WO2011064685A1 - Wear -resistant roller for crushing and method for producing the same - Google Patents
Wear -resistant roller for crushing and method for producing the same Download PDFInfo
- Publication number
- WO2011064685A1 WO2011064685A1 PCT/IB2010/055087 IB2010055087W WO2011064685A1 WO 2011064685 A1 WO2011064685 A1 WO 2011064685A1 IB 2010055087 W IB2010055087 W IB 2010055087W WO 2011064685 A1 WO2011064685 A1 WO 2011064685A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- wear
- roller
- resistant
- groove
- elements
- Prior art date
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C4/00—Crushing or disintegrating by roller mills
- B02C4/28—Details
- B02C4/30—Shape or construction of rollers
- B02C4/305—Wear resistant rollers
Definitions
- the present invention relates to a wear-resistant roller for crushing of particulate material, such as crude ore for use in the mineral industry, comprising a roller provided with a plurality of grooves in the crushing surface of the roller and at least one element of wear-resistant material placed in each groove, where the element of wear-resistant material is composed of a material which is harder than the material of the roller.
- the invention also relates to a method for carrying out the invention.
- the wear-resistant roller may for example be used in a high-pressure roller press, in a vertical roller mill or in similar equipment for crushing of particulate material.
- a wear-resistant roller of the aforementioned kind is known from EP 0516952 Bl.
- the European patent describes a roller press where the rollers comprise a plurality of cylindrical pins embedded in the crushing surface.
- the cylindrical pins which are made of wear-resistant material, are inserted in drilled holes in the crushing surface of the roller and secured by means of a shrink fit connection or a similar arrangement. A part of the pins protrudes from the surface of the roller. Given that the pins and holes must fit each other exactly in order to withstand the high loads occurring during operation they must be manufactured with a relatively high degree of precision and since the entire circumference of the roller is covered with pins it is a very time- consuming process to manufacture such a roller. Because of this the manufacture of the roller involves significant costs.
- the grooves may have all kinds of shapes and sizes as long as at least one element of wear-resistant material can be put into the groove and be secured by welding material introduced in the groove.
- the grooves should preferentially be longitudinal grooves in the axial direction of the roller which grooves may vary in length, width and depth so as to compensate for variations in the wear rates on the roller.
- the grooves should preferentially be placed in a pattern over the entire circumference of the roller.
- grooves may be provided in the edge of the roller, thereby making it possible to ensure significant wear protection at the roller edge.
- the grooves may either be machined or prepared when casting the roller.
- the elements of wear-resistant material which are harder and have a greater wear resistance than the surrounding welding material and the roller material, may have all kind of possible shapes as long as they have the sufficient strength to withstand the loads imposed during the operation of the roller press.
- the elements of wear-resistant material are conically configured. When a conical element of wear- resistant material is used and the wide end is placed in the bottom of the groove there will also be mechanical locking of the element when the welding material solidifies. This means that it will be possible to use welding material which does not form a substantial bond with the elements of wear-resistant material but forming only a substantial bond with the roller material.
- elements of wear-resistant material without been limited by a requirement which involves that the welding material must form a substantial bond between both the roller material and the elements of wear-resistant material.
- Other shapes of elements of wear-resistant material which also are mechanically locked may e.g. be elements formed like a truncated pyramid. The elements may either protrude from the roller surface or be in line with the roller surface.
- the surface of the groove is prepared with a buffer layer onto which the element of wear-resistant material is placed and temporarily attached to prior to welding.
- the buffer layer comprises an alloy which ensures that a substantial bond also is obtained between the roller material and the element of wear-resistant material during the welding process and after solidification of the welding material.
- two or more elements of wear-resistant material are provided in each groove.
- the number of grooves in the roller can be reduced, and, even though the grooves must be larger in size, this will reduce the time used to prepare a roller for the wear elements.
- the time used for securing the elements with welding material will be reduced when more elements are secured in a single groove.
