Abstract:
A roller with replaceable edge reinforcements is provided. A plurality of removable edge reinforcements are disposed radially along the peripheral edge of the end face of the roller. The reinforcements are slidably connected to the end face of the roller, either directly or indirectly, using male and female interlocking members, preferably in a U-shaped dovetail. The edge reinforcements are constructed from a suitably hard material and accept wear in place of the peripheral edge of the roller itself. In some embodiments, a pin and dimple arrangement is provided to assist the sliding engagement of the male and female members. A tool recess may also be provided to assist with removing the edge reinforcements.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a continuation of International App. No. PCT/CA2015/050121 entitled “ROLLER WITH REPLACEABLE EDGE REINFORCEMENTS” filed on Feb. 18, 2015; which claims priority on U.S. App. No 61/941,884 entitled “ROLLER WITH REPLACEABLE EDGE REINFORCEMENTS” filed on Feb. 19, 2014, both of which are incorporated by reference herein in their entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to rollers and grinders for industrial use, including mining, trash compaction and other uses. In particular, the present invention relates to surface reinforcements for rollers subjected to wear conditions and methods of replacing same. 
       BACKGROUND 
       [0003]    Friction-based rollers are common components of many machines. A frequent problem with such rollers is wear on the roller surface over time, particularly if the roller is subjected to large frictional forces. When the surface of the roller begins to wear out or becomes uneven, the roller must then be replaced or the surface of the roller must be remanufactured. 
         [0004]    Frictional wear is particularly problematic for industrial rollers used to crush, compact, shred, or grind materials. Industrial rollers are used extensively in mining operations to crush rock, ore, and other brittle materials into smaller particles. Industrial rollers can also be used for trash compaction or in other applications where high throughput crushing, shredding, or compaction is required. 
         [0005]    Two basic types of industrial rollers are commonly used for crushing, compacting, or shredding ; the first being a single roller operating adjacent to a stationary curved anvil plate and the second being a double counter-rotating set of rollers having parallel axes and a gap between the rollers. Particle output size from a roller or pair of rollers is determined by the size of the gap, also known as the ‘nip’, between the roller surface and the opposing surface, such as an anvil plate or opposing roller. Material is drawn into the nip by the rotating motion of the roller surface and exits the nip in a continuing stream of crushed, compacted, or shredded material. 
         [0006]    In many industrial applications, particularly in the mining industry, industrial rollers are subjected to extremely high pressures and/or are used to crush relatively hard materials, both of which can result in significant frictional wear on the rollers. While wear can occur at various points along the surface of the roller, the peripheral edges of the roller are often susceptible to wear. 
         [0007]    One conventional approach to extending the life of an industrial roller is to reinforce the roller surface with extremely hard materials, such as tungsten carbide. Nevertheless, even the hardest materials will wear out over time and so this approach can only extend the time required before the roller must be replaced or remanufactured in order to provide an even surface. 
         [0008]    Although conventional carbide stud arrangements provide protection for the working surface of the roller, they often leave the end faces of the roller and the peripheral edges thereof exposed to wear. Wear along the peripheral edge of the roller can be particularly problematic for rollers used for ore crushing. 
         [0009]    When an industrial roller reaches the end of its service life, it must be replaced or remanufactured. In many applications, particularly in the mining industry, industrial rollers can be quite large and so remanufacture is often preferred over complete replacement of the roller. 
         [0010]    The remanufacture of a worn roller is not a simple or inexpensive task, involving removal of the entire roller from service, followed by extensive cutting, machining, and re-welding of the roller surface. 
         [0011]    If the roller has no edge protection, the peripheral edges of a worn roller surface may exhibit a rounded profile. In order to eliminate these rounded edges, the peripheral edge of the roller must be either built up through welding processes or the surface of the roller must be machined down until the peripheral edge becomes square. In either case, the process is expensive and time consuming. 
       SUMMARY OF THE INVENTION 
       [0012]    The present invention is directed to a roller with replaceable edge reinforcements. A plurality of removable edge reinforcements are disposed radially along the peripheral edge of the end face of the roller. The reinforcements are slidably connected to the end face of the roller, either directly or indirectly, using male and female interlocking members, preferably in a U-shaped dovetail. The edge reinforcements are constructed from a suitably hard material and accept wear in place of the peripheral edge of the roller itself. In some embodiments, a pin and dimple arrangement is provided to assist the sliding engagement of the male and female members. A tool recess may also be provided to assist with removing the edge reinforcements. 
