WO2013066933A1

WO2013066933A1 - Edge protection for roller presses

Info

Publication number: WO2013066933A1
Application number: PCT/US2012/062680
Authority: WO
Inventors: David M. Sharman; Michael R. Massaro; Steven C. Jones; Jason S. Euculano
Original assignee: Flsmidth A/S
Priority date: 2011-10-31
Filing date: 2012-10-31
Publication date: 2013-05-10

Abstract

A roller press having an improved edge wear assembly is disclosed. The roller press comprises a roller shaft having an axis and a roller sleeve assembly. The roller sleeve assembly comprises a roller sleeve having an outer surface, and an annular abutment surface proximate an end of the outer surface. The annular abutment surface extends generally transversely with respect to the outer surface of the roller sleeve. A plurality of mounting bosses extend from the abutment surface in a direction generally parallel to the axis of the roller shaft, wherein one or more of the mounting bosses are circumferentially spaced from one another. A plurality of wear components which are received and supported by the mounting bosses.

Description

EDGE PROTECTION FOR ROLLER PRESSES

CROSS-REFERENCE TO RELATED APPLICATION This application claims priority to US Provisional Patent Application Serial No.

61/553,289 filed on 31 October 2011.

BACKGROUND OF THE INVENTION

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, and minerals processing industries.

Currently, when roller edges erode, workers must fill gaps and worn-away roller sleeve material with hard-facing weld material. Subsequent grinding and machining process on the roller sleeve may be necessary after welding in order to bring the roller back to original specifications. Such methods are time-consuming, inefficient, and therefore costly.

Recent attempts have been made to address edge wear. For instance, KHD and Polysius have pursued roller designs which incorporate fastening of removable hard bodies to the roller edges (see U.S. Patent Nos. 7,497,397 and 7,510,135). However, these designs fail to provide adequate support and stability for the hard bodies under tangential shear loads in at least a circumferential direction, while still preserving ease of maintenance and/or removal of the hard bodies.

OBJECTS OF THE INVENTION

It is, therefore, an object of the invention to provide a mechanically-robust edge wear component system.

This 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.

SUMMARY OF THE INVENTION

A roller for use in a roller press is disclosed. The roller press comprises a roller shaft having an axis, and a roller sleeve assembly. The roller sleeve assembly comprises a roller sleeve having an outer surface, an annular abutment surface proximate an end of the outer surface and extending generally transversely with respect to the outer surface, and a plurality of mounting bosses extending from the abutment surface in a direction generally parallel to the axis of the roller shaft. One or more of the mounting bosses are circumferentially spaced from one another.

The roller sleeve assembly comprises a plurality of wear components which are received and supported by the mounting bosses. In some embodiments, a plurality of retainers is provided for holding wear components to the roller sleeve. The retainers may be held within receiving portions provided to the wear components. One or more fasteners may pass through the retainers, the wear components, and the roller sleeve. The fasteners may be held in place by attachment features in the roller sleeve.

In some embodiments, one or more interlocking features such as a mating lip, a tongue- in-groove structure, a dovetail structure, a peg-in-hole connection, mating serpentine surfaces, mating undulated surfaces, mating stepped portions, or interfitting castellation features may be provided between the wear components and the retainers. In some embodiments, the mounting bosses generally extend in a radial direction with respect to the axis of the roller shaft.

In other embodiments, a plurality of receiving portions extending into an abutment surface of a roller shell may be provided, wherein one or more of the receiving portions are circumferentially spaced from one another. Wear components may be received and supported by the receiving portions. Fasteners may pass through the wear components and the roller sleeve, and held within attachment features in the roller sleeve. Mounting bosses provided to the wear components may be received in a corresponding number of receiving portions a plurality of retainers may be received within and supported by the receiving portions in the roller sleeve, and the retainers may further be received within one or more second receiving portions provided within the wear components. Retainers may be captured between body portions of the wear components and the roller shell, while still permitting the wear components to contact the abutment surface.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an end view of a roller sleeve assembly according to some embodiments;

FIG. 2 is an end view of a roller sleeve from the assembly of FIG. 1;

FIG. 3 is an alternative view of the roller sleeve in FIG. 2;

FIG. 4 is a close-up view of a partially-assembled roller sleeve shown in FIG. 1;

FIG. 5 is a detailed view of a wear component from the roller sleeve assembly of FIG. 1; FIG. 6 is an end view of a roller sleeve according to other embodiments; FIG. 7 is a detailed view of a wear component for use with the roller sleeve shown in

FIG. 6;

FIG. 8 is an end view of a roller sleeve according to yet even other embodiments; FIG. 9 is a detailed view of a wear component for use with the roller sleeve shown in

FIG. 8;

FIG. 10 illustrates a roller sleeve assembly according to some embodiments;

FIG. 11 illustrates a roller sleeve assembly according to other embodiments;

FIG. 12 illustrates a roller sleeve assembly according to yet even other embodiments;

FIG. 13 shows a wear component assembly according to some embodiments, wherein complementary interlocking features are provided between a wear component and a retainer;

