Abstract:
A roller press comprises a roller [ 100]  having: a roller edge [ 110]  formed by the intersection of a roller end [ 126]  and an outer surface [ 128],  an edge wear component [ 150]  provided at said roller edge [ 110],  and a mounting insert [ 160]  provided within a mounting insert pocket [ 129]  located inland of said roller end [ 126]  and spaced from said roller edge [ 110].  A fastener [ 140]  extends between the edge wear component [ 150]  and the mounting insert [ 160]  to keep the edge wear component [ 150]  attached to the roller [ 100].  The fastener [ 140]  threadedly engages female threads [ 164]  provided within the mounting insert [ 160].  Also disclosed, is an edge protection system and method of mounting an edge wear component [ 150]  to a roller [ 100]  in a roller press.

Description:
CROSS-REFERENCE OF RELATED APPLICATIONS 
       [0001]    This application is an international application which claims the benefit of U.S. Provisional Patent Application No. 61/580,342, filed on 27 Dec. 2011. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates to crushing, grinding, and comminution equipment, and more particularly to high pressure grinding roller (HPGR) press systems used, for instance, in the mining, cement, coal, and minerals processing industries. 
         [0003]      FIG. 1  shows a conventional edge wear component  950  which is threadedly secured to the edge  910  of a roller sleeve  920  which forms a portion of a roller  900 . A series of wear inserts  930  are distributed over an outer surface  928  of the roller sleeve  920  and are disposed within wear insert pockets  922 . A fastener  940  having a head  944 , a socket  942 , and a shaft  946  comprising male threads  948  is inserted into a hole within roller sleeve  920 , the hole comprising female threads  924 . The head  944  of the fastener fits within a head recess  952  provided within the edge wear component  950  and the shaft  946  extends through a shaft recess  954 . An abutment surface  956  of the edge wear component  950  rests against an end  926  of the roller sleeve  920 . 
         [0004]    In such configurations, the hole having female threads  924  is positioned well below wear insert pockets  922  in order to avoid interferences between the wear inserts  930  and the fastener  940 . This lower fastening position makes the edge wear component  950  more susceptible to premature “pull-off” due to larger moment forces, which are created, for instance, when feed and/or autogenous layer material pushes against upper regions of the edge wear component  950 . 
         [0005]    Currently, when a roller edge  910  erodes, it is repaired by filling gaps, holes, and worn-away material on the roller sleeve  920  with hardface weld material. Subsequent grinding and machining processes on the roller sleeve  920  may be necessary after hardface welding, in order to bring the roller  900  back to original specifications. Such methods are time-consuming, inefficient, and costly. Moreover, with the aforementioned prior art designs, if female threads  924  in the roller shell  920  become stripped by the fastener  940 , the roller sleeve  920  needs to be reworked. 
         [0006]    Recent attempts have been made to prevent premature edge wear grinding rollers. For instance, KHD and Polysius have pursued roller designs which incorporate the fastening of removable hard bodies to the roller edges (see U.S. Pat. Nos. 7,497,396 and 7,510,135). However, these designs are susceptible to “washout”, where roller sleeve substrate material begins to erode due to the migration of abrasive particles forming the autogenous layer. 
       OBJECTS OF THE INVENTION 
       [0007]    It is, therefore, an object of the invention to provide a mechanically-robust edge wear component system. 
         [0008]    It is also an object of the invention to provide edge wear components having adequate support, stability, and resistance to “pull off”. 
         [0009]    It is yet another object of the invention to provide a means for quickly repairing stripped or damaged female threads which would otherwise require the reworking of a roller or sleeve portion thereof. 
         [0010]    These and other objects of the invention will be apparent from the drawings and description herein. Although every object of the invention is believed to be attained by at least one embodiment of the invention, there is not necessarily any one embodiment of the invention that achieves all of the objects of the invention. 