         [0013]    In one broad aspect, there is provided a roller having a reinforced edge. The roller comprises a roller body rotating about a central axis, the roller body having a roller surface and a roller end face that meets the roller surface at a peripheral edge; and a plurality of detachable edge reinforcements slidably engaged to the roller end face via opposed interlocking male and female members, the edge reinforcements arranged radially along the peripheral edge to form a reinforced edge of the roller. 
         [0014]    In some embodiments, the interlocking male and female members form a dovetail connection, preferably a U-shaped dovetail. In some cases, at least one female member is disposed on the roller end face and at least one male member is disposed on the edge reinforcement. Alternatively, or in addition, at least one male member is disposed on the roller end face and at least one female member is disposed on the edge reinforcement. 
         [0015]    In some embodiments, the roller end face comprises one or more detachable annular plates disposed along the peripheral edge of the roller body for receiving the plurality of detachable edge reinforcements slidably engaged thereto. 
         [0016]    In some embodiments, the roller end face comprises one or more surface segments disposed along the surface of the roller, adjacent the peripheral edge, for receiving the plurality of detachable edge reinforcements slidably engaged thereto. 
         [0017]    In some embodiments, the male or female member further comprises a pin disposed on the male or female member and extending into the slidable engagement there between; and a dimple disposed on the opposing female or male member in alignment with and for receiving the pin. 
         [0018]    In some embodiments, the roller further comprises a plurality of tool recesses disposed on the roller end face, each tool recess being in communication with at least one of the plurality of edge reinforcements for assisting the detachment of the edge reinforcement. In some examples, each of the plurality of edge reinforcements is in communication with at least one tool recess, the tool recesses are oriented in a radial pattern along the roller end face, and the plurality of tool recesses are closer to the central axis of the roller than the edge reinforcements. 
         [0019]    In some embodiments at least one of the plurality of edge reinforcements comprises a shoulder that forms a portion of the roller surface. 
         [0020]    In another broad aspect, there is provided a detachable edge reinforcement for a roller having a roller surface and a roller end face which meets the roller surface at a peripheral edge, the detachable edge reinforcement comprising a body for resisting wear at the peripheral edge; and an interlocking member for slidable engagement with an opposed interlocking member on the roller end face. 
         [0021]    In some embodiments, the interlocking member on the edge reinforcement is a male member and the opposed interlocking member on the roller end face is a female member. In some cases, the interlocking member is dovetailed, preferably a U-shaped dovetail. 
         [0022]    In some embodiments, the detachable edge reinforcement further comprises a dimple for receiving a pin disposed on the roller end face; or a pin for engaging a dimple disposed on the roller end face. In some examples, the edge reinforcement further comprises a shoulder that forms a portion of the roller surface. 
         [0023]    In another broad aspect of the invention, there is provided an annular plate for a roller having a roller surface and a roller body which meets the roller surface at a peripheral edge, the annular plate detachabiy coupled to the peripheral edge, the annular plate comprising a dovetailed male or female member for slidable engagement with a detachable edge reinforcement as described above. 
         [0024]    In some embodiments, the annular plate further comprises a tool recess for assisting the detachment of the slidable edge reinforcement, the tool recess disposed on the roller end face in communication with the edge reinforcement and extending away from the roller surface. 
         [0025]    In another broad aspect of the invention, there is provided a surface segment for a roller having a roller surface and a roller end face which meets the roller surface at a peripheral edge, the surface segment comprising a dovetailed male or female member at the peripheral edge for slidable connection with a detachable edge reinforcement as described above. 
         [0026]    In some embodiments, the surface segment further comprises a tool recess disposed on the surface segment in communication with the edge reinforcement and extending away from the roller surface for assisting the detachment of the edge reinforcement. 
         [0027]    Directional terms such as “front” and “rear”, “top” and “bottom”, “first” and “second”, “right” and “left” are used herein purely for convenience of description. Such terms are used for illustration purposes and are not intended to limit the present disclosure. As well, and dimensions herein are not intended to limit the scope of the invention unless specifically stated. Furthermore, geometric terms such as “straight”, “flat”, “point” and the like are not intended to limit the invention to the level of geometric precision, but should instead be understood in the context of the invention which includes such departures from geometric position as the manufacturing tolerances that are normal and/or acceptable in the field of this invention, as well as the functional requirements of products in the field of the invention wherein a high level of precision may not be required. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]    The invention will now be described with reference to the attached drawings, which illustrate, by way of example only, embodiments of the invention contemplated herein : 
           [0029]      FIG. 1  is a perspective view of a reinforced roller according to a first embodiment of the present invention. 
