Abstract:
A roller press having an improved edge wear assembly is disclosed. The roller press comprises a roller [ 200]  having an axis [ 203].  The roller [ 200]  comprises an outer surface [ 205]  containing one or more wear inserts [ 280]  and an annular abutment surface [ 207]  proximate an end of the outer surface [ 205].  The annular abutment surface [ 207]  extends generally transversely with respect to the outer surface [ 205]  of the roller [ 200].  A plurality of wear components [ 211]  extend from the abutment surface [ 207]  in a direction generally parallel to the axis [ 203]  of the roller [ 200],  wherein at least two of the wear components [ 211]  are circumferentially interlocked with one another so as to resist axial and/or radial pull-off forces as material flows between other wear inserts [ 280]  located on the roller [ 200].  Fasteners [ 230]  are received by receiving portions [ 215]  in and secure the wear components [ 211]  to the abutment surface [ 207]  of the roller [ 200].

Description:
BACKGROUND OF THE INVENTION 
       [0001]    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 industries. 
         [0002]    Currently, when roller edges erode, workers must fill gaps and worn-away roller material with hard-facing weld material. Subsequent grinding and machining process on the roller may be necessary after welding in order to bring the roller back to original specifications. 
         [0003]    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. Pat. 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 in at least a circumferential direction, while still preserving ease of maintenance and/or removal of the hard bodies. Moreover, the designs fail to provide adequate resistance to axial pull-off forces as material flows axially between studs or other wear inserts located on the roller. Moreover, these designs fail to provide adequate resistance to radial pull-out forces. 
       OBJECTS OF THE INVENTION 
       [0004]    It is, therefore, an object of the invention to provide a mechanically-robust edge wear component system. 
         [0005]    It is also an object of the invention to provide adequate support and stability for wear components under tangential shear loads in at least a circumferential direction, while still preserving ease of maintenance and/or removal of the hard bodies. 
         [0006]    Furthermore, it is an object of the invention to provide adequate resistance to axial pull-off forces as material flows axially between wear inserts located on the roller. 
         [0007]    Moreover, it is an object of the invention to provide adequate resistance to radial pull-off forces as material flows between wear inserts located adjacent edge portions of the roller. 
         [0008]    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 
       [0009]    A roller press having an improved edge wear assembly is disclosed. The roller press comprises a roller having an axis. The roller comprises an outer surface containing one or more wear inserts 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. A plurality of wear components extend from the abutment surface in a direction generally parallel to the axis of the roller, wherein at least two of the wear components are circumferentially interlocked with one another so as to resist axial and/or radial pull-off forces as material flows between other wear inserts located on the roller. Fasteners are received by receiving portions in and secure the wear components to the abutment surface of the roller. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a side view of a roller sleeve assembly according to the prior art, showing edge wear components which fail to provide resistance to axial pull-off forces; 
           [0011]      FIG. 2  is a side view of a roller sleeve assembly according to some embodiments, showing interlocking edge wear components which provide resistance to axial pull-off forces; 
           [0012]      FIG. 3  is a detailed view of an interlocking edge wear component as shown in  FIG. 2 ; 
           [0013]      FIG. 4A  is a cross-sectional view of a roller edge according to some embodiments; 
           [0014]      FIG. 4B  is an isometric view of a chevron- or feathered-style first hard material component; 
           [0015]      FIG. 5  is an exploded detailed view of the assembly shown in  FIG. 4A ; 
           [0016]      FIG. 6  is an end view of the roller edge shown in  FIG. 4 ; 
           [0017]      FIGS. 7A-7D  are detailed views of a wear component according to some embodiments; 
           [0018]      FIG. 8  is an end view of an alternative wear component according to some embodiments; 
           [0019]      FIG. 9  is a cross-sectional view of a roller edge according to some embodiments; 
           [0020]      FIG. 10  is a side view of a roller according to some embodiments; 
           [0021]      FIG. 11  is a side view of a roller according to some embodiments; 
           [0022]      FIG. 12  is an isometric view of a roller according to some embodiments; 
           [0023]      FIG. 13  is a detailed side view of a wear component shown in  FIG. 12 ; and, 
           [0024]      FIG. 14  is a side view of a wear component according to embodiments incorporating a radially-oblique angle. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]      FIG. 1  is a side view of a roller according to the prior art, showing edge wear components which fail to adequately provide resistance to axial pull-off forces. Autogenous layer material builds up on the outer surface  5  of roller  1  between wear inserts  80  and follows a path of least resistance, along flow path  90  in a direction generally parallel to the roller axis  3 . Over time, the autogenous layer material washes out portions of the roller  1  and pushes axially against inner side portions of edge wear components  11 . Over time, wear components  11  become less and less supported by the roller  1 , and eventually move past an abutment surface  7  of the roller. Finally, wear components  11  dislodge from the roller  1 , thereby leaving the roller  1  susceptible to damage and expedited wear. 
