BR112019008022B1 - WEAR PROTECTION ASSEMBLY, METHOD FOR FORMING A WEAR PROTECTION AND SCREEN ASSEMBLY - Google Patents

Abstract

In one aspect there is shown a wear guard assembly (10) for coupling to an external structure with a fastener (13) in an installed condition. In one example, the wear guard assembly (10) includes: a wear layer (14) including a series of wear sections (20) made of a wear resistant cast material, a substrate layer (16) including a metallic material and a bonding layer (18) including rubber that is substantially vulcanized between the wear layer (14), the substrate layer (16) and at least at the joints (23) between adjacent sections of the series of wear sections ( 20). A second example of wear protection assembly (110) and methods for forming such assemblies (10, 110) are also disclosed.

Description

technical field

[0001] The invention relates to a wear protection assembly such as a wear plate or tile, and a method of forming such a wear protection assembly to provide such a plate or tile.

Background

[0002] Wear resistant parts or units are used in a wide variety of applications such as gutter linings for material handling in mining. Various types of abrasion or wear resistant materials have been proposed for use in wear parts. One such abrasion-resistant material is white cast iron.

[0003] A problem with using white cast iron is that this material is brittle and relatively expensive. This is why layered materials have been developed in which white cast iron is used only as an outer layer. CA 01112597 discloses an abrasion resistant unit comprising: a series of outer wear resistant plates made of cast iron, a substrate plate made of mild steel. The cast iron wear plate and the mild steel substrate plate are vulcanized together using rubber. The mild steel substrate plate is disclosed as being mounted to an external structure by welding, bolting, riveting or pinning.

[0004] One problem with this layering is that it can be difficult to install and remove the drive or board, or parts thereof. Furthermore, this layering relies solely on the rubber to bond the mild steel substrate to the white cast iron, so the white cast iron plates can shift. Another problem concerns wear between the series of wear-resistant cast iron outer plates, especially along the rubber joints.

[0005] The invention disclosed herein is intended to solve one or more of the problems identified above or at least provide a useful alternative.

summary

[0006] According to a first broad aspect, an anti-wear assembly is provided for coupling to an external structure with a fastener in a nested condition, with the anti-wear assembly including: an anti-wear layer having a series of anti-wear sections formed of a wear resistant cast material, a substrate layer including a metal material and a bonding layer including rubber which is vulcanized substantially between the wear layer, the substrate layer and at least at the joints between adjacent series of wear sections ; wherein the series of wear sections are shaped so that the joints between at least some of the series of wear sections are misaligned and/or displaced.

[0007] In one aspect, the series of wear sections are arranged in rows extending between opposite sides of the wear assembly, adjacent sides of the series of wear sections in each row being shaped to fit together in such a way that the joints between the rows are misaligned.

[0008] In another aspect, the series of wear sections are arranged in rows extending between opposite sides of the wear assembly, each of the series of wear sections including at least one angled side arranged to complement the at least one angled side of a series of adjacent wear sections arranged so that the joints in each row are angled and offset from the joints in an adjacent row.

[0009] In yet another aspect, at least one of the series of wear sections of the wear layer, the substrate layer and the bonding layer each include one or more corresponding fastener openings arranged to allow the fastener is passed therethrough to secure the wear assembly to the outer structure in the installed condition, the one or more fastener openings of the at least one of the series of wear section sections of the wear layer including a recessed surface arranged to enable the fastener applies a compressive force to the wear assembly.

[0010] According to a second broad aspect, a method of forming a wear assembly is provided, the method including the steps of: providing a wear layer that includes a series of wear sections made of a cast material wear resistant, the series of wear sections being arranged in rows and shaped so that the joints between at least some of the series of wear sections in adjacent rows are misaligned; providing a substrate layer including a metallic material; and introducing a layer of rubber substantially between the wear layer, the substrate and the joints between at least some of the series of wear sections, the rubber layer being hot vulcanized thereby joining the wear assembly.

[0011] According to a third broad aspect there is provided a tile or wear plate formed according to the method described above in the present invention.