           [0030]      FIGS 2A-2E  are perspective ( FIG. 2A ), front ( FIG. 2B ), end ( FIG. 2C ), side ( FIG. 2D ), and top ( FIG. 2E ) views of an edge reinforcement according to an embodiment of the present invention. 
           [0031]      FIG. 3  is a perspective view of a reinforced roller according to another embodiment of the present invention. 
           [0032]      FIG. 4  is an enlarged perspective view, partly broken away, of the reinforced roller of  FIG. 3 . 
           [0033]      FIG. 5  is a perspective view of the reinforced roller of  FIG. 3 , in a partially disassembled state. 
           [0034]      FIG. 6  is a front view of an annular plate according to one embodiment of the present invention. 
           [0035]      FIG. 7  is a perspective view of a reinforced roller according to a further embodiment of the present invention, in a partially disassembled state. 
           [0036]      FIGS 8A-8B  are a perspective view ( FIG. 8A ) and plan view ( FIG 8B ) of a surface segment of the roller of  FIG. 7 . 
           [0037]      FIG. 9  is a perspective view of a reinforced roller according to yet another embodiment of the present invention, in a partially disassembled state. 
           [0038]      FIGS 10A-10B  are a side view ( FIG. 10A ) and enlarged top view ( FIG. 10B ) of a female member of the roller of  FIG. 9 . 
           [0039]      FIGS 11A-11D  are perspective ( FIG. 11A ), front ( FIG. 11B ), end ( FIG. 11C ), and side ( FIG. 11D ) views of an edge reinforcement of the roller of  FIG. 9 . 
       
    
    
     DETAILED DESCRIPTION 
       [0040]    Referring now to the drawings, various embodiments of the invention will now be disclosed. 
         [0041]      FIG. 1  depicts an edge-reinforced roller  100  according to a first embodiment of the present invention. Generally speaking, a plurality of edge reinforcements  120  surround the peripheral edge  106  of the end face  108  of the roller  100 . The edge reinforcements  120  slidably engage the end face  108  of the roller  100  via male and female members  122 ,  130 . 
         [0042]    In this embodiment, the male member  122  is disposed on the edge reinforcements  120  and slidably engages with a female member  130  disposed on the end face  108  of the roller  100 . In other embodiments, the relationship of the male and female members  122 ,  130  may be reversed, such that the edge reinforcements  120  bear female members  130  and the end face  108  of the roller  100  bears male members  122 . 
         [0043]    In the embodiment shown in  FIG. 1 , the sliding engagement between the male and female members  122 ,  130  is an interlocking relationship, in this case a dovetail. More specifically, a U-shaped dovetail is provided in which the angle subtended between the side and face of the member is preferably between 70 and 75 degrees. This interlocking arrangement secures the edge reinforcement  120  against movement along the axis of the roller  100 . Other forms of interlocking relationships between the male and female members  122 ,  130  are also contemplated, such as members having interlocking concave/convex shapes or various profiles having a narrow stem and a wider head. 
         [0044]    The edge reinforcements  120  provide wear surfaces along the peripheral edge  106  of the roller  100  and can be individually replaced when lost, worn, or broken. The edge reinforcements  120  are preferably constructed of a hardened material, such as tungsten carbide. When assembled, the wear surfaces of the plurality of edge reinforcements  120  provide a reinforced edge  126  to resist wear along the peripheral edge  106  the roller  100 . 
         [0045]    In this embodiment, the invention further comprises a series of tool recesses  140 , which are aligned with the edge reinforcements  120 . When an edge reinforcement  120  is damaged or broken, the tool recesses  140  permit the insertion of a finger or a tool in the tool recess  140  to thereby access the bottom of the edge reinforcement  120 , on the side closer to the axis of rotation. Pulling, pushing, or hammering actions may then be used to loosen and withdraw the edge reinforcement  120  from its slidable engagement to the female member  130  disposed on the end face  108  of the roller  100 . The presence of tool recesses  140  is optional, and where present, preferably includes one tool recess  140  for each edge reinforcement  120 . 