FIGS. 14 and 15 show an alternative embodiment of a wear component assembly;

FIGS. 16A and 16B are isometric end views of a roller sleeve assembly according to some embodiments;

FIGS. 17A and 17B are isometric end views of a roller sleeve assembly according to other embodiments;

FIG. 18 is a cross-sectional view of FIG. 17B along line XVIII-XVIII;

FIG. 19 is an isometric end view of the roller sleeve in FIG. 18;

FIGS. 20 A and 20B are outer and inner surface views of the wear component shown in FIGS. 16A and 16B, respectively;

FIGS. 21 A and 2 IB are outer and inner surface views of the wear component shown in FIGS. 17A and 17B, respectively;

FIG. 22 shows a wear component assembly comprising an encapsulated retainer; FIG. 23 is an alternate view of a wear component in the assembly of FIG. 22, better showing a receiving portion configured to accept the retainer;

FIG. 24 is an end view of a roller sleeve and roller shaft assembly according to some embodiments having radial gaps or radial abutments between wear components;

FIG. 25 is an end view of a roller sleeve and roller shaft assembly according to some embodiments, wherein the roller sleeve comprises a series of radial bosses; and,

FIGS. 26A-28B show wear components according to three other embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION FIGS. 1-4 show a roller sleeve assembly 10 according to a first embodiment. The roller sleeve assembly 10 comprises a roller sleeve 20 having a plurality of mounting bosses 22 extending axially from an abutment surface 26, one or more wear inserts 30 arranged on an outer surface 25 of the roller sleeve 20, and a plurality of wear components 40 arranged along an edge of the roller sleeve 20. Each mounting boss 22 is configured to mate with a cutout 48 formed in a respective wear component 40. Each mounting boss 22 comprises at least one receiving portion 24 configured for receiving a retainer 50, and one or more attachment features 28. Each wear component 40 comprises a first side 42, second side 46, a first receiving portion 44A, a second receiving portion 44B, and a cutout 48 generally defined by a first side 48A, a second side 48B, and a third side 48C. One or more receiving portions 58 provided in the retainer 50 accept fasteners (not shown) which may be recessed within or flush with receiving portions 58. Alternatively, said fasteners may sit proud on each wear component 40. First and second receiving portions 44A, 44B of each wear component 40 and respective receiving portion 24 are configured to receive the retainer 50. Retainer 50 secures the wear component 40 to the roller sleeve 20.

FIGS. 6 and 7 show a roller sleeve 120 according to a second embodiment. The roller sleeve 120 comprises a plurality of mounting bosses 122 extending axially from an abutment surface 126, which are configured to receive a plurality of wear components 140 along an edge portion of the roller sleeve 120. Each mounting boss 122 is configured to mate with a cutout 148 in a respective wear component 140. Each mounting boss 122 comprises at least one receiving portion 124 configured for receiving a retainer (not shown), one or more attachment features 128, and a cutout 123 preferably extending between a first side 122A and a second side 122B. However, while not illustrated the cutout 123 may be provided to other areas of the mounting boss 122 in various embodiments. For instance, cutout 123 may be located at radially inside portions of the mounting boss 122, adjacent an inside diameter of the roller sleeve 120. Cutout 123 may comprise an undercut as shown, but may also comprise a groove, a channel, a portion of a lap joint, or a portion of a dovetail joint without limitation.

Each wear component 140 comprises a first side 142, second side 146, a first receiving portion 144A, a second receiving portion 144B, and a cutout 148 defined by a first side 148 A, a second side 148B, and a third side 148C. First and second receiving portions 144A, 144B of each wear component 140 and respective receiving portion 124 are configured to receive a retainer (not shown), which secures the wear component 140 to the roller sleeve 120. In the embodiment shown, wear component 140 comprises a shelf 147 extending between the third side 148C and a fourth side 149. In use, surfaces of the shelf 147, third side 148C, and fourth side 149 mate with surfaces of the mounting boss 122 which form the cutout 123, in order to provide additional stability to the wear component 140 with respect to the roller sleeve 120 when mounted.

FIGS. 8 and 9 show a roller sleeve 220 according to a third embodiment. The roller sleeve 220 comprises a plurality of mounting bosses 222 extending axially from an abutment surface 226, which are configured to receive a plurality of wear components 240 along an edge portion of the roller sleeve 220. Each mounting boss 222 is configured to mate with a cutout 248 in a respective wear component 240. Each mounting boss 222 comprises a receiving portion 224 configured for receiving a retainer (not shown), one or more attachment features 228, a first cutout 223A on a first side 222A of the mounting boss 222, a second cutout 223B on a second side 222B of the mounting boss 222, and a third cutout 223C which may extend for a portion or the entire distance between the first side 222A and the second side 222B as shown. Cutouts 223 A-C may comprise undercuts as shown, but may also comprise grooves, channels, portions of a lap joint, or portions of a dovetail joint without limitation. While not illustrated, additional cutouts may be provided. Moreover, while not illustrated, cutouts may be alternatively or additionally provided to radially inside portions of the mounting boss 222, adjacent an inside diameter of the roller sleeve 220.

