AU2020256375A1

AU2020256375A1 - Components for crushers and mills and method for manufacturing same

Info

Publication number: AU2020256375A1
Application number: AU2020256375A
Authority: AU
Inventors: Douglas Paul
Original assignee: Kcl Ind Pty Ltd
Current assignee: Muddie's Holding Pty Ltd
Priority date: 2019-10-15
Filing date: 2020-10-14
Publication date: 2021-04-29
Anticipated expiration: 2040-10-14
Also published as: AU2020256375B2; AU2022100114A4

Abstract

A component for a crusher or a mill, characterised in that the component is made by 3-D printing or that the component includes at least one region that is hollow.

Description

TITLE

Components for crushers and mills and method for manufacturing same.

TECHNICAL FIELD

[0001] The present invention relates to components for crushers and mills and a method for manufacturing same.

BACKGROUND ART

[0002] Mineral processing, hard rock processing and coal processing invariably requires that size reduction of the minerals or coal takes place. Size reduction of minerals or coal typically occurs in crushers and/or mills. These pieces of equipment are extremely widely used and are very well known to persons skilled in the art.

[0003] Crushers and grinding mills have components that are subject to high-impact loads, exposure to abrasive conditions and therefore are subject to high rates of wear. These components typically need replacing as part of a regular maintenance schedule or when they are worn out or break. To date, these components have been made by casting and, as a result, the components are solid metal components. Although these components are suitable for their intended task, as they are solid metal components they are heavy, which can cause Occupational Health & Safety issues when replacing those components. Due to the components being manufactured by casting, these components have always been solid metal components.

[0004] In some cases, hollow components can be assembled from two or more other components. However, the two or more other components will themselves be solid metal components.

[0005] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

SUMMARY OF INVENTION

[0006] The present invention is directed to components for crushers and mills, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

[0007] With the foregoing in view, the present invention in one form, resides broadly in a component for a crusher or a mill, characterised in that the component includes at least one region that is hollow.

[0008] In one embodiment, the region that is hollow includes a reinforcing structure. The reinforcing structure may comprise a honeycomb structure. The honeycomb structure is not limited to honeycomb structures having hexagonal shaped openings therein. The honeycomb structure may have triangular, rectangular, pentagonal, hexagonal openings, or indeed it may have any shaped openings. The reinforcing structure may comprise a plurality of intersecting walls or contacting walls. These walls may form one or more box sections within the hollow region.

[0009] The reinforcing structure may be integrally formed with the component.

[0010] In one embodiment, the region that is hollow is completely enclosed within a solid surface or surfaces or is completely enclosed by solid metal.

[0011] By providing a component for a crusher or a mill that has at least a region that is hollow, the component can be made lighter to thereby facilitate fitting and removal of the component in a crusher or a mill. This improves workplace health and safety issues surrounding maintenance and replacement of the components. However, it is also possible to increase the lightness of the component without sacrificing strength of the component.

[0012] The component may comprise a segment for a crusher/sizer, a roll screen component for a crusher/sizer, a sizer shell component for a crusher/sizer, a roller component, a feeder breaker component, a primary breaker component, a pick or an intermediate for a feeder breaker or indeed any other crusher/sizer component that is subject to high wear and requires regular replacement. The component may comprise a shaft for a mill, a component for a drum of a mill, a shell lifter for a mill, a stirring element for a mill, a grinding disc for a mill, a component of a classifier in a mill, or indeed any other component that is subject to high wear and requires regular replacement.

[0013] Throughout this specification, reference to a crusher shall be taken to include reference to a crusher/sizer.

[0014] In one embodiment, the component comprises a surface that contacts minerals or coal during use and an internal feature that does not contact minerals or coal during use, wherein the internal feature includes at least one region that is hollow.

[0015] In one embodiment, the component comprises a segment for a crusher, the segment comprising a segment of a cylinder having an outer surface that contacts minerals or coal during use and an inner surface that includes one or more inwardly extending projections, the one or more inwardly extending projections including at least one hollow region.

[0016] In some embodiments, the surface of the component that contacts minerals or coal during use has hard facing material applied thereto.