         [0046]    The sliding engagement between the male and female members  122 ,  130  may be further enhanced in some embodiments through the use of a pin  132  in alignment with a dimple  124  on the opposing member. In the embodiment shown in  FIG. 1 , the pin  132  is provided on the female member and aligns with a dimple  124  on the male member of the edge reinforcement  120  (See  FIG. 2A ). The pin  132  extends into the slidable engagement between the male and female members  122 ,  130 , in a direction substantially parallel to the axis of rotation. In other embodiments, the arrangement of the pin  132  and dimple  124  may also be reversed as between the male and female parts. For example, in some embodiments, the pin  132  may be disposed on the male member  122  and the dimple may be disposed on the female member  130 . 
         [0047]    Insertion of the edge reinforcement  120  into the female member  130  aligns the pin  132  with the dimple  124 . In some embodiments, this results in an audible ‘click’ that informs the technician that the edge reinforcement  120  has been fully and correctly inserted in the roller  100 . Frictional engagement of the pin  132  against the dimple  124  may also assist in holding the edge reinforcement  120  in place against centrifugal forces generated during operation. In such cases, the use of a pin  132  may also aid other fasteners, such as glues, in holding the edge reinforcement  120  in place. 
         [0048]    The insertion process can be made easier in some embodiments by constructing the pin  132  from a resilient material, such as a polymer plastic. As can be best seen in  FIG. 10B , a pin  132  constructed of a resilient material, such as plastic, can be set in a recess  134  which provides lateral support so as to resist shearing during use. Non-resilient pins may also benefit from such construction, particularly when they are not a unitary component of the male or female member, nevertheless a recessed arrangement is preferable where the pin  132  is of resilient construction. 
         [0049]      FIGS 2A-2E  provide a number of views of an edge reinforcement  120  according to the present invention. A reinforced edge  126  is located at the periphery of the roller  100  when assembled. In this embodiment, a dimple  124  is provided on the male member  122 . As discussed above, in other embodiments the pin  132  may be provided on the male member  122 . In still further embodiments, the pin  132  or dimple  124  may be absent. 
         [0050]    A number of alternative embodiments also exist, in which the end face  108  includes one or more additional parts that mediate the sliding engagement with the edge protectors  120 . 
         [0051]    For example,  FIGS 3-5  depict an alternative embodiment in which the edge reinforcements  120  are received by detachable annular side plates  210 , which are bolted to the roller at bolt holes  212 . The inclusion of a detachable annular plate  210  on the end face  108  of the roller  200  allows for easier repair of male or female members on the end face  108  of the roller if they become damaged during operation of the roller  200 . In this embodiment, the annular plate  210  also includes tool recesses  240  and pins  232 , which serve the same functions described above for tool recess  140  and pin  132 .  FIG. 6  provides an enlarged view of an annular plate  210 , including pin recesses  234  disposed therein to strengthen the pins  232 . As with the embodiment described above, the male and female engagement between the end face  108  of the roller  200 , in this case via the annular plate  210 , can be reversed such that a male member (not shown) is provided on the annular plate  210 . Similarly, the pin and dimple arrangement is optional and where present, may be reversed in some embodiments, such that the annular plate  210  carries the dimple (not shown) rather than a pin  232 . 
         [0052]      FIGS 7-8B  depict another variation in which the surface  102  of the roller  300  is comprised of a number of surface segments  380 . Such surface segments  380  are the subject of U.S. provisional application by CSP Innovative Engineering Ltd. entitled “Roller With Replaceable Surface Segments and Method of Reconditioning Same”, filed Feb. 19, 2014, which is incorporated herein by reference. In this embodiment, the surface segments  380  are attached to a central hub  382 , in this case by a sliding dovetail engagement. 
         [0053]    In this embodiment, surface segments  380  situated along the periphery  106  of the roller  300  form a portion of the end face  108  of the roller  300  and carry the female members  330  to which the male member  122  of the edge reinforcement  120  slidably engage. In other embodiments, tool recesses are provided on the surface segment, which serve an analogous function to tool recesses  140  and  240  discussed above. 
