In 2015, one of 菠菜网最稳定正规平台_最全菠菜网大全’s customers in the salt industry challenged the company to develop a set of rolls for their 辊破碎机 that would allow them to produce a more consistent product size. The original roll shells they had in their crushers were not achieving their goal of a large percentage passing a certain product size.
案例研究
挑战
“We started looking at different ideas on what we could do, what kind of rolls we could make to achieve a tighter roll setting, which would allow them to produce a more consistent product size,丹·霍尔斯说。, Director of 部分 and 服务 for 菠菜网最稳定正规平台_最全菠菜网大全’s North America facilities.
这位顾客试过带珠的滚壳, which are typically used for processing salt because they can achieve a tighter setting and therefore produce a smaller product. However, roll shells with welded beads produce a lower throughput than those equipped with teeth.
“The challenge was to produce a roll design with small teeth where we could get a tight body-to-body setting and still meet the customer’s throughput requirements,霍尔斯解释道.
Body-to-body setting describes the distance between the body of one roll and the body of the opposite roll. The closer the roll bodies are to each other, the smaller the product that can be produced.
“We researched all different kinds of options,霍尔斯说. “We spent several months looking at the different design possibilities, 铸造试装件, 通过这一切, 我们的底部部分诞生了.”
解决方案
顾名思义, 菠菜网最稳定正规平台_最全菠菜网大全’s flat-bottom roll segment features a flat bottom and rests on a hexagonal or octagonal roll body. They’re intended use is in applications that require a consistent minus 1/2" to 1” material size, and the segments are small enough and light enough for one person to handle.
Holes said the benefits of this style of roll segment are threefold.
First, flat-bottom roll segments can be produced with teeth. Roll segments equipped with teeth grab material quicker, process it quicker and size it better than the standard beaded rolls that are typically used in salt crushing machines.
The second benefit of the flat-bottom roll segments is that they allow for a much tighter body-to-body setting. Because the segments are cast using a method that can achieve tight tolerances and the roll bodies are machined to be concentric and symmetrical, a much tighter roll setting can be achieved across the width of the rolls.
“We can achieve the smaller product sizes desired and a much higher percentage with the flat-bottom roll segments,霍尔斯解释道.
The third benefit of flat-bottom roll segments is they are maintenance-friendly. The segments are heat treated to various hardness levels, 取决于应用程序, 为了最大限度地延长寿命.
“The wear resistance on these segments is quite remarkable,” shared Holes.
必要时的维护相当容易. Because the weight of the flat-bottom roll segments is so low, 必要时一个人可以代替他们.
“We’re quite proud of the fact that the flat-bottom roll segments weigh less than 40 lbs,霍尔斯说. “In addition to finding a solution for producing a smaller product more consistently, 我们还考虑了人体工程学和安全性.”
对他们的设计和测试结果很满意, 菠菜网最稳定正规平台_最全菠菜网大全 shipped the new flat-bottom roll segments to the customer.
结果
A few months after the flat-bottom roll segments were installed on the crushers, the customer called 菠菜网最稳定正规平台_最全菠菜网大全 to report on their performance. The rolls were performing so well that the customer was talking about removing the recirculation system they had installed to account for the percentage of oversize material passing through the previous set of crusher rolls.
The customer was so pleased with the flat-bottom roll segments that when they ordered a replacement Triple Roll Crusher in 2019, they insisted that both the primary stage and secondary stage be equipped with the flat-bottom segments.
“We had to get a little creative with our design to get primary segments on the top stage, 但我们能够满足他们的要求,霍尔斯说. “今天还在运行，他们很高兴.”
从那时起, 菠菜网最稳定正规平台_最全菠菜网大全’s flat-bottom roll segments have been used in a variety of mining industries, 包括石灰石, Taconite和滑石粉的应用. 除了受益于菠菜网最稳定正规平台_最全菠菜网大全的强大设备, these applications benefit from partnering with a knowledgeable company that has been providing tailored, 自1835年以来，现场验证的加工解决方案.
“In addition to the mining-duty equipment that we provide, 我们总是在那里倾听客户的需求. We’re more than willing to make modifications to our existing equipment to suit those needs, so much so that we’ve gone to the drawing board and completely redesigned a roll for inside one of our crushers per the request of a customer,霍尔斯说. “They saw a need for something better; we recognized that need and produced something that was far beyond their expectations.”