Each wear component 240 comprises a first side 242, a second side 246, a first receiving portion 244A, a second receiving portion 244B, and a cutout 248 defined by a first side 248A, a second side 248B, and a third side 248C. First 244A and second 244B receiving portions of each wear component 240 and respective receiving portion 224 are configured to receive a retainer (not shown), which secures the wear component 240 to the roller sleeve 220. In the embodiment shown, a wear component 240 comprises a first shelf 247A, a second shelf 247B, and a third shelf 247C defining a fourth side 249A, a fifth side 249B, and a sixth side 249C.

In use, surfaces of the first, second, and third shelves 247A-C, sides 248A-C, and sides 249 A-C will mate with surfaces of the mounting boss 222 adjacent to and forming the cutouts 223 A-C, in order to provide additional stability to the wear component 240 with respect to the roller sleeve 220 when mounted.

FIG. 10 shows a roller sleeve assembly 310 according to a fourth embodiment. The roller sleeve assembly 310 comprises a roller sleeve 320 having an outer surface 325 comprising a number of wear inserts 330, a plurality of mounting bosses 322 extending axially from an abutment surface 326, and a plurality of wear components 340 having one or more cutouts 348 which are provided to the mounting bosses 322. In the embodiment shown, each wear component 340 slides axially over each mounting boss 322, and then one or more fasteners (not shown) are received within one or more receiving portions 344 and joined to the roller sleeve 320. First 342 and second 346 sides of each wear component 340 abut each other around the entire circumference of the roller sleeve 320, thereby providing resistance to movement in a radial direction by converting radial loads to compressive hoop forces which act tangentially between the wear components 340. Surfaces of the mounting bosses 322 provide resistance to compressive forces experienced by wear components 340 and prevent radially-inwardly movement of the components 340 in a radial direction regardless of whether or not fasteners are received in portions 344 and engage the roll sleeve 320. Moreover, outwardly-flared sides 322A, 322B provided to mounting bosses 322 provide resistance to radially-outwardly movement of the wear components 340 in a radial direction regardless of whether or not fasteners are received in portions 344 and engage the roll sleeve 320.

FIG. 11 shows a roller sleeve assembly 410 according to a fifth embodiment. The roller sleeve assembly 410 comprises a roller sleeve 420 having an outer surface 425 comprising a number of wear inserts 430, a plurality of mounting bosses 422 extending axially from an abutment surface 426, and a plurality of wear components 440 having one or more circular or arcuate cutouts 448 which are provided to the mounting bosses 422. In the embodiment shown, each wear component 440 slides axially and/or radially over each mounting boss 422, and then one or more fasteners (not shown) are received within one or more receiving portions 444 and joined to the roller sleeve 420. First 442 and second 446 sides of each wear component 440 abut each other around the entire circumference of the roller sleeve 420, thereby providing resistance to movement in a radial direction by converting radial loads to compressive hoop forces which act tangentially between the wear components 440. Moreover, as shown, mounting bosses 422 provide resistance to compressive forces experienced by wear components 440 and prevent radially-inwardly movement of the wear components 440 in a radial direction regardless of whether or not fasteners are received in portions 444 and engage the roll sleeve 420.

FIG. 12 shows a roller sleeve assembly 510 according to a sixth embodiment. The roller sleeve assembly 510 comprises a roller sleeve 520 having an outer surface 525 comprising a number of wear inserts 530, a plurality of mounting bosses 522 extending axially from an abutment surface 526, and a plurality of wear components 540 having one or more oblong (e.g., rectangular, oval) cutouts 548 which are provided to the mounting bosses 522. In the embodiment shown, each wear component 540 slides axially and/or radially over each mounting boss 522, and then one or more fasteners (not shown) are received within one or more receiving portions 544 and joined to the roller sleeve 520. First 542 and second 546 sides of each wear component 540 abut each other, thereby providing resistance to movement in a radial direction by converting radial loads to compressive hoop forces which act tangentially between the wear components 540. Moreover, as shown, mounting bosses 522 provide resistance to compressive forces experienced by wear components 540 and prevent radially-inwardly movement of the wear components 540 in a radial direction regardless of whether or not fasteners are received in receiving portions 544 and engage the roll sleeve 520.