- smaller particles of wear-resistant material are added to the welding material in the grooves, when the welding material is in the liquid phase.
- the wear-resistant particles must be present in the upper part of the welding material when it solidifies. If they only are present at the bottom of the grooves they will have no effect. This means that the size of the wear-resistant particles must be small enough (low weight), compared to the viscosity of the liquid welding material, to remain in the upper part of the pool of welding material. Therefore it is preferred that the particles do not exceed five millimetres in size.
- the roller comprises a roller body equipped with a shrunk- on tyre into which the grooves are provided. This is an advantageous way of producing a roller as it then will be possible to remove the tyre from the roller body. Thus, if the tyre is severe damaged and it not is possible to repair, it only will be necessary to change the tyre.
- All types of welding processes for securing the elements of wear-resistant material in the grooves may be used, as long as the process is capable of filling the whole groove around the elements with a liquid pool of welding material.
- flood- welding using a Plasma Transfer Arc welding process should preferentially be used since this process is very fast and due to the fact that such a welding can be repaired in a fairly simple manner thus making it possible to carry out required repair work at site.
- This process makes it possible to use very complex welding material whereby the elements of wear-resistant material for example can be enclosed by a very ductile nickel-based material which prevents fractures from propagating deeply into the roller body. Also there is no need for preheating of the roller.
- the process which is comparatively noiseless, can be automated in a straightforward way.
- Fig. 1 shows a section of a roller press with two rollers according to the invention.
- Fig. 2 shows a roller provided with grooves on the edge of the roller.
- Fig. 3 shows a cross-sectional view of a groove in a wear-resistant roller where elements of wear-resistant material have been secured in a groove.
- Fig. 4 shows a cross-sectional view of a groove in a wear-resistant roller where elements of wear-resistant material are locked mechanically.
- Fig. 1 shows a roller press 1 for crushing particulate material, for example crude ore for use in the mineral industry or raw material for cement production, comprising two oppositely rotating rollers 2,3 forming between them a roller gap 4 to which the particulate material is directed.
- a plurality of grooves 5 are provided in the crushing surface of the rollers 2,3.
- T he grooves 5 in the surface of the rollers 2,3 may be arranged in different patterns (only the location and shape of the grooves 5 are shown, not the depth of the grooves 5).
- the pattern for each roller 2,3 may be similarly configured or may vary as illustrated. By varying the length, width and depth of the longitudinal grooves 5 it will be possible to compensate for variations in wear rates on the rollers 2,3.
- the grooves 5 may either be machined or made when casting the rollers 2,3.
- FIG. 2 shows a roller according to the invention where grooves 5a are provided on the edge of the roller, whereby wear protection at the roller edge is ensured (only the location and shape of the grooves 5, 5a are shown, not the depth of the grooves 5).
- FIG. 3 shows a cross-sectional view of a single groove 5 in a roller 2 into which
- the buffer layer 8 comprises an alloy which ensures that a substantial bond also is obtained between the roller material and the elements 6 of wear-resistant material during the welding process and after solidification of the welding material 7.
- the elements 6 of wear-resistant material are temporarily attached to the buffer layer 8 prior to being secured by welding material introduced directly into the groove 5 around the elements 6.
- the elements 6, which are harder than the surrounding welding material 7 and the roller material, is shown to be in line with the surface of the roller 2 but may also protrude from the surface of the roller 2. During the welding process small particles 9 of wear-resistant material are added to the welding pool.
- the wear-resistant particles 9 must be present in the upper part of the welding material 7 when it solidifies which means that the size of the wear-resistant particles 9 must be small enough, compared to the viscosity of the liquid welding material 7, to remain in the upper part of the pool of welding material 7.
- Fig. 4 shows an embodiment with conical elements 6a of wear-resistant material.