[0017] The present invention also relates to a method for forming components of the first aspect of the present invention. Accordingly, in a second aspect, the present invention provides a method for forming a component of the first aspect of the present invention, wherein the component is formed by 3-D printing. Suitably, the component is formed by 3-D printing of metal.

[0018] The 3-D printing process that is used in the present invention may include EBAM, SLM, LMD/DED, laser powder deposition, and laser wire deposition and 3D printing using a combination of wire and powder. The skilled person would readily understand these methods. The method of the second aspect of the present invention also encompasses any other 3-D printing method that can 3-D print metal components.

[0019] In one embodiment, the method comprises welding wire deposition or of 3D printing using a combination of wire and powder. The present applicant has found that this method enables components for mills or crushers having at least one hollow region to be manufactured that are lighter than corresponding cast metal components and yet are also stronger than corresponding cast metal components. The present applicant also believe that other 3-D metal printing processes can also result in the production of components for mills or crushers having at least one hollow region to the manufactured that are lighter than corresponding cast metal components and yet are also stronger than corresponding cast metal components.

[0020] In another aspect, the present invention provides a component for a crusher or a mill, characterised in that the component is made by 3-D printing.

[0021] The component may comprise a segment for a crusher/sizer, a roll screen component for a crusher/sizer, a sizer shell component for a crusher/sizer, a roller component, a feeder breaker component, a primary breaker component, a pick or an intermediate for a feeder breaker or indeed any other crusher/sizer component that is subject to high wear and requires regular replacement. The component may comprise a shaft for a mill, a component for a drum of a mill, a shell lifter for a mill, a stirring element for a mill, a grinding disc for a mill, a component of a classifier in a mill, or indeed any other component that is subject to high wear and requires regular replacement.

[0022] In one embodiment of this aspect of the present invention, the component may include at least one region that is hollow.

[0023] In one embodiment, the component comprises a surface that contacts minerals or coal during use and an internal feature that does not contact minerals or coal during use, wherein the internal feature includes at least one region that is hollow.

[0024] In one embodiment, the component comprises a segment for a crusher, the segment comprising a segment of a cylinder having an outer surface that contacts minerals or coal during use and an inner surface that includes one or more inwardly extending projections, the one or more inwardly extending projections including at least one hollow region.

[0025] In a further aspect, the present invention provides a method for manufacturing a component for a crusher or a mill, characterised in that the component is made by 3-D printing.

[0026] The component may comprise a segment for a crusher/sizer, a roll screen component for a crusher/sizer, a sizer shell component for a crusher/sizer, a roller component, a feeder breaker component, a primary breaker component, a pick or an intermediate for a feeder breaker or indeed any other crusher/sizer component that is subject to high wear and requires regular replacement. The component may comprise a shaft for a mill, a component for a drum of a mill, a shell lifter for a mill, a stirring element for a mill, a grinding disc for a mill, a component of a classifier in a mill, or indeed any other component that is subject to high wear and requires regular replacement.

[0027] In one embodiment of this aspect of the present invention, the component may include at least one region that is hollow.

[0028] In one embodiment, the component comprises a surface that contacts minerals or coal during use and an internal feature that does not contact minerals or coal during use, wherein the internal feature includes at least one region that is hollow.

[0029] In one embodiment, the component comprises a segment for a crusher, the segment comprising a segment of a cylinder having an outer surface that contacts minerals or coal during use and an inner surface that includes one or more inwardly extending projections, the one or more inwardly extending projections including at least one hollow region.

[0030] The 3-D printing process that is used in this aspect of the present invention may include EBAM, SLM, LMD/DED, laser powder deposition, and laser wire deposition and 3D printing using a combination of wire and powder. The skilled person would readily understand these methods. The method of the second aspect of the present invention also encompasses any other 3-D printing method that can 3-D print metal components. All aspects of the present invention may use a 3-D printing process in which a binder is sprayed onto a metal powder and heated after printing.