FIG. 13 shows yet another embodiment of a wear component assembly for the edge of a roller sleeve section 620. In the embodiment shown, a roller sleeve section 620 is provided, which forms a segmented circumferential portion of an entire roller sleeve. Roller sleeve section 620 comprises an attachment feature 621, for instance, a shelf 627 having an opening 623 sized and configured to receive a locking member such as a screw, tab, or protuberance provided to a roller shaft (not shown). Attachment feature 621 serves to facilitate mounting the roller sleeve section 620 to the roller shaft and prevent rotation of the roller sleeve section 620 with respect to said roller shaft. Shelf 627 may be received within an overhanging channel feature provided on a roller shaft, or it may be held to a roller shaft 1400 by a suitable clamping device. For example, a suitable clamping device may comprise a block having one or more captured threaded fastener assemblies. The block (not shown) rests on top of the shelf 627 and is secured to the roller shaft 1400, thereby providing a clamping force to the shelf 627. A complimentary threaded opening in the roller shaft receives the threaded fastener and clamping forces are applied to the shelf 627 upon torquing/tightening of said fastener. At least one mounting boss 622 is provided to each end of the roller sleeve section 620, wherein the at least one mounting boss 622 extends generally axially from an abutment surface 626 of the roller shell section 620. Each mounting boss 622 comprises a shelf 629 configured to support a retainer 650 which holds a wear component 640 against the abutment surface 626. In some embodiments, the wear component 640 is flush with an outer surface 625 of the roller sleeve section 620. In other embodiments (not shown), the wear component 640 may be slightly recessed or sit proud with respect to the outer surface 625 of the roller sleeve section 620. One or more interlocking features 641 such as a mating lip, a tongue-in-groove structure, a dovetail structure, a peg-in-hole connection, mating serpentine surfaces, mating undulated surfaces, mating stepped portions, or interfitting castellation features may be provided between the wear component 640 and mounting boss 622 without limitation. A cutout 654 provided on the retainer 650 enables the retainer 650 to straddle and be supported by the mounting boss 622. The retainer 650 and wear component 640 combination may be further supported (or alternatively, fully-supported) on shelf 627. In the latter case, cutout 654 would be configured to provide a slight gap between the retainer 650 and shelf 629. Each wear component 640 comprises a first side 642 and a second side 646, and each retainer 650 comprises a first side 652 and a second side 656, wherein in use, circumferentially adjacent retainers 650 and wear components 640 abut each other along sides 642, 646, 652, 656. One or more receiving portions 658 are provided to the retainer 650 which are configured to receive one or more fasteners. The fasteners (not shown) may be joined to the roller shell 620 via one or more attachment features (not shown) to hold the wear components 640 in place. It will be understood by those in the art that while not shown, one or more interlocking features as previously described may be provided between the retainer 650 and the mounting boss 622. For example one or more undercuts may be provided as shown in FIGS. 6 and 8. Moreover, the wear component assembly shown in FIG. 13 may be equally utilized on single-piece constructed roller sleeves in addition to sleeve sections 620.

FIGS. 14-15 show yet even another embodiment of a wear component assembly for the edge of a roller sleeve section 720. In the embodiment shown, roller sleeve section 720 forms a segmented circumferential portion of an entire roller sleeve. Roller sleeve section 720 comprises an attachment feature 721, for instance, a shelf 727 having opening 723 sized and configured to receive a locking member such as a screw, tab, or protuberance provided on a roller shaft (not shown). Shelf 727 may be received within an overhanging channel feature provided on the roller shaft. Attachment feature 721 serves to facilitate mounting the roller sleeve section 720 to a roller shaft and prevent rotation of the roller sleeve section 720 with respect to said roller shaft. At least one mounting boss 722 is provided to each end of the roller sleeve section 720, wherein the at least one mounting boss 722 extends generally axially from an abutment surface 726 of the roller shell section 720. Each mounting boss 722 comprises a shelf 729 configured to support a retainer 750 which holds a wear component 740 against the abutment surface 726. In some embodiments, the wear component 740 is flush with an outer surface 725 of the roller sleeve section 720. In other embodiments (not shown), the wear component 740 may be slightly recessed or sit proud with respect to the outer surface 725 of the roller sleeve section 720. While not shown, one or more interlocking features such as a mating lip, a tongue-in-groove structure, a dovetail structure, a peg-in-hole connection, mating serpentine surfaces, mating undulated surfaces, mating stepped portions, or interfitting castellation features may be provided between the wear component 740 and mounting boss 722 as shown in FIG. 13. The retainer 750 is supported by the mounting boss 722 and may span the length of the mounting boss 722 across the entire roller sleeve section 720. While not shown, the retainer 750 and wear component 740 combination may be further supported (or alternatively, fully-supported) on shelf 727 by extending first 742 and second 746 side portions of the wear component 740 as shown in FIG. 13. Each retainer 750 comprises a first side 752 and a second side 756, and in use,

circumferentially adjacent retainers 750 and wear components 740 abut each other along sides 742, 746, 752, 756. One or more receiving portions 758 are provided to the retainer 750 which are configured to receive one or more fasteners. The fasteners (not shown) may be joined to the roller shell 720 via one or more attachment features 728 to hold a wear component 740 in place.

FIGS. 16A and 16B show isometric views of a roller sleeve assembly 810 according to other embodiments. The roller sleeve assembly 810 comprises a roller sleeve 820 having an outer surface 825 and a series of wear components 840 arranged on an abutment surface 826 along an edge of the roller sleeve 820. At least one fastener 860 holds each wear component 840 to the roller sleeve 820. Detailed views of each wear component 840 are shown in FIGS. 20 A and 20B. Each wear component 840 comprises a body 842 (e.g., in the form of an arcuate plate, block, flange, or wedge element) having a mounting boss 844 extending therefrom, a first receiving portion 848A which is configured to receive a first portion of a fastener (e.g., a head portion), a second receiving portion 848B which is configured to receive another portion of a fastener (e.g., a shank or shaft portion), and a shelf 847 defined between the first 848A and second 848B receiving portions. As demonstrated by ghost lines in FIG. 20B, a mounting boss 1044 may be positioned proximate outer portions of the body 842, as well as other locations, and may take the form of other shapes including polyhedrons such as a rectangular prism as shown. Moreover, the number of first and second receiving portions 1048 A may vary in number.