[0012] According to a fourth broad aspect there is provided a wear assembly for coupling to an external structure with a fastener in an assembled condition, the wear assembly including: a wear layer including a wear resistant cast material, a wear layer of substrate including a metallic material and an intermediate layer including rubber that is vulcanized between the wear layer and the substrate layer, each of the wear layer, substrate layer and intermediate layer including one or more corresponding apertures for fasteners arranged to enable the fastener to be baked through to secure the wear assembly to the outer frame in the installed condition.

[0013] In one aspect, the assembly includes at least one spacer between the wear layer and the substrate layer.

[0014] In another aspect, the assembly includes one or more spacers or washers between the wear layer and the substrate layer to create an edge in each of the one or more openings in the installed condition with the one or more fasteners passing through the same.

[0015] In yet another aspect, the one or more openings of the wear layer include a recessed surface arranged to enable the fastener to rest on the recessed surface and pull the wear layer towards the outer structure in the installed condition.

[0016] In yet another aspect, each of the wear layer, the substrate layer and the intermediate layer include one or more corresponding holes arranged so that the wear assembly provides a screen.

[0017] According to a fifth broad aspect, a method is provided for forming an anti-wear assembly that can be attached to an external structure with a fastener in an installed condition, the method including the steps of: providing an anti-wear layer that includes a cast wear-resistant material having one or more fastener openings therethrough, providing a substrate layer that includes a metallic material having one or more fastener openings therethrough, providing at least one spacer between the wear layer, and the substrate layer, and insert an intermediate layer of rubber between the wear layer and the substrate layer by means of hot vulcanization joining all parts, with the fastener openings of the wear layer and the substrate layer aligned with each other to enable the fastener to be passed through them in the installed condition, with the spacer being captured between the counter layer of wear and the substrate layer in order to define a minimum thickness of the intermediate rubber layer.

Brief description of figures

[0018] The invention is described, by way of non-limiting examples only, with reference to the attached figures, in which;

[0019] Figure 1a is a front view of the parts in exploded perspective illustrating a set against wear in the form of a tile;

[0020] Figure 1b is an exploded perspective front view illustrating the wear-resistant assembly in the form of a tile, with the substrate encapsulated by the bonding material.

[0021] Figure 2a is a front perspective view illustrating the anti-wear assembly in the form of a tile;

[0022] Figure 2b is a perspective view of a hidden detail illustrating a fastener opening of the wear assembly;

[0023] Figure 2c is a front view illustrating the anti-wear assembly in the form of a tile;

[0024] Figure 3 is a top sectional view illustrating the anti-wear assembly in the form of a tile, taken along section C-C indicated in Figure 2c;

[0025] Figure 4 is a side view of hidden details illustrating the tile-shaped wear assembly;

[0026] Figure 5 is a detailed cross-sectional view illustrating a joint between sections of the wear assembly, along section B-B indicated in Figure 2c;

[0027] Figure 6 is a detailed cross-sectional view illustrating a side of the wear assembly;

[0028] Figure 7 is a perspective view illustrating a fastener for securing the wear assembly to a structure;

[0029] Figure 8 is a front view of the parts in exploded perspective illustrating a second example of the set against wear in the form of a screen;

[0030] Figure 9 is a rear view of parts in exploded perspective of the screen-shaped wear assembly;

[0031] Figure 10 is a rear perspective view illustrating the screen-shaped wear assembly;

[0032] Figure 11 is a side view illustrating the set against wear in the form of a screen;

[0033] Figure 12 is a rear view illustrating the set against wear in the form of a screen;

[0034] Figure 13 is a hidden detail view illustrating a recessed surface of an aperture for fastening a wear layer of the wear assembly; It is

[0035] Figure 14 is a perspective view illustrating a fastener for securing the wear assembly to a structure.

Detailed Description Example 1

[0036] With reference to Figures 1 to 7, a first example of an assembly against wear or a part against wear 10 in the form of a tile 12 for coupling to an external structure (not shown) with a fastener 13 (shown in Figure 7) in installed condition. The outer frame may be the skeleton or a sidewall of a chute or the like and the fastener 13 is preferably in the form of a screw 15 sized to pass through the wear assembly 10 and engage the outer frame.