         [0026]      FIGS. 2-3  show an improved roller  100  according to a first embodiment. The roller  100  comprises a plurality of wear inserts  180  provided on an outer surface  105 . Flow paths  190  may exist, defining paths of least resistance for autogenous layer material. Interlocking edge wear components  111  are provided at the edge of the roller  100 . The wear components  111  may be provided within an annular shelf, one or more pockets, grooves, a series of circumferentially-spaced holes, or bolted to an abutment surface  107  defining an end side portion of the roller  100 . In the shown embodiment, wear components  111  are received within a series of circumferentially-spaced holes (not shown) provided on the roller  100  in areas adjacent the edge. One or more mounting bosses  115  provided on each wear component  111  help secure the wear component  111  to the roller  100 . 
         [0027]    As shown in more detail in  FIG. 3 , wear components  111  generally comprise at least a first hard material component  116 , a male interlocking feature  112 , and a female interlocking feature  114 . Preferably, the interlocking features  112 ,  114  are aligned along an axis  117  which runs generally parallel to a tangent line along the edge of the roller  100 . The first hard material component  116  of each wear component  111  may comprise a carbide (e.g., tungsten carbide), and a first base material component  118  may comprise a softer material such as vanadium or tool steel. 
         [0028]    As autogenous material and/or feed follows flow paths  190  in a direction along roller axis  103 , it is held back by wear components  111 . Wear components  111  may be recessed, flush, or sit proud with respect to the outer surface  105 , in order to form a material dam. Since male and female interlocking features  112 ,  114  are interconnected or interfitted with adjacent male and female interlocking features  112 ,  114  of circumferentially-adjacent wear components  111 , a greater resistance to axial pull-off is provided, as each wear component  111  is additionally supported by surrounding wear components. 
         [0029]      FIG. 4A  is a cross-sectional view of a roller edge according to another embodiment. A roller  200  comprises a plurality of wear inserts  280  provided on an outer surface  205 . A number of interlocking wear components  211  are provided at the edge of the roller  200 . The wear components  211  may be provided within an annular shelf, a series of circumferentially-spaced holes, or bolted to a planar abutment surface  207  defining an end side portion of the roller  200  as shown. As shown in more detail in  FIG. 4B , wear components  211  may generally comprise at least a first hard material component  216  having a male interlocking feature  212 , and a female interlocking feature  214 . Preferably, the interlocking features  212 ,  214  are aligned perpendicular to the axis  203  of the roller  200 . The first hard material component  216  of each wear component  211  may comprise a carbide (e.g., tungsten carbide), and a first base material component  218  (e.g., permanently attached to the first hard material component via soldering, welding, adhering, or other permanent joining technique) may comprise a softer material such as vanadium or tool steel. First base material component  218  may reduce the overall manufacturing cost of the wear component  211 , and may facilitate machining of at least one receiving portion  215  configured to receive at least one fastener  230  having an attachment feature  232  (e.g., threads). One or more complimentary attachment features  202  provided to the roller  200  accept said at least one fastener  230  and hold the wear component  211  against abutment surface  207  at the edge of the roller  200 . 
         [0030]    A second hard material component  217  may also be attached to the first base material component  218  in order to prevent backside washout and wear. A series of channels  213  may be provided within the second hard material component to accommodate a solder or weld bead  219  to join the second hard material component  217  to the first base material component  218 . 
         [0031]      FIG. 5  is an exploded detailed view of the assembly shown in  FIG. 4A . A single piece wear component  211  is formed by soldering, welding, gluing, adhering, pressing, or otherwise fusing together, a first base material component  218 , a first hard material component  216 , and a second hard material component  217 .  FIG. 6  is an end view of the roller edge shown in  FIG. 4 , showing the wear component  211  installed onto the abutment surface  207  of the roller  200 ; 
         [0032]      FIGS. 7A-7D  are detailed views of a wear component  311  according to some embodiments. The wear component  311  shown may be used alone and applied to receiving portions within an edge surface of a roller (as shown in  FIGS. 2 and 3 ), or may be permanently attached to other components to form a larger wear component (as shown in  FIGS. 4A ,  5 ,  6 , and  9 ). The wear component  311  comprises a first hard material component  316 , an optional first base material component  318  formed of a softer material, a female interlocking feature  314  and a male interlocking feature  312  preferably aligned along an axis  317 , and a mounting boss  315  which extends from the first base material component  318 . Male  312  and female  314  interlocking features are complimentary in shape and size and may form a puzzle-like fit when joined. As shown in  FIG. 7D  in dotted lines, the first hard material component  316  may be rounded or chamfered in at least one profile view to reduce fracture during commissioning and break-in period of the roller. For example, in some instances, such as the embodiment shown in  FIG. 8 , a wear component  411  may comprise a first hard material component  416  in the form of a semi-spherical button. The wear component  411  may similarly comprise a first base material component  418  and mounting boss  415 . 