FIGS. 17A and 17B show isometric views of a roller sleeve assembly 910 according to other embodiments. The roller sleeve assembly 910 comprises a roller sleeve 920 having an outer surface 925 and a series of wear components 940 arranged on an abutment surface 926 along an edge of the roller sleeve 920. A plurality of fasteners 960 holds each wear component 940 to the roller sleeve 920. Detailed views of each wear component 940 are shown in FIGS. 21A and 21B.

FIG. 18 shows a cross-sectional view of FIG. 17B along line XVIII -XVIII. Each wear component 940 comprises a body 942 (e.g., in the form of an arcuate plate, block, flange, or wedge element) having a mounting boss 944 extending therefrom, a first receiving portion 948A which may be configured to receive a head portion of a fastener, a second receiving portion 948B which may be configured to receive a shank or shaft portion of a fastener, and a shelf 947 defined between the first 948A and second 948B receiving portions. In some instances, shelf 947 may be a taper, a chamfer, a step, a ridge, a fillet, or a ledge. A series of receiving portions 924 provided on the roller sleeve 920 accept the mounting bosses 944 of each wear component 940. One or more attachment features 928 may be provided within and/or adjacent to the receiving portions 924 as shown to accept the fasteners 960 to hold the wear components 940 to the roller sleeve 920. In some instances, glue, weld studs, or plastically-deformed material (inserted, for example, by means of a mechanical force, explosion, welding, swaging, or pressing) may fill the first 948A and second 948B receiving portions, gaps existing between the mounting boss 944 and receiving portions 924, and/or attachment feature(s) 928 to secure mounting bosses permanently within each receiving portion 924. Detailed views of each wear component 840 are shown in FIGS. 21A and 21B.

FIGS. 22 and 23 show yet another embodiment of a wear component assembly for a roller sleeve 1120 comprising a fastener 1160, a wear component 1140 having a first receiving portion 1148 A, a second receiving portion 1148B, a shelf 1147 extending between said first 1148A and second 1148B receiving portions, and a retainer 1150 having a receiving portion 1158. The retainer 1150 is configured to be received within a complimentary-shaped receiving portion 1121 in the roller sleeve 1120 and is also configured to be fittingly received within the second receiving portion 1148B of the wear component 1140, while still allowing the wear component 1140 to contact abutment surface 1126 on the roller sleeve 1120 for support in at least an axial direction. An attachment feature 1128 within the roller sleeve 1120 communicates with the fastener 1160 to secure the wear component 1140 to the roller sleeve 1120. While not shown, chamfered surfaces between outer portions of the wear component 1140 and roller sleeve 1120, adjacent and along outer surface 1125 may be provided and later filled with weld material after assembly to form a permanent connection.

In the particular instance shown, fastener 1160 is received entirely through receiving portions 1148A, 1148B and receiving portion 1158, and then secured to an attachment feature 1128 which is located within the receiving portion 1121. However, it will be apparent to those of ordinary skill in the art that the retainer 1150 may alternatively be a solid stand-alone piece provided without a receiving portion 1158, and the first receiving portion 1148A and the one or more attachment features 1128 may alternatively be located at other portions of the wear component 1140 and roller sleeve 1120 - for example, spaced a distance away from the retainer 1150, second receiving portion 1148B, and shaped receiving portion 1121. Moreover, a plurality of fasteners 1160, receiving portions 1148 A, 1148B, 1127, and attachment features 1128 may be employed in any number and arranged in any configuration, without limitation. Furthermore, retainer 1150 may comprise various shapes and forms other than what is shown. For instance, one end section of the retainer 1150 may be different in size and/or shape than another end section, wherein receiving portions 1121 and 1148B are different in size and/or shape with respect to one another. Retainer 1150 may be circular for ease of manufacturing, or it may be oblong (e.g., rectangular, linear, cruciform, or ovoid as shown) to increase a resistance to rotation of the wear component 1140.

FIG. 24 shows an embodiment of a roller assembly 1210 comprising a roller sleeve 1220 and a roller shaft 1400 having a roller shaft axis 1403. The roller sleeve 1220 comprises an outer surface 1225 and an abutment surface 1226 comprising a plurality of wear components 1240 thereon. The wear components 1240 each comprise one or more receiving portions 1248 for receiving one or more fasteners (not shown), which are used to join the wear components 1240 to the roller sleeve 1220 (e.g., via threaded holes or other attachment feature in the roller sleeve 1220). As shown, wear components 1240 may extend axially past roller shaft face 1483, or may alternatively sit flush or recessed with respect to the roller shaft face 1483. While not shown, gaps between wear components 1240 in a circumferential direction may be filled with hard face welding material in-situ, to form and build up mounting bosses therebetween and permanently join the wear components 1240 to the roller sleeve 1220 and to each other.