       SUMMARY OF THE INVENTION 
       [0011]    A roller press is disclosed. The roller press comprises a roller having a roller edge formed by the intersection of a roller end and an outer surface. An edge wear component is provided adjacent said roller edge, and a mounting insert is provided within a mounting insert pocket which is located inland of said roller end and spaced from said roller edge. A fastener extends between the edge wear component and the mounting insert to keep the edge wear component attached to the roller. The fastener threadedly engages female threads which are provided within the mounting insert. In some embodiments, the edge wear component may comprise at least one of an end face liner and an outer face liner. In some embodiments, the edge wear component comprises first and second sides that are configured to form a radial weld channel when the first and second sides abut respective second and first sides of adjacent edge wear components in side-by-side relationship. In some embodiments, at least one of said first and second sides comprises a protrusion. In some embodiments, the edge wear component comprises a circumferential weld channel which is configured to accept a bead of weld material. The bead of weld material may help secure the edge wear component to the roller. In some embodiments, the circumferential weld channel comprises a first weld channel face and a second weld channel face for increased surface area. In some embodiments, the edge wear component accepts a plurality of fasteners, wherein at least one of said plurality of fasteners threadedly engages female threads in the mounting insert, and at least one of said plurality of fasteners threadedly engages female threads in another portion of the roller, which may be a roller sleeve. The mounting insert may be cylindrically-shaped, block-shaped, or generally shaped and/or sized similar to other wear inserts provided on the outer surface of the roller. The mounting insert pocket may comprise a blind recess or may alternatively comprise a continuous annular circumferential groove which extends around the roller. 
         [0012]    A method of mounting an edge wear component to a roller is also disclosed. The method comprises the steps of: providing a roller having a roller edge formed by the intersection of a roller end and an outer surface, providing a mounting insert pocket located inland of said roller end and spaced from said roller edge, providing a clearance hole extending between the roller end and the mounting insert pocket; providing an edge wear component; providing a mounting insert; positioning said edge wear component adjacent said roller edge; positioning said mounting insert within said mounting insert pocket; aligning the edge wear component with said mounting insert; extending a fastener through said clearance hole and between the edge wear component and the mounting insert; and fixedly engaging the fastener with the mounting insert to keep the edge wear component attached to the roller. 
         [0013]    An edge protection system for a roller in a roller press is also disclosed. The edge protection system comprises: an edge wear component; a mounting insert having female threads therein and being configured to be placed within a mounting insert pocket on the roller which is located inland of a roller end; and a fastener configured to extend between the edge wear component and the mounting insert and configured to threadedly engage said female threads within the mounting insert. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is a diametrical cross-sectional view of an edge section of a grinding roller according to the prior art; 
           [0015]      FIG. 2  is an end plan view of an edge section of a grinding roller shown in  FIG. 1 ; 
           [0016]      FIG. 3  is a diametrical cross-sectional view of an edge section of a grinding roller according to some embodiments; 
           [0017]      FIG. 4  is an isometric view of a mounting insert shown in  FIG. 3 ; 
           [0018]      FIG. 5  is an end plan view of an edge section of the grinding roller shown in  FIG. 3 ; 
           [0019]      FIG. 6  is a diametrical cross-sectional view of an edge section of a grinding roller according to other embodiments; 
           [0020]      FIG. 7  is an end plan view of an edge section of the grinding roller shown in  FIG. 6 ; 
           [0021]      FIG. 8  is a diametrical cross-sectional view of an edge section of a grinding roller according to yet other embodiments; 
           [0022]      FIG. 9  is an isometric view of a block-shaped mounting insert shown in  FIG. 8 ; 
           [0023]      FIG. 10  is an end plan view of an edge section of the grinding roller shown in  FIG. 8 ; 
           [0024]      FIG. 11  is an isometric view of a grinding roller according to further embodiments; 
           [0025]      FIG. 12  is a close-up view of the grinding roller shown in  FIG. 11 ; 
           [0026]      FIG. 13  is a large isometric view of a mounting insert in accordance with the embodiment shown in  FIGS. 11 and 12 ; 
           [0027]      FIG. 14  is a large isometric view of an edge wear component in accordance with the embodiment shown in  FIGS. 11 and 12 ; 
           [0028]      FIG. 15  is an isometric cutaway view of the grinding roller shown in  FIG. 11 ; and, 
           [0029]      FIG. 16  is a diametrical cross-sectional view of an edge section of the grinding roller shown in  FIG. 15 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0030]      FIGS. 3-5  show a roller  100  according to some embodiments. The roller  100  may comprise a roller sleeve  120  having a roller end  126  and a roller edge  110 . An edge wear component  150  may be threadably secured to the edge  110  of the roller sleeve  120 . Wear inserts  130  may be distributed over a cylindrical outer surface  128  of the roller sleeve  120  and may be disposed within wear insert pockets  122 . A fastener  140  having a head  144 , a drive socket  142 , and a shaft  146  comprising male threads  148  may be inserted through the edge wear component  150  until the male threads  148  engage female threads  164  provided within a cylindrically-shaped mounting insert  160 . The mounting insert  160  may be disposed within a mounting insert pocket  129 , and may be provided with an alignment device  166  such as directional indicia or means for rotating the mounting insert  160 , in order to align and facilitate threaded engagement between male threads  148  of the fastener  140  and female threads  164  within the mounting insert  160 . A clearance hole  127  may be provided in the roller sleeve  120  between the edge wear component  150  and mounting insert  160  in order to make way for the shaft  146  of the fastener  140 . 