         [0033]      FIG. 9  is a cross-sectional view of a roller edge according to some embodiments. A roller  500  comprises a plurality of wear inserts  580  provided on an outer surface  505 . A number of interlocking wear components  511  are provided at the edge of the roller  500 . The wear components  511  may be provided within an annular shelf, a series of circumferentially-spaced holes, or bolted to a planar abutment surface  507  defining an end side portion of the roller  500  as shown. Wear components  511  may generally comprise at least a first hard material component  516 , which may have male and female interlocking feature (not shown). The first hard material component  516  of each wear component  511  may comprise a carbide (e.g., tungsten carbide), and a first base material component  518  (e.g., permanently attached to the first hard material component via soldering, welding, adhering, or other permanent joining technique) may comprise a softer material such as vanadium or tool steel. An intermediate second base material component  510  may be provided between the first hard material component  516  and the first base material component  518  to facilitate manufacturing assembly and bonding. Second base material component  510  may comprise one or more mounting bosses  520  which are received within first base material component  518 . First  518  and second  510  base material components may reduce the overall manufacturing cost of the wear component  511 , and may facilitate machining of receiving portions  515  configured to receive fasteners  530  having attachment features  532 . One or more complimentary attachment features  502  are provided to the roller  500  and accept said fasteners  530  and hold the wear component  511  against abutment surface  507  at the edge of the roller  500 . 
         [0034]    A second hard material component  517  may also be attached to the first base material component  518  in order to prevent backside washout and wear. A series of channels  513  may be provided within the second hard material component to accommodate a solder or weld bead  519  to join the second hard material component  517  to the first base material component  518 . 
         [0035]      FIG. 10  is a side view of a roller  600  according to some embodiments. The roller  600  comprises a plurality of wear inserts  680  provided on an outer surface  605 . Flow paths  690  may exist, defining paths of least resistance for autogenous layer material. Interlocking edge wear components  611  are provided at the edge of the roller  600 . The wear components  611  may be provided within an annular shelf, one or more pockets, grooves, a series of circumferentially-spaced holes, or bolted to an abutment surface  607  defining an end side portion of the roller  600 . In the shown embodiment, wear components  611  are received within a series of circumferentially-spaced holes (not shown) provided on the roller  600  in areas adjacent the edge. One or more mounting bosses may be provided to each wear component  611  in order to help secure the wear component  611  to the roller  600 . 
         [0036]    Wear components  611  generally comprise a male interlocking feature  612 , and a female interlocking feature  614 . The interlocking features  612 ,  614  are generally aligned and may comprise a polyhedral shape. While not shown, interlocking features  612 ,  614  may comprise undercuts or dovetail joint portions therebetween. 
         [0037]    As autogenous material and/or feed follows flow paths  690  in a direction along roller axis  603 , it is held back by wear components  611 . Wear components  611  may be recessed, flush, or sit proud with respect to the outer surface  605 , in order to form a material dam. Since male and female interlocking features  612 ,  614  are interconnected or interfitted with adjacent male and female interlocking features  612 ,  614  of circumferentially-adjacent wear components  611 , a greater resistance to axial pull-off is provided, as each wear component  611  is additionally supported by surrounding wear components  611 . 
         [0038]      FIG. 11  is a side view of a roller  700  according to some embodiments. The roller  700  comprises a plurality of wear inserts  780  provided on an outer surface  705 . Flow paths  790  may exist, defining paths of least resistance for autogenous layer material. Interlocking edge wear components  711  are provided at the edge of the roller  700 . The wear components  711  may be provided within an annular shelf, one or more pockets, grooves, a series of circumferentially-spaced holes, or bolted to an abutment surface  707  defining an end side portion of the roller  700 . In the shown embodiment, wear components  711  are received within a series of circumferentially-spaced holes (not shown) provided on the roller  700  in areas adjacent the edge. One or more mounting bosses may be provided to each wear component  711  in order to help secure the wear component  711  to the roller  700 . 
         [0039]    Wear components  711  generally comprise a male interlocking feature  712 , and a female interlocking feature  714 . The interlocking features  712 ,  714  are generally aligned and may comprise a polyhedral shape. While not shown, interlocking features  712 ,  714  may comprise undercuts or dovetail joint portions therebetween. 