Landscapes
- Engineering & Computer Science (AREA)
- Food Science & Technology (AREA)
- Crushing And Grinding (AREA)
Abstract
A description is given of a wear-resistant roller for crushing of particulate material, such as crude ore for use in the mineral industry, which wear-resistant roller comprises a plurality of grooves (5) in the crushing surface of the roller (2) and at least one element (6) of wear-resistant material placed in each groove (5), where the element(s) (6) of wear-resistant material is composed of a material which is harder than the material of the roller (2). The roller press is characterized in that welding material (7), introduced directly into each groove (5), surrounds and secures the element(s) (6) of wear-resistant material in each groove (5). In this way it will be relatively easy and fast to manufacture a wear-resistant roller and it will be possible to repair the roller at site as there are no particular demands to the precision of the grooves or the wear elements. Therefore ordinary hand tools can be used to repair the roller. Furthermore various shapes of wear resistant elements, also without any particular demands to precision, can be used as they to a certain degree are independent of the shape and form of the groove.
Description
Description
WEAR -RESISTANT ROLLER FOR CRUSHING AND METHOD FOR PRODUCING THE SAME
[1] The present invention relates to a wear-resistant roller for crushing of particulate material, such as crude ore for use in the mineral industry, comprising a roller provided with a plurality of grooves in the crushing surface of the roller and at least one element of wear-resistant material placed in each groove, where the element of wear-resistant material is composed of a material which is harder than the material of the roller. The invention also relates to a method for carrying out the invention.
[2] The wear-resistant roller may for example be used in a high-pressure roller press, in a vertical roller mill or in similar equipment for crushing of particulate material.
[3] A wear-resistant roller of the aforementioned kind is known from EP 0516952 Bl.
The European patent describes a roller press where the rollers comprise a plurality of cylindrical pins embedded in the crushing surface. The cylindrical pins, which are made of wear-resistant material, are inserted in drilled holes in the crushing surface of the roller and secured by means of a shrink fit connection or a similar arrangement. A part of the pins protrudes from the surface of the roller. Given that the pins and holes must fit each other exactly in order to withstand the high loads occurring during operation they must be manufactured with a relatively high degree of precision and since the entire circumference of the roller is covered with pins it is a very time- consuming process to manufacture such a roller. Because of this the manufacture of the roller involves significant costs. Sometimes during operation large lumps of rock impact a single pin, whereby the pin is subjected to quite substantial loads which may sometimes lead to breakage of the pin. Other process situations may also lead to breakage of pins. Due to the precision work required for the holes and pins and given the difficulties involved in removing the rest of the broken pins which are stuck in the roller it will not normally be possible to perform a reconditioning of the roller at site. Therefore the reconditioning of rollers must be carried out in specialized workshops. This is a time-consuming as well as labour-intensive task since the very heavy rollers must be removed from the roller press and must usually be transported a long distance to such a workshop. Furthermore it would be advantageous to use wear-resistant material which is not cylindrical, instead having various shapes, in order to optimize the strength of the wear-resistant material to increase the service life of the roller. This is not possible with the invention disclosed in the European patent.
[4] It is the object of the present invention to provide a wear-resistant roller by means of which the described disadvantages are eliminated or reduced.
[5] This is obtained by a wear-resistant roller of the kind mentioned in the introduction, and being characterized in that welding material, introduced directly into each groove,
surrounds and secures the element of wear-resistant material in each groove.
[6] In this way it will be relatively easy and fast to manufacture a wear-resistant roller and it will be possible to repair the roller at site as there are no particular demands to the precision of the grooves or the wear elements. Therefore ordinary hand tools can be used to repair the roller. Furthermore various shapes of wear resistant elements, also without any particular demands to precision, can be used as they to a certain degree are independent of the shape and form of the groove.
[7] In principle the grooves may have all kinds of shapes and sizes as long as at least one element of wear-resistant material can be put into the groove and be secured by welding material introduced in the groove. However, the grooves should preferentially be longitudinal grooves in the axial direction of the roller which grooves may vary in length, width and depth so as to compensate for variations in the wear rates on the roller. The grooves should preferentially be placed in a pattern over the entire circumference of the roller. Furthermore grooves may be provided in the edge of the roller, thereby making it possible to ensure significant wear protection at the roller edge. The grooves may either be machined or prepared when casting the roller.