[0031] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[0032] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

[0033] Various embodiments of the invention will be described with reference to the following drawings, in which:

[0034] Figure 1 shows a photograph of a conventional segment for a secondary sizer or tertiary sizer (crushers);

[0035] Figure 2 shows a cross sectional view of a segment for a secondary sizer or tertiary sizer in accordance with one embodiment of the present invention;

[0036] Figure 3 is a top view of the segment shown in figure 2;

[0037] Figure 4 is a cross sectional view taken along section V-V of figure 3;

[0038] Figure 5 is a cross sectional view taken along section W-W of figure 3;

[0039] Figure 6 is a photograph of a known roll screen used for particle sizing between a secondary sizer (crusher) and a tertiary sizer (crusher);

[0040] Figure 7 is a pictorial view of a component used in the roll screen shown in figure 6;

[0041] Figure 8 is a pictorial view of another component used in the roll screen shown in figure 6;

[0042] Figure 9 is a pictorial view of a pick or an intermediate for use with a feeder breaker of a crusher;

[0043] Figure 10 is a cross sectional view of the pick or intermediate shown in figure 9; and

[0044] Figure 11 is an end on view of a reinforcing structure that can be included in at least one hollow region in the components for crushers or mills in accordance with an embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

[0045] The skilled person will understand that the drawings have been provided for the purpose of illustrating preferred embodiments of the present invention. Therefore, it will be understood that the invention should not be considered to be limited to the features as shown in the drawings.

[0046] Figure 1 shows a photograph of known or prior art segments for use in crushers. In figure 1, two separate segments are shown. The segment 10 is in the form of a segment of a cylinder. In particular, the segment 10 circumscribes a quarter of a cylinder. The segment 10 has an arcuate shell region 12. The shell region 12 has a plurality of teeth 14 formed on an outer surface thereof. Although not shown in figure 1, the segment 10 may also have some inwardly extending projections that engage with complementary recesses on a shaft so that the segment 10 turns with the shaft during use when the shaft is rotated.

[0047] The segment 10 shown in figure 1 may form part of a roller for use in a roll crusher. Known segments, such as that shown in figure 1, are formed by casting of metal. The segments are solid components, with the exception of holes 16 that are provided in the segment 10 in order to allow the segment 10 to be mounted to the shaft.

[0048] Figures 2 to 5 show various views of a segment in accordance with an embodiment of the present invention. The segment 20 circumscribes a quarter of the cylinder. Therefore, four segments 20 may be used together to form a cylinder. The segment 20 has a shell region 22 and a plurality of teeth 24. As will be known to person skilled in the art, the teeth 24 may be hard faced with a hard wearing material. The segment 20 also has a plurality of inwardly extending projections 26, 28. These projections 26, 28 engage with complementary shaped recesses on a shaft or core of a roller to ensure that the segment 20 rotates with the shaft or core of the roller.

[0049] If the segment 20 shown in figure 2 was formed in accordance with known manufacturing techniques by casting from molten metal, the segment 20 would be made entirely of solid metal. However, the segment 20 shown in figure 2 has a number of hollow regions. For example, the projection 26 has a hollow region 30 therein. Similarly, projection 28 has a hollow region 32 therein. The shell region 22 has hollow regions 34, 36, 38 formed therein. The hollow regions 30, 32, 34, 36, 38 reduce the weight of the segment 20 when compared to a corresponding segment 10 that is made by casting. The segment 20 may have similar or even greater strength to the segment 10 even though it is of lighter weight than segment 10.

[0050] In order to ensure that structural integrity and strength of the segment 20 is maintained at levels that correspond to the structural of or strength of prior art segment 10 (or even has a higher strength), the hollow regions 30, 32, 34, 36, 38 may include a reinforcing structure, such as a honeycomb structure. Further details of the honeycomb structure will be described hereunder with reference to figure 11.

[0051] The hollow regions shown in figures 2 to 5 are fully encased by regions or surfaces of solid metal. These regions or surfaces of solid metal that encase the hollow regions have a wall thickness that is set by the engineering and strength requirements of these regions, together with the design of the reinforcement in those regions. If the wall thickness of the solid metal that encases the high regions is sufficiently strong, it may not be necessary to include a reinforcing structure inside the hollow regions. However, the present applicant believes that the additional weight incurred by including the reinforcing structure in the hollow regions is more than offset by the reduced wall thickness that can be utilised for the metal regions that encase the hollow regions that include the reinforcing structure. Some of the wall regions are numbered as 40, 42 and 44 in figure 5.

