments, the edge wear component comprises first and second sides that are configured to form a radial weld channel when the first and second sides abut respective second and first sides of adjacent edge wear components in side-by-side relationship. In some embodiments, at least one of said first and second sides comprises a protrusion. In some embodiments, the edge wear component comprises a circumferential weld channel which is configured to accept a bead of weld material. The bead of weld material may help secure the edge wear component to the roller. In some embodiments, the circumferential weld channel comprises a first weld channel face and a second weld channel face for increased surface area. In some embodiments, the edge wear component accepts a plurality of fasteners, wherein at least one of said plurality of fasteners threadedly engages female threads in the mounting insert, and at least one of said plurality of fasteners threadedly engages female threads in another portion of the roller, which may be a roller sleeve. The mounting insert may be cylindrically-shaped, block-shaped, or generally shaped and/or sized similar to other wear inserts provided on the outer surface of the roller. The mounting insert pocket may comprise a blind recess or may alternatively comprise a continuous annular circumferential groove which extends around the roller.
A method of mounting an edge wear component to a roller is also disclosed. The method comprises the steps of: providing a roller having a roller edge formed by the intersection of a roller end and an outer surface, providing a mounting insert pocket located inland of said roller end and spaced from said roller edge, providing a clearance hole extending between the roller end and the mounting insert pocket; providing an edge wear component; providing a mounting insert; positioning said edge wear component adjacent said roller edge; positioning said mounting insert within said mounting insert pocket; aligning the edge wear component with said mounting insert; extending a fastener through said clearance hole and between the edge wear component and the mounting insert; and fixedly engaging the fastener with the mounting insert to keep the edge wear component attached to the roller.
An edge protection system for a roller in a roller press is also disclosed. The edge protection system comprises: an edge wear component; a mounting insert having female threads therein and being configured to be placed within a mounting insert pocket on the roller which is located inland of a roller end; and a fastener configured to extend between the edge wear component and the mounting insert and configured to threadedly engage said female threads within the mounting insert.
The head 144 of each fastener 140 may fit within a head recess 152 provided on the edge wear component 150 and the shaft 146 of each fastener 140 may extend through a shaft recess 154. An abutment surface 156 of the edge wear component 150 may flushly rest against an end 126 of the roller sleeve 120.
The head 244 of each fastener 240 may fit within a head recess 252 provided on the edge wear component 250 and the shaft 246 of each fastener may extend through a shaft recess 254. An abutment surface 256 of the edge wear component 250 may flushly rest against an end 226 of the roller sleeve 220. Supplemental fasteners 240 may be fixed to female threads 224 provided within the substrate of the roller sleeve 220. In the particular embodiment shown, fasteners 240 are aligned radially along edge wear component 250 in relation to the roller 200, whereas the embodiment shown in
The head 444 of each fastener 440 may fit within a head recess 452 provided within the edge wear component 450 and the shaft 446 may extend through a shaft recess 454. A washer 449 may be provided within the head recess 452 under the head 444 and surrounding shaft 446. An abutment surface 456 of the edge wear component 450 may rest against an end 426 of the roller sleeve 420. Supplemental fasteners 440 may be fixed to female threads 424 provided within the substrate of the roller 400. In the particular embodiment shown, the fasteners 440 are arranged in a staggered pattern along the edge wear component 450, wherein an upper set of fasteners 440 threadedly engage mounting inserts 460, and a lower set of fasteners 440 threadedly engage roller sleeve 420.
Edge wear components 450 may comprise a circumferential weld channel 457 formed by a first weld channel face 457A which intersects with a second weld channel face 457B. A circumferential weld 421 may be disposed in the circumferential weld channel 457 to further secure the edge wear component 450 to the roller 400. A first side 451B of the edge wear component 450 may comprise a first protrusion 451A, and a second side 453B of the edge wear component 450 may comprise a second protrusion 453A. When edge wear components 450 are abutted circumferentially, in side-by-side relationship, respective first 451A and second 453A protrusions of neighboring edge wear components 450 may communicate to form radial weld channels 490 which may be filled with hardface weld material. As shown, the edge wear component 450 may be formed by fusing, bonding, or otherwise mechanically fastening a harder end face liner 458A and/or a harder outer face liner 458B to a softer body substrate. Fusion of the end face liner 458A and/or harder outer face liner 458B to a softer body substrate may be accomplished using explosion welding, soldering, friction welding, graded powdered metallurgy, heat treatments, adhesives, or other conventional means. One or more recesses or clearance bands 459 may also be provided adjacent the one or more shaft recesses 454, in order to facilitate threaded engagement and deformation compensation between male threads 464 of fasteners 440 and female threads 424 during tightening.
A contractor or other entity may provide a grinding roller, or operate a grinding roll apparatus in whole, or in part, as shown and described. For instance, the contractor may receive a bid request for a project related to designing or operating a grinding roll apparatus, or the contractor may offer to design such a system or a process for a client. The contractor may then provide, for example, any one or more of the devices or features thereof shown and/or described in the embodiments discussed above. The contractor may provide such devices by selling those devices or by offering to sell those devices. The contractor may provide various embodiments that are sized, shaped, and/or otherwise configured to meet the design criteria of a particular client or customer. The contractor may subcontract the fabrication, delivery, sale, or installation of a component of the devices disclosed, or of other devices used to provide said devices. The contractor may also survey a site and design or designate one or more storage areas for stacking the material used to manufacture the devices, or for storing the devices and/or components thereof. The contractor may also maintain, modify, or upgrade the provided devices. The contractor may provide such maintenance or modifications by subcontracting such services or by directly providing those services or components needed for said maintenance or modifications, and in some cases, the contractor may modify a preexisting grinding roll apparatus, or parts thereof with a “retrofit kit” to arrive at a modified grinding roll apparatus comprising one or more method steps, devices, components, or features of the systems and processes discussed herein.
Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed. For example, in some embodiments, mounting inserts 160, 260, 360, 460 may comprise softer, more machinable materials than other wear inserts 130, 230, 330, 430. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
This application is an international application which claims the benefit of U.S. Provisional Patent Application No. 61/580,342, filed on 27 Dec. 2011.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US12/69346 | 12/13/2012 | WO | 00 | 6/19/2014 |
Number | Date | Country | |
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61580342 | Dec 2011 | US |