[8] The elements of wear-resistant material, which are harder and have a greater wear resistance than the surrounding welding material and the roller material, may have all kind of possible shapes as long as they have the sufficient strength to withstand the loads imposed during the operation of the roller press. In one embodiment the elements of wear-resistant material are conically configured. When a conical element of wear- resistant material is used and the wide end is placed in the bottom of the groove there will also be mechanical locking of the element when the welding material solidifies. This means that it will be possible to use welding material which does not form a substantial bond with the elements of wear-resistant material but forming only a substantial bond with the roller material. In this way it will be possible to choose a wide range of materials for the elements of wear-resistant material without been limited by a requirement which involves that the welding material must form a substantial bond between both the roller material and the elements of wear-resistant material. Other shapes of elements of wear-resistant material which also are mechanically locked may e.g. be elements formed like a truncated pyramid. The elements may either protrude from the roller surface or be in line with the roller surface.
[9] In another embodiment the surface of the groove is prepared with a buffer layer onto which the element of wear-resistant material is placed and temporarily attached to prior to welding. The buffer layer comprises an alloy which ensures that a substantial bond also is obtained between the roller material and the element of wear-resistant material during the welding process and after solidification of the welding material.
[10] In a preferred embodiment two or more elements of wear-resistant material are
provided in each groove. In this way the number of grooves in the roller can be reduced, and, even though the grooves must be larger in size, this will reduce the time used to prepare a roller for the wear elements. Furthermore the time used for securing the elements with welding material will be reduced when more elements are secured in a single groove.
In yet another embodiment smaller particles of wear-resistant material are added to the welding material in the grooves, when the welding material is in the liquid phase. In this way the welding material between the elements of wear-resistant material will achieve improved wear resistance characteristics. The wear-resistant particles must be present in the upper part of the welding material when it solidifies. If they only are present at the bottom of the grooves they will have no effect. This means that the size of the wear-resistant particles must be small enough (low weight), compared to the viscosity of the liquid welding material, to remain in the upper part of the pool of welding material. Therefore it is preferred that the particles do not exceed five millimetres in size.
In a special embodiment the roller comprises a roller body equipped with a shrunk- on tyre into which the grooves are provided. This is an advantageous way of producing a roller as it then will be possible to remove the tyre from the roller body. Thus, if the tyre is severe damaged and it not is possible to repair, it only will be necessary to change the tyre.
All types of welding processes for securing the elements of wear-resistant material in the grooves may be used, as long as the process is capable of filling the whole groove around the elements with a liquid pool of welding material. However flood- welding using a Plasma Transfer Arc welding process should preferentially be used since this process is very fast and due to the fact that such a welding can be repaired in a fairly simple manner thus making it possible to carry out required repair work at site. This process makes it possible to use very complex welding material whereby the elements of wear-resistant material for example can be enclosed by a very ductile nickel-based material which prevents fractures from propagating deeply into the roller body. Also there is no need for preheating of the roller. Furthermore, the process, which is comparatively noiseless, can be automated in a straightforward way.
The invention will now be explained in greater detail with reference to the drawing, being diagrammatical, and where
Fig. 1 shows a section of a roller press with two rollers according to the invention.
Fig. 2 shows a roller provided with grooves on the edge of the roller.
Fig. 3 shows a cross-sectional view of a groove in a wear-resistant roller where elements of wear-resistant material have been secured in a groove.
Fig. 4 shows a cross-sectional view of a groove in a wear-resistant roller where
elements of wear-resistant material are locked mechanically.