[0037] The wear assembly 10, provided here in the form of the tile 12, generally includes three main parts or layers including a first outer wear layer 14, a second substrate layer 16 and a third bonding layer 18. The tile formed 12, as shown in Figure 2a, has opposite sides 27, a top 29 and a bottom 31. It should be noted that, for explanatory purposes, in the drawings, the binding layer 18 is shown as being formed after vulcanization, as described in detail below.

[0038] The first outer layer 14 is preferably formed from sections or fragments 20 of cast iron material with a high chromium content. In this example, three rows 37a, 37b and 37c are provided with two laterally adjacent sections 20 in each row. Of course, other arrangements can be used.

[0039] The sections 20 each include an outer side 33, an inward facing side 35, a top side 37, a bottom side 39, a top wear face 38 and a bottom face 45. sections 20 are arranged to form a generally square or rectangular shape with gaps or joints 23 therebetween. In this example, the sections 20 are shaped such that the gaps or junctions 23 between adjacent rows, i.e. between 37a to 37c, for example, are misaligned or offset relative to each other.

[0040] The misalignment or offset helps to minimize wear lines in a particular "D" direction shown in Figure 2c along joints 23. The "D" direction is a passing material direction, and that direction is not necessarily vertical. It should be noted that tile 12 can be rotated 180 degrees to achieve the same or similar function.

[0041] In more detail, in the present example, each of the sections 20 is generally trapezoidal in shape with the sides 35 facing inwards of adjacent sections 20 in the same rows 37 being at a complementary angle so that the gaps or junctions 23 between them they are likewise at an angle and misaligned or offset with respect to gaps or junctions 23 of adjacent rows 37. The remaining sides 37, 39 and 33 of each of the sections 20 in this example are straight. As best shown in Figure 5, at least the inwardly facing sides 35 of adjacent sections 20 may be slightly thicker towards the outer wear face 38 of sections 20.

[0042] In this example, the inward facing sides 35 of adjacent sections 20 are arranged so that the angle of the spans or joints 23 is about 10 to 30 degrees relative to the vertical between the top 29 and the bottom 31 of the assembly against wear 10. It should be noted that misalignment or displacement between the gaps or joints 23 can be achieved by various means, such as rounded or jagged inward facing sides 35. The wear face 38 of the sections 20 is relatively flat and the opposite bottom face 45 may include a circular recess 47, shown in Figure 1b, which may assist in connecting and cushioning the sections 20.

[0043] The second substrate layer 16 is provided in the form of a mild steel substrate layer 22 and the third layer or intermediate bonding layer 18 is provided in this example in the form of rubber inserts or a vulcanized rubber insert layer 24 between each of the wear sections 20, and between the wear sections 20 and the mild steel substrate layer 22. The rubber layer 24 occupies the joints 23 and extends between the wear sections 20 and the substrate layer mild steel 22.

[0044] The rubber layer 24 may be natural rubber. It should be noted that the rubber layer 24 can also be used or extended to form an encapsulating layer 41 which substantially encapsulates the mild steel substrate layer 22 and surrounds the opposite sides 27, top 29 and bottom 31 of the tile. 12. The encapsulation layer 41 thus enables adjacent sets of tiles 10 to be installed side by side or one above the other with rubber padding between them. In this arrangement, of course, the mild steel substrate layer 22 need not be the last rear layer of the set 10.

[0045] In more detail, in this example, an intermediate pair of sections 20, indicated as 20a and 20b in Figure 1, the rubber layer 24 and the mild steel substrate layer 22 include respective corresponding openings 30, 32, 34 for fasteners arranged to enable the fastener 13, more specifically the rod 19 of the fastener 13, to be passed therethrough to secure the fabric 12 to the outer frame.

[0046] As best shown in Figure 2b and Figure 3, the fastener openings 30 of the wear sections 20 include a tapered or angled recessed surface 36 for receiving and engaging the corresponding tapered surfaces 25 of the head 17 of the fastener 13, as shown in Figure 7. The recessed surfaces 36 enable the fasteners 13 to be flush or recessed relative to the outer surface 38 of the high chromium cast iron sections 20, and in particular the recessed surfaces 36 enable the head 17 of the fastener 13 to engage there and apply a compressive force to tile 12 helping to hold the assembly together.

[0047] A method for forming the wear assembly 10 will now be discussed. The method below refers to the tile-shaped example 12. However, a similar method can be used to form the other wear assemblies or wear parts.