         [0031]    The head  144  of each fastener  140  may fit within a head recess  152  provided on the edge wear component  150  and the shaft  146  of each fastener  140  may extend through a shaft recess  154 . An abutment surface  156  of the edge wear component  150  may flushly rest against an end  126  of the roller sleeve  120 . 
         [0032]      FIGS. 6 and 7  show a roller  200  according to other embodiments. The roller  200  may comprise a roller sleeve  220  having a roller end  226  and a roller edge  210 . An edge wear component  250  may be threadably secured to the edge  210  of the roller sleeve  220 . Wear inserts  230  may be distributed over a cylindrical outer surface  228  of the roller sleeve  220  and may be disposed within wear insert pockets  222 . A fastener  240  having a head  244 , a drive socket  242 , and a shaft  246  comprising male threads  248  may be inserted through the edge wear component  250  until the male threads  248  engage female threads  264  provided within a mounting insert  260 , which may be shaped like other wear inserts  230  (as shown). The mounting insert  260  may be configured to be positioned within a mounting insert pocket  229  in the roller sleeve  220 . An alignment device  266  such as directional indicia or means for rotating the mounting insert  260  may be provided to the mounting insert  260 , in order to facilitate alignment and threaded engagement between male threads  248  of the fastener  240  and female threads  264  within the mounting insert  260 . A clearance hole  227  may be provided in the roller sleeve  220  between the edge wear component  250  and mounting insert  260  in order to make way for the shaft  246  of the fastener  240 . 
         [0033]    The head  244  of each fastener  240  may fit within a head recess  252  provided on the edge wear component  250  and the shaft  246  of each fastener may extend through a shaft recess  254 . An abutment surface  256  of the edge wear component  250  may flushly rest against an end  226  of the roller sleeve  220 . Supplemental fasteners  240  may be fixed to female threads  224  provided within the substrate of the roller sleeve  220 . In the particular embodiment shown, fasteners  240  are aligned radially along edge wear component  250  in relation to the roller  200 , whereas the embodiment shown in  FIGS. 3-5  shows fasteners  140  which are staggered and not aligned radially in relation to the roller  100 . While not expressly shown in the drawings, embodiments employing combinations of radially-aligned fasteners  240  and staggered fasteners  140  are also envisaged. 