[19] Fig. 1 shows a roller press 1 for crushing particulate material, for example crude ore for use in the mineral industry or raw material for cement production, comprising two oppositely rotating rollers 2,3 forming between them a roller gap 4 to which the particulate material is directed. A plurality of grooves 5 are provided in the crushing surface of the rollers 2,3. T he grooves 5 in the surface of the rollers 2,3 may be arranged in different patterns (only the location and shape of the grooves 5 are shown, not the depth of the grooves 5). The pattern for each roller 2,3 may be similarly configured or may vary as illustrated. By varying the length, width and depth of the longitudinal grooves 5 it will be possible to compensate for variations in wear rates on the rollers 2,3. The grooves 5 may either be machined or made when casting the rollers 2,3.
[20] Fig. 2 shows a roller according to the invention where grooves 5a are provided on the edge of the roller, whereby wear protection at the roller edge is ensured (only the location and shape of the grooves 5, 5a are shown, not the depth of the grooves 5).
[21] Fig. 3 shows a cross-sectional view of a single groove 5 in a roller 2 into which
groove 5 elements 6 of wear-resistant material have been secured by welding material 7. Prior welding a buffer layer 8 is attached to the surface of the groove 5. The buffer layer 8 comprises an alloy which ensures that a substantial bond also is obtained between the roller material and the elements 6 of wear-resistant material during the welding process and after solidification of the welding material 7. The elements 6 of wear-resistant material are temporarily attached to the buffer layer 8 prior to being secured by welding material introduced directly into the groove 5 around the elements 6. The elements 6, which are harder than the surrounding welding material 7 and the roller material, is shown to be in line with the surface of the roller 2 but may also protrude from the surface of the roller 2. During the welding process small particles 9 of wear-resistant material are added to the welding pool. In this way the welding material 7 surrounding the elements 6 of wear-resistant material will achieve improved wear resistance characteristics. The wear-resistant particles 9 must be present in the upper part of the welding material 7 when it solidifies which means that the size of the wear-resistant particles 9 must be small enough, compared to the viscosity of the liquid welding material 7, to remain in the upper part of the pool of welding material 7.
[22] Fig. 4 shows an embodiment with conical elements 6a of wear-resistant material.
When a conical element 6a of wear-resistant material is used and the wide end is placed in the bottom of the groove the element 6a is locked mechanically when the welding material 7 solidifies. This means that it will be possible to use welding material 7 which does not form a substantial bond with the elements 6a of wear- resistant material but only form a substantial bond with the material of the roller 2.
Furthermore the buffer layer 8, shown in Fig. 3, can thus be dispensed with.
Claims
A wear-resistant roller for crushing of particulate material, such as crude ore for use in the mineral industry, comprising a roller (2) provided with a plurality of grooves (5) in the crushing surface of the roller (2) and at least one element (6) of wear- resistant material placed in each groove (5), where the element (6) of wear-resistant material is composed of a material which is harder than the material of the roller (2) characterized in that welding material (7), introduced directly into each groove (5), surrounds and secures the element (6) of wear-resistant material in each groove (5).
A wear-resistant roller according to claim 1 characterized in that the grooves (5) are longitudinal grooves in the axial direction of the roller.
A wear-resistant roller according to any preceding claim characterized in that two or more elements (6) of wear-resistant material are provided in each groove (5).
A wear-resistant roller according to any preceding claim characterized in that the elements (6) of wear-resistant material are conically.
A wear-resistant roller according to any preceding claim characterized in that the elements (6) of wear-resistant material are formed as truncated pyramids.
A method for producing a wear-resistant roller for crushing of particulate material, such as crude ore for use in the mineral industry, by which method a roller (2) is provided with a plurality of grooves (5) in the crushing surface of the roller (2) and with at least one element (6) of wear-resistant material placed in each groove (5), where the element(s) (6) of wear-resistant material is composed of a material which is harder than the material of the roller (2) characterized in that welding material (7) for securing the element(s) of wear-resistant material in each groove (5) is introduced directly into each groove (5) around the element(s) (6) of wear-resistant material.
A method for producing a wear-resistant roller according to claim 6 characterized in that the surface of each groove (5) is prepared with a buffer layer (8), before placing the element(s) of wear- resistant material into the grooves (5), for ensuring that a substantial bond is obtained between the roller material and the elements (6) of wear-resistant material.