[0048] The method of forming the wear assembly 10, in this example the tile 12, includes providing a series of pre-fragmented interlocking wear sections 20 and the mild steel substrate layer 22. The cast iron sections 20 with a high chromium content can be formed by a casting process. Some of the high chromium cast iron sections 20 may be formed with the fastener openings 30 having recessed surfaces 36 therein. The mild steel substrate layer 22 can be formed by cutting the metal to size and creating the apertures 34 by machining.

[0049] The method then includes installing or inserting the intermediate rubber layer 24, which may be supplied in multiple parts or cut strips, between the high chromium mild iron sections 20 and the steel substrate layer 22 and in the gaps 23 between and in each of the sections 20. The respective openings 30 and 32 are aligned with each other. The sandwich is then hot vulcanized using a heat or similar process to fuse the rubber layer 24 with bonding sections 20 to each other and to the mild steel substrate layer 22. The multiple parts or strips rubber cuts forming the rubber layer 24 thus become bonded together. The assembly 10 can be formed in a suitable mold (not shown), such as a square mold, allowing heat and pressure for vulcanization to be applied.

[0050] It should be noted that the respective openings 32 of the rubber layer 24 of the wear tile 12 are typically made afterwards as the rubber layer 24 is hot vulcanized and squeezed into the gaps or joints 23. The rubber layer 24 may also be extended, typically by using the mold to form the encapsulation layer 41 over the mild steel substrate layer 22 and encircle opposite sides 27, top 29 and bottom 31 of tile 12. wear 38 of section 20 remain substantially free of rubber 24.

[0051] In some examples, the tile 12 may be about 300 mm by 300 mm in flat form, and the thickness may be about 30 mm. The thickness of the rubber can be about 2 mm.

[0052] In use, the wear protection assembly 10 is secured to the outer frame with fasteners 13, preferably in the form of screws 15. In particular, it should again be noted that the recessed surfaces 36 of the openings 30 allow the head 17 of the fastener 13 rests and applies a compressive force on the tile 12 thus helping to keep the "sandwich" intact.

[0053] Advantageously, the wear protection assembly disclosed in the present invention provides a wear layer that is pre-fragmented and has multiple parts or sections to help minimize breakage of the wear layer, especially when it is made of cast iron material with a high chromium content that can be brittle and prone to splintering. The rubber layer between the shredded sections helps cushion movement and/or impacts between the shredded sections. Further advantageously, offsetting or misaligning the joints between the sections helps to minimize the appearance of lines or wear bands along the joints and distributes wear more evenly over the multi-part fragmented wear layer. In addition, the assembly allows for the use of screws to exert a compressive force on the wear protection layer to secure it to the outer frame. Cap screws allow for ease of installation and removal of the wear guard assembly.

second example

[0054] With reference to Figures 8 to 14, a second example of a wear protection assembly or a wear part 110 is shown in the form of a screen 112, such as a drum-type screen, for coupling to an external structure ( not shown) with a fastener 113 (shown in Figure 14) in the installed condition. The outer frame may be the skeleton or a sidewall of a chute or the like and the fastener 113 is preferably in the form of a bolt 115 sized to pass through the wear assembly 110 and engage the outer frame.

[0055] The wear protection assembly 110, provided herein in the form of the fabric 112, may include three layers including a first outer wear layer 114, a second substrate layer 116 and a third intermediate bonding layer 118. The first layer shell 114 is preferably made of a tough, highly abrasive material and is provided in this example as a layer of high chromium cast iron 120.

[0056] The second substrate layer 116 is provided in the form of a mild steel substrate layer 22 and the third intermediate bonding layer 118 is provided in this example in the form of a layer of a vulcanized rubber insert 124 between the layer of high chromium cast iron 120 and the mild steel substrate layer 122. The rubber insert 124 may be made of natural rubber.

[0057] In more detail, in this example, each of the high chromium cast iron layer 120, the rubber insert layer 124 and the mild steel substrate layer 122 include respective corresponding openings 130, 132, 134 clips arranged to enable the clip 113, more specifically the rod 119 of the clip 113, to be passed therethrough to secure the web 112 to the outer frame.