         [0034]      FIGS. 8-10  show a roller  300  according to yet other embodiments. The roller  300  may comprise a roller sleeve  320  having a roller end  326  and a roller edge  310 . An edge wear component  350  may be threadedly secured to the edge  310  of the roller sleeve  320 . Wear inserts  330  may be distributed over a cylindrical outer surface  328  of the roller sleeve  320  and may be disposed within wear insert pockets  322 . A fastener  340  having a head  344 , a drive socket  342 , and a shaft  346  comprising male threads  348  may be inserted through the edge wear component  350  until the male threads  348  of the fastener engage female threads  364  provided within a block-shaped mounting insert  360 . The mounting insert  360  may be provided with an alignment device  366  such as directional indicia or means for indexing the circumferential position of mounting insert  360 , in order to align and facilitate threaded engagement between male threads  348  of the fastener  340  and female threads  364  within the mounting insert  360 . The mounting insert  360  may be configured to be positioned within a mounting insert pocket  329  in the roller sleeve  320 . The mounting insert pocket  329  may comprise individual recesses which are spaced from each other along the outer surface  328 , or the mounting insert pocket  329  may comprise a continuous annular groove or channel which surrounds roller sleeve  320  as shown in  FIG. 10 . A clearance hole  327  may be provided in the roller sleeve  320  between the edge wear component  350  and mounting insert  360  in order to make way for the shaft  346  of the fastener  340 . The head  344  of each fastener  340  may fit within a head recess  352  provided within the edge wear component  350  and the shaft  346  of each fastener  340  may extend through a shaft recess  354 . An abutment surface  356  of the edge wear component  350  may rest against an end  326  of the roller sleeve  320 . Supplemental fasteners  340  may be fixed to female threads  324  provided within the substrate of the roller sleeve  320 . In the particular embodiment shown, fasteners  340  are aligned radially along edge wear component  350  in relation to the roller  300 . 
         [0035]      FIGS. 11-16  show a roller  400  according to further embodiments. The roller  400  may comprise a roller sleeve  420  having a recessed roller end  426  and a roller edge  410 . The recessed roller end  426  may be recessed from other portions of the roller sleeve  420  as shown, thereby forming a support rim  423 . An edge wear component  450  may be threadably secured to the edge  410  of the roller sleeve  420  and supported by the support rim  423 . The edge wear component  450  may be recessed so as to not be flush or sit proud with respect to other portions of the roller  100 , (e.g., a cylindrical outer surface  428 , or the end  426  of roller sleeve  420  as shown). A series of wear inserts  430  may be distributed over the outer surface  428  of the roller sleeve  420  and may be disposed within wear insert pockets  422 . A fastener  440  having a head  444  including a drive socket  442  and a shaft  446  comprising male threads  448  may be inserted through the edge wear component  450  until the male threads  448  engage female threads  464  provided within a mounting insert  460 . The mounting insert  460  may have a lower chamfer  463  to assist with insertion into and positioning within a mounting insert channel or pocket  429  in the roller sleeve  420 . While not shown, the mounting insert  460  may comprise a composite structure, wherein a lower/inner portion of the insert  460  may comprise a softer material and an upper/outer portion of the insert  460  may comprise a harder material. The harder and softer portions may be separately-joined pieces, or may be a monolithic structure having a harness gradient therewithin. The harder upper/outer portion of the insert  460  may provide wear protection, whereas the softer lower/inner portion of the insert  460  may be easier to machine threads designed to engage the male threads  448  of the fastener  440 . A clearance hole  427  may be provided in the roller sleeve  420  between the edge wear component  450  and mounting insert  460  in order to make way for the shaft  446  of the fastener  440 . An alignment device  466  such as directional indicia may be provided to mounting insert  460 . 
         [0036]    The head  444  of each fastener  440  may fit within a head recess  452  provided within the edge wear component  450  and the shaft  446  may extend through a shaft recess  454 . A washer  449  may be provided within the head recess  452  under the head  444  and surrounding shaft  446 . An abutment surface  456  of the edge wear component  450  may rest against an end  426  of the roller sleeve  420 . Supplemental fasteners  440  may be fixed to female threads  424  provided within the substrate of the roller  400 . In the particular embodiment shown, the fasteners  440  are arranged in a staggered pattern along the edge wear component  450 , wherein an upper set of fasteners  440  threadedly engage mounting inserts  460 , and a lower set of fasteners  440  threadedly engage roller sleeve  420 . 
         [0037]    Edge wear components  450  may comprise a circumferential weld channel  457  formed by a first weld channel face  457 A which intersects with a second weld channel face  457 B. A circumferential weld  421  may be disposed in the circumferential weld channel  457  to further secure the edge wear component  450  to the roller  400 . A first side  451 B of the edge wear component  450  may comprise a first protrusion  451 A, and a second side  453 B of the edge wear component  450  may comprise a second protrusion  453 A. When edge wear components  450  are abutted circumferentially, in side-by-side relationship, respective first  451 A and second  453 A protrusions of neighboring edge wear components  450  may communicate to form radial weld channels  490  which may be filled with hardface weld material. As shown, the edge wear component  450  may be formed by fusing, bonding, or otherwise mechanically fastening a harder end face liner  458 A and/or a harder outer face liner  458 B to a softer body substrate. Fusion of the end face liner  458 A and/or harder outer face liner  458 B to a softer body substrate may be accomplished using explosion welding, soldering, friction welding, graded powdered metallurgy, heat treatments, adhesives, or other conventional means. One or more recesses or clearance bands  459  may also be provided adjacent the one or more shaft recesses  454 , in order to facilitate threaded engagement and deformation compensation between male threads  464  of fasteners  440  and female threads  424  during tightening. 