FIG. 25 shows an embodiment of a roller assembly 1310 comprising a roller sleeve 1320 and a roller shaft 1400 having a roller shaft axis 1403. The roller sleeve 1320 comprises an outer surface 1325 and an abutment surface 1326 comprising a number of radially-extending mounting bosses 1322 protruding therefrom. A plurality of wear components 1340 are situated in receiving portions 1324 which are defined in the roller sleeve 1320 between the radially- extending mounting bosses 1322. The wear components 1340 each comprise one or more receiving portions 1348 for receiving one or more fasteners (not shown), which are used to join the wear components 1340 to the roller sleeve 1320 (e.g., via threaded holes or other attachment feature in the roller sleeve 1320). As shown, wear components 1340 may extend axially past roller shaft face 1483, or may alternatively sit flush or recessed with respect to the roller shaft face 1483. While not shown, gaps between wear components 1340 and/or between wear components 1340 and mounting bosses 1322 may be filled with hard face weld material to permanently join the wear components 1340 to the roller sleeve 1320 and to each other.

Moreover, while not shown, mating surfaces between the mounting bosses 1322 and wear components 1340 may comprise one or more interlocking features such as a mating lip, a tongue- in-groove structure, a dovetail structure, a peg-in-hole connection, mating serpentine surfaces, mating undulated surfaces, mating stepped portions, or interfitting castellation features, in order to increase surface contact.

FIGS. 26A and 26B show a wear component 1440 joined to an abutment surface 1426 of a roller sleeve 1420 according to another embodiment. The roller sleeve 1420 comprises an outer surface 1425 and a series of wear components 1440 arranged on an abutment surface 1426 along an edge of the roller sleeve 1420. A plurality of fasteners (not shown) holds each wear component 1440 to the roller sleeve 1420. Each wear component 1440 comprises a body 1442 (e.g., in the form of an arcuate plate, block, flange, or wedge element) having at least one mounting boss 1444 extending therefrom, a first receiving portion 1448 A which may be configured to receive a head portion of a fastener, a second receiving portion 1448B which may be configured to receive a shank or shaft portion of a fastener, and a shelf 1447 defined between the first 1448A and second 1448B receiving portions. In some instances, shelf 1447 may comprise a taper, a chamfer, a countersunk bore (e.g., conical bore), a step, a ridge, a fillet, a flange, or a ledge. A series of receiving portions 1424 provided on the roller sleeve 1420 accept the mounting bosses 1444 of each wear component 1440. One or more attachment features may be provided within and/or adjacent to the receiving portions 1424 to accept the fasteners to hold the wear components 1440 to the roller sleeve 1420. In some instances, glue, weld studs, or plastically-deformed material (inserted, for example, by means of a mechanical force, explosion, welding, swaging, or pressing) may fill the first 1448A and second 1448B receiving portions, gaps existing between the mounting boss 1444 and receiving portions 1424, and/or attachment feature(s) to secure mounting bosses 1444 permanently within each receiving portion 1424. In the particular instance shown, receiving portion 1424 comprises a radially-extending groove tapering from a narrow radially-inner portion to a wider radially-outer portion. Mounting boss 1444 comprises a cylindrical protrusion in said particular instance. The groove may have parallel sidewalls as shown; however, it may comprise one or more non-parallel sidewalls (e.g., in the form an undercut channel to capture the wear component 1440 in an axial direction, or in the form of a flared open channel) without limitation. Sidewalls of the groove 1424 slidingly and wedgingly engage outer walls of the mounting boss 1444 and support the wear component 1440 in at least a radial direction. It should be known that only one receiving portion 1448 A, 1448B is necessary if recessing a head(s) of a fastener(s) is not desired. FIGS. 27A and 27B show a wear component 1540 joined to an abutment surface 1526 of a roller sleeve 1520 according to another embodiment. The roller sleeve 1520 comprises an outer surface 1525 and a series of wear components 1540 arranged on an abutment surface 1526 along an edge of the roller sleeve 1520. A plurality of fasteners (not shown) holds each wear component 1540 to the roller sleeve 1520. Each wear component 1540 comprises a body 1542 (e.g., in the form of an arcuate plate, block, flange, or wedge element) having at least one mounting boss 1544 extending therefrom, a first receiving portion 1548 A which may be configured to receive a head portion of a fastener, a second receiving portion 1548B which may be configured to receive a shank or shaft portion of a fastener, and a shelf 1547 defined between the first 1548 A and second 1548B receiving portions. In some instances, shelf 1547 may be a taper, a chamfer, a countersunk bore (e.g., conical), a step, a ridge, a fillet, a flange, or a ledge. A series of receiving portions 1524 provided on the roller sleeve 1520 accept the mounting bosses 1544 of each wear component 1540. One or more attachment features may be provided within and/or adjacent to the receiving portions 1524 to accept the fasteners to hold the wear components 1440 to the roller sleeve 1520 via the mounting bosses 1544. In some instances, glue, weld studs, or plastically-deformed material (inserted, for example, by means of a mechanical force, explosion, welding, swaging, or pressing) may fill the first 1548 A and second 1548B receiving portions, gaps existing between the mounting boss 1544, receiving portions 1524, and/or attachment feature(s) to secure mounting bosses 1544 permanently within each receiving portion 1524. In the particular instance shown, receiving portion 1524 comprises a radially-extending groove tapering from a narrow radially-inner portion to a wider radially-outer portion. Mounting boss 1544 comprises a cylindrical protrusion in said particular instance. The groove may have parallel sidewalls as shown; however, it may comprise one or more non- parallel sidewalls (e.g., in the form an undercut channel or flared open channel) without limitation. Sidewalls of the groove 1524 slidingly and wedgingly engage the outer surfaces of the mounting boss 1544 and support the wear component 1540 in at least a radial direction.