[0058] As best shown in Figure 13, the fastener openings 130 of the high chromium cast iron layer 120 include tapered or angled recessed surfaces 136 for receiving and engaging the corresponding tapered surfaces of the head 117 of a fastener 113 , as shown in Figure 14. The recessed surfaces 136 enable the fasteners 113 to be flush or recessed relative to the outer surface 138 of the high chromium cast iron layer 120, and in particular the recessed surfaces 136 enable the fastener 113 to engage there and apply a compression force to the screen 112 helping to hold the assembly together.

[0059] The wear protection assembly 110, provided here in the form of the screen 112, also includes one or more spacers 140 that are placed between the high chromium cast iron layer 120 and the mild steel substrate layer 122 The purpose of the spacers 140 is to maintain a predetermined minimum spacing between the high chromium cast iron layer 120 and the mild steel substrate layer 122 to inhibit excessive compression of the rubber insert layer 124. it may be, for example, 1 mm to 10 mm, and preferably about 1.5 to 3 mm. The spacers 140 may be slightly less thick than the rubber insert layer 124 so that there is some compression on the rubber insert layer 124.

[0060] In this example, the spacers 140 are provided in the form of metal washers or torus pieces 142 concentrically fitted and welded to the fastener openings 134 of the mild steel substrate layer 122. fastener openings 132 of the rubber insert 124 are sized to receive the metal washers 142 to allow the metal washers to abut directly against an inner face 144 of the high chromium cast iron layer 120 in the installed condition.

[0061] In this example, the high chromium cast iron layer 120, the rubber insert layer 124, and the mild steel substrate layer 122 each include corresponding respective screen holes 150, 152, and 154 arranged to align with each other in the installed condition. Screen holes 150, 152 and 154 may be elongated in shape and have rounded ends. It should be noted that in some examples the high chromium cast iron layer 210 and the mild steel substrate layer 122 may be curved in shape.

[0062] A method for forming the wear protection assembly 110 will now be discussed. The method for forming the wear protection assembly 110, in this example the screen 112, includes providing the high chromium iron layer 120 and the mild steel substrate layer 122. The wear layer made of high chromium cast iron 120 is formed by a casting process with the fastener apertures 130 having recessed surfaces 136 and elongated holes 150 therein. The wear protection layer made of high chromium 120 cast iron can be formed to be curved.

[0063] The mild steel substrate layer 122 can be formed by cutting the metal to the right size and creating in it, through machining, the openings 134 and the elongated holes 154. The spacers 140 in the form of washers metal strips 142 may be welded to the mild steel substrate layer 122 and around the openings 134.

[0064] The method then includes installing or "sandwiching" the rubber layer 124 between the wear protection layer made of high chromium cast iron 120 and the mild steel substrate layer 122. The respective openings 130 , 132, 134 and holes 150, 152, 154 are aligned with each other. The sandwich is then hot vulcanized using a heat or similar process to melt the rubber layer 124 and bond the high chromium cast iron wear part layer 120 and the steel substrate layer. soft 122 each other.

[0065] It should be noted that the respective openings and holes 132 and 152 of the intermediate rubber layer 124 can be pre-formed or pre-drilled or can be made after vulcanization. Preferably, however, the openings 132 are pre-cut to allow the spacers 140 to rest directly against the high chromium cast iron layer 120 to aid spacing and alignment prior to vulcanization. The wear guard assembly 110 is then allowed to cool and then formed as a unitary structure.

[0066] In use, the wear protection assembly 110 is secured to the outer structure with fasteners 113, preferably screws 115. In particular, it is again pointed out that the recessed surfaces 136 of the openings 132 allow the head 117 of the fastener 113 to lean on the screen 112 and apply a compression force to it, thus helping to maintain the integrity of the sandwich. After fastener 113 is tightened, spacer 140 inhibits excessive compression of rubber layer 124.

[0067] Advantageously, the wear protection assembly disclosed in the present invention makes it possible to unite a high-wear resistant layer, which can be brittle, with a metal substrate by means of an intermediate layer of rubber and fixing screws that compress and maintain the integrity of the assembly and secure it to the external structure. The spacers help to maintain a thickness of the rubber layer to retain its cushioning characteristics while at the same time allowing the screws to exert a compressive force on the wear protection layer to keep it attached to the outer structure. Cap screws provide ease of installation and removal of the wear guard assembly.