         [0038]    A contractor or other entity may provide a grinding roller, or operate a grinding roll apparatus in whole, or in part, as shown and described. For instance, the contractor may receive a bid request for a project related to designing or operating a grinding roll apparatus, or the contractor may offer to design such a system or a process for a client. The contractor may then provide, for example, any one or more of the devices or features thereof shown and/or described in the embodiments discussed above. The contractor may provide such devices by selling those devices or by offering to sell those devices. The contractor may provide various embodiments that are sized, shaped, and/or otherwise configured to meet the design criteria of a particular client or customer. The contractor may subcontract the fabrication, delivery, sale, or installation of a component of the devices disclosed, or of other devices used to provide said devices. The contractor may also survey a site and design or designate one or more storage areas for stacking the material used to manufacture the devices, or for storing the devices and/or components thereof. The contractor may also maintain, modify, or upgrade the provided devices. The contractor may provide such maintenance or modifications by subcontracting such services or by directly providing those services or components needed for said maintenance or modifications, and in some cases, the contractor may modify a preexisting grinding roll apparatus, or parts thereof with a “retrofit kit” to arrive at a modified grinding roll apparatus comprising one or more method steps, devices, components, or features of the systems and processes discussed herein. 
         [0039]    Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed. For example, in some embodiments, mounting inserts  160 ,  260 ,  360 ,  460  may comprise softer, more machinable materials than other wear inserts  130 ,  230 ,  330 ,  430 . Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof. 
       REFERENCE NUMERAL IDENTIFIERS 
       [0000]    
       
           100 ,  200 ,  300 ,  400 ,  900  Roller 
           110 ,  210 ,  310 ,  410 ,  910  Edge 
           120 ,  220 ,  320 ,  420 ,  920  Roller sleeve/tire body 
           122 ,  222 ,  322 ,  422 ,  922  Wear insert pocket 
           124 ,  224 ,  324 ,  424 ,  924  Female threads 
           126 ,  226 ,  326 ,  426 ,  926  End 
           127 ,  227 ,  327 ,  427  Clearance hole 
           128 ,  228 ,  328 ,  428 ,  928  Outer surface 
           129 ,  229 ,  329 ,  429  Mounting insert pocket 
           130 ,  230 ,  330 ,  430 ,  930  Wear insert 
           140 ,  240 ,  340 ,  440 ,  940  Fastener 
           142 ,  242 ,  342 ,  442 ,  942  Socket 
           144 ,  244 ,  344 ,  444 ,  944  Head 
           146 ,  246 ,  346 ,  446 ,  946  Shaft 
           148 ,  248 ,  348 ,  448 ,  948  Male threads 
           150 ,  250 ,  350 ,  450 ,  950  Edge wear component 
           152 ,  252 ,  352 ,  452 ,  952  Head recess 
           154 ,  254 ,  354 ,  454 ,  954  Shaft recess 
           156 ,  256 ,  356 ,  456 ,  956  Abutment surface 
           160 ,  260 ,  360 ,  460  Mounting insert 
           164 ,  264 ,  364 ,  464  Female threads 
           166 ,  266 ,  466  Alignment device/Directional indicia/rotational means 
           421  Circumferential weld 
           423  Support rim 
           449  Washer 
           451 A First protrusion 
           451 B First side 
           453 A Second protrusion 
           453 B Second side 
           457  Circumferential weld channel 
           457 A First weld channel face 
           457 B Second weld channel face 
           458 A End face liner 
           458 B Outer face liner 
           459  Clearance band 
           463  Chamfer 
           490  Radial weld channel