[0052] The segment 20 shown in figures 2 to 5 is made by 3-D printing using, in combination, welding wire and powder 3-D printing. As the skilled person will understand, 3-D printed items are prepared by designing the items, preparing a computer file/program that includes instructions to the 3-D printer to print the item and thereafter printing the item using a 3-D printer. The instructions to the 3-D printer include instructions to form the hollow regions and 3-D print the reinforcement in the hollow regions at the same time. Other 3-D printing besides welding wire and powder deposition may also be used. In one embodiment, the 3-D printing equipment is based on spraying a binder onto a powder then heating it after printing.

[0053] Figure 6 is a photograph of a known roll screen used for particle sizing in a crusher circuit. The roll screen 50 comprises a shaft made of a plurality of shaft segments, some of which are numbered at 52, 54. A plurality of disks, one of which is numbered at 56, are mounted to the shaft. The disk 56 has alternating ridges and recesses extending around the periphery. The disk 56 may be hard faced in certain regions.

[0054] Figure 7 shows a pictorial view of a shaft segment 52. The shaft segment 52 comprises a generally cylindrical shell 59. Inwardly extending projections 60, 62 are located on an inner periphery of the shell 59. Hard faced regions, some of which are numbered at 64 and 66, are formed on the outer periphery of the shaft segment 52.

[0055] The shaft segment 52 shown in figure 7 is a prior art segment made by casting. Therefore, it comprises solid ridges of metal. However, in accordance with the present invention, one or more hollow regions may be provided. For example, projections 60, 62 may be provided with a hollow region and the shell 59 may also be provided with one or more hollow regions.

[0056] Figure 8 shows a pictorial view of a disk 58. The disk 58 has alternating ridges 68 and recesses 70 extending around and forming its outer periphery. The projections 68 have hard faced material 72 applied thereto. The disk 58 has a central opening 74 so that the disk can be mounted over a roller shaft or core. Inwardly extending projections 76, 78 are provided on the disk 58. These engage with complementary shaped regions on the roller shaft or core to ensure that the disk rotates with the shaft or core. In some embodiments, the projection 76, 78 may be formed on a separate circular element that is welded to, friction fit with or otherwise attached to the disk 58.

[0057] The disk 58 shown in figure 8 is made by casting and therefore it is constituted by solid metal regions only. However, in accordance with embodiments of the present invention, the disk 58 may have some hollow regions. For example, hollow regions may be provided in the vicinity of the projections 68 or in the vicinity of the recesses 70. Similarly, hollow regions may be provided in the inwardly extending projection 76, 78.

[0058] Although the roller segment 52 and the disk 58 both have central openings therein, the central openings are not encased in solid metal because they are open at either end. In these embodiments of the present invention, providing hollow regions in the shaft segment and the disk, with the hollow regions being fully encased by metal, provides hollow regions in what would otherwise be solid regions of metal in these components. This lowers the weight of these components without compromising strength. Again, these components may be manufactured by 3-D printing using 3-D printing techniques that are capable of 3-D printing components from metal.

[0059] Figures 9 and 10 are views of a pick or an intermediate for use with a feeder breaker of a crusher. The pick 80 has a stem 82 that has a threaded end 84. The threaded end 84 allows the pick 80 to be bolted into a holder on a drum so that the pick extends outwardly from the surface of the drum in a generally radial direction. The pick 80 also has a somewhat bulbous tapered head 86 that tapers towards a front point 88. The front region 90 of the head 86 is faced with a hard faced material 92 and additional lines of hard faced material 94 extend rearwardly therefrom.

[0060] As with the components shown in figures 7 and 8, the pick shown in figures 9 and 10 is made by casting. However, in accordance with embodiments of the present invention, the bulbous head 86 may have one or more hollow regions therein. Similarly, the stem 82 may have one or more hollow regions therein. The one or more hollow regions are suitably encased or completely surrounded by solid metal. The one or more hollow regions may be provided with reinforcing, such as honeycomb material. The honeycomb material may be integrally formed with the component. A pick having hollow regions may be manufactured by 3-D printing, such as by 3-D printing using a combination of welding wire deposition and powder.