8. A method for producing a wear-resistant roller according to claim 6 or 7 characterized in that particles (9) of wear-resistant material are added to the pool of welding material (7) in the grooves (5), when the welding material (7) is in the liquid phase. A method for producing a wear-resistant roller according to claim 6, 7 or 8 characterized in that the elements (6) of wear-resistant material are shaped in a way so a mechanically lock of the elements (6) is obtained when the welding material (7) solidifies. A method for producing a wear-resistant roller according to claim 6, 7, 8 or 9 characterized in that flood welding using a Plasma Transfer Arc welding process is used for securing the elements (6) of wear-resistant material in the grooves (5).
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DKPA200901248 | 2009-11-25 | ||
| DKPA200901248 | 2009-11-25 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO2011064685A1 true WO2011064685A1 (en) | 2011-06-03 |
| WO2011064685A9 WO2011064685A9 (en) | 2011-08-11 |
Family
ID=43500343
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/IB2010/055087 WO2011064685A1 (en) | 2009-11-25 | 2010-11-09 | Wear -resistant roller for crushing and method for producing the same |
Country Status (2)
| Country | Link |
|---|---|
| TW (1) | TW201134554A (en) |
| WO (1) | WO2011064685A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU2016102005A4 (en) * | 2016-11-18 | 2016-12-15 | Muddie's Holdings Pty Ltd | Method of Application of Hard Facing to Wear Parts and Apparatus formed therefrom |
| US20220410168A1 (en) * | 2019-11-26 | 2022-12-29 | Thyssenkrupp Industrial Solutions Ag | Wear-resistant element for a comminuting apparatus |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0271336A2 (en) * | 1986-12-09 | 1988-06-15 | I N G Shoji Co., Ltd. | Crushing members for crushers |
| EP0516952B1 (en) | 1991-05-28 | 1995-09-20 | Klöckner-Humboldt-Deutz Aktiengesellschaft | Wear-resistant roller to be used in roller crushers, in particular high-pressure roller crushers |
| US5516053A (en) * | 1993-10-07 | 1996-05-14 | Hannu; Donald W. | Welded metal hardfacing pattern for cone crusher surfaces |
| JP2001347175A (en) * | 2000-06-08 | 2001-12-18 | Ing Shoji Kk | Crushing surface member used in pulverizer |
| EP2181797A1 (en) * | 2008-10-31 | 2010-05-05 | Welding Alloys Limited | Method of manufacture of composite press rollers with welded high abrasion resistant material in cavities ; Composite press roller with such filled cavities |
-
2010
- 2010-11-09 WO PCT/IB2010/055087 patent/WO2011064685A1/en active Application Filing
- 2010-11-25 TW TW099140817A patent/TW201134554A/en unknown
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0271336A2 (en) * | 1986-12-09 | 1988-06-15 | I N G Shoji Co., Ltd. | Crushing members for crushers |
| EP0516952B1 (en) | 1991-05-28 | 1995-09-20 | Klöckner-Humboldt-Deutz Aktiengesellschaft | Wear-resistant roller to be used in roller crushers, in particular high-pressure roller crushers |
| US5516053A (en) * | 1993-10-07 | 1996-05-14 | Hannu; Donald W. | Welded metal hardfacing pattern for cone crusher surfaces |
| JP2001347175A (en) * | 2000-06-08 | 2001-12-18 | Ing Shoji Kk | Crushing surface member used in pulverizer |
| EP2181797A1 (en) * | 2008-10-31 | 2010-05-05 | Welding Alloys Limited | Method of manufacture of composite press rollers with welded high abrasion resistant material in cavities ; Composite press roller with such filled cavities |
Also Published As
| Publication number | Publication date |
|---|---|
| TW201134554A (en) | 2011-10-16 |
| WO2011064685A9 (en) | 2011-08-11 |
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