FIGS. 28A and 28B show a wear component 1640 joined to an abutment surface 1626 of a roller sleeve 1620 according to another embodiment having a mounting boss 1644 in the form of a wedge protrusion. The roller sleeve 1620 comprises an outer surface 1625 and a series of wear components 1640 arranged on an abutment surface 1626 along an edge of the roller sleeve 1620. A plurality of fasteners (not shown) holds each wear component 1640 to the roller sleeve 1620. Each wear component 1640 comprises a body 1642 (e.g., in the form of an arcuate plate, block, flange, or wedge element) having at least one mounting boss 1644 extending therefrom, a first receiving portion 1648 A which may be configured to receive a head portion of a fastener, a second receiving portion 1648B which may be configured to receive a shank or shaft portion of a fastener, and a shelf 1647 defined between the first 1648A and second 1648B receiving portions. In some instances, shelf 1647 may be a taper, a chamfer, a countersunk bore (e.g., conical), a step, a ridge, a fillet, a flange, or a ledge. A series of receiving portions 1624 provided on the roller sleeve 1620 accept the mounting bosses 1644 of each wear component 1640. One or more attachment features may be provided within and/or adjacent to the receiving portions 1624 to accept the fasteners to hold the wear components 1640 to the roller sleeve 1620 via the mounting bosses 1644. In some instances, glue, weld studs, or plastically-deformed material (inserted, for example, by means of a mechanical force, explosion, welding, swaging, or pressing) may fill the first 1648 A and second 1648B receiving portions, gaps existing between the mounting boss 1644, receiving portions 1624, and/or attachment feature(s) to secure mounting bosses 1644 permanently within each receiving portion 1624. In the particular instance shown, receiving portion 1624 comprises a radially-extending groove tapering from a narrow radially- inside portion to a wider radially-outside portion. Mounting boss 1644 comprises a radially-extending "wedge" protrusion which complements the shape of the receiving portion 1624. The groove may have parallel sidewalls as shown; however, it may comprise one or more non-parallel sidewalls (e.g., in the form an undercut channel or flared open channel) without limitation. Sidewalls of the groove 1624 slidingly and wedgingly engage sidewalls of the wedge protrusion and support the wear component 1640 in at least a radial direction.

A contractor or other entity may provide a roller press, roller press sleeve, wear component, or wear component assembly, or operate a roller press 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 roller press or edge wear component assembly, 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. 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 an existing roller press, roller sleeve, wear component assembly, or parts thereof with a "retrofit kit" to arrive at a modified roll press system comprising one or more method steps, devices, 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, it is envisaged cutouts and corresponding mounting bosses may comprise different shapes and relative sizes depending on the sizes and design specifications for roller assemblies. Moreover, while receiving portions are primarily shown in the drawings as blind or through holes, may comprise any one or more of the following without limitation: openings (threaded or non-threaded), apertures, recesses, pockets, grooves, channels, dovetails, cutout portion, or undercuts. Additionally, attachment features may comprise threaded holes, connectors, undercuts for receiving plastically-deformed material (e.g., via explosion or mechanical deformation), weld chamfers for accommodating weld pools, glue holes, anchors, inserts, etc. Furthermore, mounting bosses may be modular and therefore may be interchanged or added to existing roller sleeve assemblies.

It is contemplated that male and female components disclosed herein may be reversed and still be within the scope of the disclosure. For example, male mounting bosses and female receiving portions for the mounting bosses may be reversed so that the mounting bosses contain female components and the receiving portions contain male components. Moreover, joining of fasteners and attachment features may be accomplished using a threaded connection, plastic deformation, welding, gluing, combinations thereof, or other equivalent means without limitation.

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.