[0068] In this specification and in the claims that follow, unless the context indicates otherwise, the term "comprises", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of an integer declared or a step or a group of integers or steps, but not to the exclusion of any other integer or step or group of integers or steps.

[0069] Reference in this specification to any known subject or any prior art publication is not, nor should it be construed as, an acknowledgment or admission or suggestion that the known subject or prior art publication forms part of common general knowledge in the field to which to which this descriptive report refers.

[0070] While specific examples of the invention have been presented, it should be understood that the invention extends to alternative combinations of the features presented or evident in the disclosure provided herein.

[0071] Many and various modifications will be evident to those skilled in the art without departing from the scope of the disclosed invention or will be evident in the disclosure provided herein.

Claims (7)

1. Wear protection assembly, for coupling to an external structure with a fastener (113) in the installed condition, the wear protection assembly (110) being characterized in that it includes: - a wear layer (114) that includes a wear-resistant cast material, - a substrate layer (116) including a metallic material; and - an intermediate layer (118) which includes rubber and is vulcanized between the wear layer (114) and the substrate layer (116), each of which of the wear layer (114), the substrate layer (116 ) and the intermediate layer (118) include one or more corresponding fastener apertures (130, 134 and 132) arranged to enable the fastener (113) to be passed therethrough to secure the wear guard assembly (110) to the outer frame in the installed condition, the one or more fastener openings (130) of the wear layer (114) including a recessed surface (136) arranged to enable the fastener (113) to rest on the recessed surface (136) and compress the wear layer (114) towards the outer structure in the installed condition, and wherein the wear protection assembly (110) includes one or more spacers (140) between the wear layer (114) and the substrate layer (116) ) defining a thickness the minimum of the intermediate layer (118), thereby inhibiting excessive compression by the fastener (113) in the installed condition. 2. Assembly of protection against wear, according to claim 1, characterized in that a thickness of at least one spacer (140) is less than a thickness of the intermediate layer (118). 3. Wear protection assembly, according to claim 2, characterized in that one or more spacers (140) are provided in the form of one or more washers (142) arranged between the wear layer (114) and the substrate layer (116) so as to surround each of the one or more openings (130) in the installed condition, with the one or more fasteners (113) passing therethrough. 4. Wear protection set according to any one of claims 1 to 3, characterized in that each of the wear layer (114), the substrate layer (116) and the intermediate layer (118) include one or more corresponding holes (150, 152, 154) arranged so that the wear guard assembly (110) provides a screen (112). 5. Method for forming a wear protection assembly, which can be attached to an external structure with a fastener (113) in the installed condition, the method being characterized in that it includes the steps of: - forming a layer against wear (114 ) which includes a wear-resistant cast material having one or more first fastener openings (130) therethrough, the one or more first fastener openings (130) being formed with a recessed surface (136) arranged to enable that the fastener (113) applies a compressive force to the wear guard assembly (110) in the installed condition; - providing a layer of substrate (116) that includes a metallic material that has one or more second fastener apertures (134) therethrough; - providing one or more spacers (140) between the wear layer (114) and the substrate layer (116); and - sandwiching an intermediate rubber layer (118) between the wear layer (114) and the substrate layer (116) by hot vulcanizing the rubber layer (118), wear layer (114) and substrate (116) sandwiched together with the first and second fastener openings (130, 134) of the wear layer (114) and substrate layer (116) being aligned with each other to enable the fastener (113) to be passed through them with the one or more spacers (140) being positioned between the wear layer (114) and the substrate layer (116) to define a minimum thickness of the rubber intermediate layer (118), thereby inhibiting excessive compression by the fastener (113) in installed condition. 6. Method according to claim 5, characterized in that each of the wear layer (114), the substrate layer (116) and the intermediate layer (118) are formed to include one or more holes (150 , 152, 154) corresponding thereto, the holes (150, 152, 154) arranged so that the wear guard assembly (110) forms a screen (112). 7. Screen, characterized in that it is formed according to the method for forming a wear protection assembly, as defined in claim 5 or claim 6.

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