         [0054]    As seen in  FIG. 8B , the surface segments  380  in this embodiment may also include a pin  332  set in a pin recess  334 , which operates in the manner described above. As with the other embodiments, the male and female engagement between the end face  108  of the roller  300 , in this case via the surface segment  380 , can be reversed such that a male member (not shown) is provided on the surface segment  380 . Similarly, the pin and dimple arrangement is optional and where present, may be reversed in some embodiments, such that the surface segment  380  carries the dimple (not shown) rather than a pin  332 . 
         [0055]      FIGS 9-10B  depict yet another variation in which the surface  102  of the roller  400  is comprised of surface segments  480 . In this embodiment, the surface segments  480  do not form part of the end face  108  of the roller  400 . Instead, the edge reinforcements  420  engage the end face  108  of the roller  400  in a manner similar to the embodiment shown in  FIG. 1 . However, unlike the edge reinforcements  120  in  FIG. 1 , the edge reinforcements  420  in  FIG. 9  further include a shoulder  428  which forms part of the surface  102  of the roller  400 . In some applications, the use of a shoulder  428  which forms part of the surface  102  of the roller  400  may aid the retention of the edge reinforcement  420  during operation. 
         [0056]      FIGS 11A-11D  provide enlarged views of the edge reinforcement  420  shown in  FIG. 9 . As discussed above, a shoulder  428  is provided which forms part of the surface  102  of the roller  400 . In this embodiment, the shoulder  428  is continuous with the roller surface  102 . In other embodiments the shoulder  428  may extend beyond the roller surface  102  to create a surface feature along the peripheral edge  106  of the roller  400 . Thus, the shoulder  428  may also in some cases allow the edge reinforcement  420  to extend beyond the maximum height of the male or female member on the roller end face  108 . The provision of a shoulder  428  may also prevent block entry of foreign material between the sliding engagement of the male and female members, which secure the edge reinforcement  420  to the end face  108  of the roller  400 . 
         [0057]    As with the previous examples, a male member  422  is provided along with a dimple  424 , both of which operate as discussed in respect of the male member  122  and dimple  124  above. As with the other embodiments, the male and female engagement between the end face  108  of the roller  400  can be reversed such that a female member (not shown) is provided on the edge reinforcement  420 . Likewise, the pin and dimple arrangement is optional and where present, may be reversed in some embodiments, such that the edge reinforcement  420  carries the pin (not shown) rather than a dimple  424 . 
         [0058]    In operation, a roller  100 ,  200 ,  300 ,  400  according to the present invention will have a reinforced edge  126 . The resulting reinforcement may extend the service life of such rollers, by resisting rounding of the peripheral edge  106  due to frictional wear. 
         [0059]    Edge reinforcements  120 ,  420  that are broken, worn, or lost can be replaced by sliding in replacement pieces. In embodiments which include a tool recess  140 ,  240 , this process may be assisted by placing a tool on the underside of the edge reinforcement  120 ,  420  and striking it with a hammer. 
         [0060]    In embodiments which include a pin and dimple, the complete insertion of a replacement edge reinforcement  120 ,  420  may be indicated by a positive connection, preferably a click. This may help to ensure that each reinforcement is fully inserted before the unit is returned to operation, which in turn may reduce the loss of edge reinforcements and may increase safety during operation of the roller  100 ,  200 ,  300 ,  400 . 
         [0061]    In embodiments in which the end face  108  of the roller  200  includes a removable annular plate  210  to which the edge reinforcements are attached, damaged male or female members on the end face  108  of the roller  200  may be replaced by replacing the annular plate  210 . Such damage may occur when an edge reinforcement  120 ,  420  has been lost, particularly since the annular plates  210  may not be constructed from the same hardened material as the edge reinforcements  120 ,  420 . 
         [0062]    Similar considerations apply where the end face  108  of the roller  300  is comprised of surface segments  380 , in that damage to the male or female members on the end face  108  of the roller  300  can be corrected by replacing the surface segments  380 , rather than machining the roller  300  itself. 
         [0063]    The embodiments of the present disclosure are intended to be examples only. Those of skill in the art may effect alterations, modifications and variations to the particular embodiments without departing from the intended scope of the present application. 
         [0064]    In particular, features from one or more of the above-described embodiments may be selected to create alternate embodiments comprised of a subcombination of features which may not be explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternate embodiments comprised of a combination of features which may not be explicitly described above. Features suitable for such combinations and subcombinations would be readily apparent to persons skilled in the art upon review of the present application as a whole. The subject matter described herein and in the recited claims intends to cover and embrace all suitable changes in technology.