Reference numeral identifiers

10, 310, 410, 510, 810, 910, 1110 Roller sleeve assembly

20, 120, 220, 320, 420, 520, 820, 920, 1120, 1220, 1320, 1420, 1520 Roller sleeve

22, 122, 222, 322, 422, 522, 622, 722, 844, 944, 1044, 1322, 1444, 1544 Mounting boss

24, 58, 124, 224, 344, 444, 544, 658, 758, 924, 1124, 1158, 1248, 1324, 1348 Receiving portion 1424, 1524

25, 325, 425, 525, 625, 725, 825, 925, 1125, 1225, 1325, 1425, 1525 Outer surface

26, 126, 226, 326, 426, 526, 626, 726, 826, 926, 1126, 1226, 1326, 1426, 1526 Abutment surface 28, 128, 228, 728, 928, 1128 Attachment feature

30, 330, 430, 530 Wear insert

40, 140, 240, 340, 440, 540, 640, 740, 840, 940, 1140, 1240, 1340, 1440, 1540 Wear component

42, 48A, 122A, 142, 148A, 222A, 242, 248A, 342, 442, 542, 642, 652, 742, 752 First side

44A, 144A, 244A, 848A, 948A, 1148A, 1448A, 1548A First receiving portion

44B, 144B, 244B, 848B, 948B, 1048B, 1148B, 1448B, 1548B Second receiving portion

46, 48B, 122B, 146, 148B, 222B, 246, 248B, 346, 446, 546, 646, 656, 746, 756 Second side

48, 123, 148, 248, 348, 448, 548, 654 Cutout

48C, 148C Third side

50, 650, 750, 1150 Retainer

147, 627, 629, 727, 729, 847, 947, 1147, 1447, 1547 Shelf

149 Fourth side

223A First cutout

223B Second cutout

223C Third cutout

247A First shelf

247B Second shelf

247C Third shelf

248C Third side

249A Fourth side

249B Fifth side

249C Sixth side

322A, 322B Flared sides

620, 720 Roller sleeve section

621, 721 Roller sleeve attachment feature

623, 723 Opening

641 Interlocking feature

860, 960, 1160 Fastener

842, 942, 1142, 1442, 1542 Body

1210, 1310 Roller assembly

1400 Roller shaft

1403 Roller shaft axis

1483 Roller shaft face

Claims

WHAT IS CLAIMED IS:

A roller for use in a roller press comprising:

a roller shaft [1400] having an axis [1403]; and

a roller sleeve assembly [10] comprising a roller sleeve [20] having an outer surface [25], an annular abutment surface [26] proximate an end of the outer surface [25] and extending generally transversely with respect to the outer surface [25], and a plurality of mounting bosses [22] extending from the abutment surface [26] in a direction generally parallel to the axis [1403] of the roller shaft [1400], wherein one or more of the mounting bosses are circumferentially spaced from one another.

The roller of claim 1, wherein the roller sleeve assembly [10] further comprises a plurality of wear components [40] which are received and supported by the mounting bosses [22].

The roller of claim 2, wherein the roller sleeve assembly [10] further comprises a plurality of retainers [50] for holding the wear components [40] to the roller sleeve [20].

The roller of claim 3, wherein the retainers [50] are held within receiving portions [44A, 44B] provided to the wear components [40]. The roller of claim 3, wherein one or more fasteners [860] pass through the retainers [50], the wear components [40], and the roller sleeve [20], and are held within attachment features [28] in the roller sleeve [20].

The roller of claim 3, wherein one or more interlocking features [641] such as a mating lip, a tongue-in-groove structure, a dovetail structure, a peg-in-hole connection, mating serpentine surfaces, mating undulated surfaces, mating stepped portions, or interfitting castellation features are provided between the wear components [640] and the retainers [650].

The roller of claim 1, wherein the mounting bosses [1322] generally extend in a radial direction with respect to the axis [1403] of the roller shaft [1400].

A roller for use in a roller press comprising:

a roller shaft [1400] having an axis [1403]; and

a roller sleeve assembly [910] comprising a roller sleeve [920] having an outer surface [925], an annular abutment surface [926] proximate an end of the outer surface [925] and extending generally transversely with respect to the outer surface [925], and a plurality of receiving portions [924] extending into the abutment surface [926] in a direction generally parallel to the axis [1403] of the roller shaft [1400], wherein one or more of the receiving portions [924] are circumferentially spaced from one another.

9. The roller of claim 8, wherein the roller sleeve assembly [910] further comprises a plurality of wear components [940] which are received and supported by the receiving portions [924].

10. The roller of claim 9, wherein fasteners [960] pass through the wear components

[940] and the roller sleeve [920], and are held within attachment features [928] in the roller sleeve [920].

11. The roller of claim 9 wherein each wear component [940] comprises a plurality of mounting bosses [944] which are received in a corresponding number of receiving portions [924].

12. The roller of claim 9, wherein the roller sleeve assembly [1110] further comprises a plurality of retainers [1150] which are received within and are supported by the receiving portions [1124] in the roller sleeve [1120], and wherein the retainers [1150] are further received within one or more second receiving portions [1144B] in the wear components [1140] in order to support the wear components [1140].

13. The roller of claim 12, wherein the retainers [1150] are captured between body portions [1142] of the wear components [1140] and the roller shell [1120], and wherein the wear components [1140] contact the abutment surface [1126].

14. The roller of claim 12, wherein fasteners [1160] pass through the wear components [1140], the retainers [1150], and the roller sleeve [1120], and communicate with attachment features [1128] located in the roller sleeve [1120].