         [0040]    As autogenous material and/or feed follows flow paths  790  in a direction along roller axis  703 , it is held back by wear components  711 . Wear components  711  may be recessed, flush, or sit proud with respect to the outer surface  705 , in order to form a material dam. Since male and female interlocking features  712 ,  714  are interconnected or interfitted with adjacent male and female interlocking features  712 ,  714  of circumferentially-adjacent wear components  711 , a greater resistance to axial pull-off is provided, as each wear component  711  is additionally supported by surrounding wear components  711 . 
         [0041]      FIG. 12  is an isometric view of a roller  800  according to some embodiments. The roller  800  comprises a roller axis  803 , an outer surface  805 , and a plurality of wear components  811  held to an abutment surface  807  of the roller  800  by a plurality of fasteners  830 . Each wear component generally comprises a first base material component  818  supporting one or more first hard material components  816 . As shown in  FIG. 13 , first hard material components  816  provided on the first base material components  818  may comprise a male interlocking feature  812 , a female interlocking feature  814 , and one or more mounting bosses  815 , which may be keel or fin-shaped, or otherwise elongated, oblong, symmetrical, or non-symmetrical without limitation. 
         [0042]      FIG. 14  is a side view of a first hard material component  916  incorporating a radially-oblique angle  910  on both male  912  and female  914  interlocking features. The angle  910  provides support not only in a direction along the axis  803  of a roller  800  and in a tangential direction  809 , but also provides support to each first hard material component  816  in a radial direction  801 , as well. Angle  910  may be provided in many different ways, including, but not limited to providing stepped male  1012  and female  1014  interlocking features as indicated by dotted lines in  FIG. 14 . First hard material component  916  may comprise one or more mounting bosses  915 , which may be fin-shaped, or otherwise elongated, oblong, symmetrical, non-symmetrical, or provides in the form of a keel without limitation. 
         [0043]    While not shown, gaps between interlocking features may be filled with filled with weld material in order to permanently join the wear components to the roller and to each other. Moreover, while not shown, mating surfaces between the interlocking features of wear components 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. 
         [0044]    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, 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 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. 
         [0045]    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. 
         [0046]    For example, it is envisaged that interlocking features may comprise different shapes and sizes depending on the overall design specifications of a roller. Moreover, while receiving portions are primarily shown in the drawings as blind or through holes, receiving portions 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 processes like swaging), weld chamfers or channels for accommodating weld pools, glue holes, anchors, inserts, etc. Furthermore, mounting bosses may be of the same material or different material as the first hard material components. 
         [0047]    It is contemplated that male and female interlocking features disclosed herein may be reversed and still be within the scope of the disclosure. For example, male interlocking features and female interlocking features may be reversed. 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. Mounting bosses, receiving portions, fasteners, and attachment features may be provided in any number or configuration which is suitable for the intended purpose of the roller. 
         [0048]    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 
       [0049]      1 ,  100 ,  200 ,  500 ,  600 ,  700 ,  800  Roller 
         [0050]      3 ,  103 ,  203 ,  603 ,  703 ,  803  Roller axis 
         [0051]      5 ,  105 ,  205 ,  505 ,  605 ,  705 ,  805  Outer surface 
         [0052]      7 ,  107 ,  207 ,  507 ,  607 ,  707 ,  807  Abutment surface 
         [0053]      11 ,  111 ,  211 ,  311 ,  411 ,  511 ,  611 ,  711 ,  811  Wear component 
         [0054]      112 ,  212 ,  312 ,  612 ,  712 ,  812 ,  912  Male interlocking feature 
         [0055]      114 ,  214 ,  314 ,  614 ,  714 ,  814 ,  914  Female interlocking feature 
         [0056]      115 ,  315 ,  415 ,  520 ,  815 ,  915  Mounting boss 
         [0057]      116 ,  216 ,  316 ,  416 ,  516 ,  816 ,  916  First hard material component 
         [0058]      117 ,  317  Axis (follows roller edge perimeter) 
         [0059]      118 ,  218 ,  318 ,  418 ,  518 ,  818  First base material component 
         [0060]      80 ,  180 ,  280 ,  580 ,  680 ,  780  Wear insert 
         [0061]      90 ,  190 ,  690 ,  790  Flow path (of autogenous layer material) 
         [0062]      202 ,  502  Attachment feature 
         [0063]      213 ,  513  Channel 
         [0064]      215 ,  515  Receiving portion 
         [0065]      217 ,  517  Second hard material component 
         [0066]      219 ,  519  Weld or solder bead 
         [0067]      230 ,  530 ,  830  Fastener 
         [0068]      232 ,  532  Attachment feature 
         [0069]      510  Second base material 
         [0070]      801  Radial direction 
         [0071]      809  Tangential direction 
         [0072]      910  Radially-oblique angle 
         [0073]      1012  Stepped or castellated male interlocking feature 
         [0074]      1014  Stepped or castellated female interlocking feature