[0061] Figure 11 shows a cross section of a reinforcing structure that may be used in embodiments of the present invention. In figure 11, the external walls that completely surround or encase the hollow region 100 are shown at 101 and 102. A honeycomb structure having a plurality of intersecting or contacting walls 104, 105, 106, 107 is formed in the hollow region 100. This honeycomb structure extends from each of the opposed sides of the hollow region and extends from a first end to a second end of the hollow region. The honeycomb structure shown in figure 11 has a square shaped cross-section, although will be appreciated that other cross sectional shapes may be used. The honeycomb structure is formed by 3-D printing at the same time as 3-D printing of the rest of the component. In this manner, the honeycomb structure is integrally formed with the remainder of the component.

[0062] Components in accordance with the present invention provide components that are lighter than similar components made as solid metal and formed by casting. This allows the parts to be more ergonomic for manual handling, minimising the risk of back strain, repetitive strain injuries and related injuries as well as equalling or increasing the wear life of these parts. The present invention also allows moving away from traditional casting methods in this field of crushing and sizing parts, normal practice for this being lost wax or green sand casting, which makes existing parts solid in nature.

[0063] It will be appreciated that the wall thickness of the metal surrounding the hollow regions and the wall thickness of the reinforcing structure/honeycomb will vary, depending on the application.

[0064] The present applicant has made a component in accordance with the present invention. The weight of a conventional component was 14.5 kg and the weight of the component in accordance with the present invention was reduced to 8.45 kg.

[0065] In the present specification and claims (if any), the word 'comprising' and its derivatives including 'comprises' and 'comprise' include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0066] Reference throughout this specification to 'one embodiment' or 'an embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases 'in one embodiment' or 'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0067] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

1. A component for a crusher or a mill, characterised in that the component includes at least one region that is hollow.

2. A component as claimed in claim 1 wherein the region that is hollow includes a reinforcing structure.

3. A component as claimed in claim 2 wherein the reinforcing structure comprises a honeycomb structure.

4. A component as claimed in claim 3 wherein the honeycomb structure has hexagonal shaped openings therein, or triangular shaped openings therein, or rectangular shaped openings therein, or pentagonal shaped openings therein.

5. A component as claimed in claim 2 wherein the reinforcing structure comprises a plurality of intersecting walls or contacting walls.

6. A component as claimed in claim 5 wherein the plurality of intersecting walls or contacting walls form one or more box sections within the hollow region.

7. A component as claimed in any one of claims 2 to 6 wherein the reinforcing structure is integrally formed with the component.

8. A component as claimed in any one of the preceding claims wherein the region that is hollow is completely enclosed within a solid surface or surfaces or is completely enclosed by solid metal.

9. A component as claimed in any one of the preceding claims wherein the component comprises a segment for a crusher/sizer, a roll screen component for a crusher/sizer, a sizer shell component for a crusher/sizer, a roller component, a feeder breaker component, a primary breaker component, a pick or an intermediate for a feeder breaker, a shaft for a mill, a component for a drum of a mill, a shell lifter for a mill, a stirring element for a mill, a grinding disc for a mill, or a component of a classifier in a mill.

10. A component as claimed in any one of the preceding claims wherein the component comprises a surface that contacts minerals or coal during use and an internal feature that does not contact minerals or coal during use, wherein the internal feature includes at least one region that is hollow.

11. A component as claimed in claim 10 wherein the component comprises a segment for a crusher, the segment comprising a segment of a cylinder having an outer surface that contacts minerals or coal during use and an inner surface that includes one or more inwardly extending projections, the one or more inwardly extending projections including at least one hollow region.

12. A component as claimed in claim 10 or claim 11 wherein the surface of the component that contacts minerals or coal during use has hard facing material applied thereto.

13. A method for forming a components as claimed in any one of the preceding claims wherein the component is formed by 3-D printing.

14. A method as claimed in claim 13 wherein the component is formed by 3-D printing of metal.

15. A method as claimed in claim 14 wherein the 3-D printing process comprises one or more of EBAM, SLM, LMD/DED, laser powder deposition, and laser wire deposition and 3D printing using a combination of wire and powder.

16. A method as claimed in claim 15 comprising welding wire deposition or of 3D printing using a combination of wire and powder.

17. A component for a crusher or a mill, characterised in that the component is made by 3-D printing.

18. A method for manufacturing a component for a crusher or a mill, characterised in that the component is made by 3-D printing.

FIGURE 1 16 1/7

10