Roller presses grind thousands of tons of material, day after day, all year round. Unsurprisingly, this causes progressive wear, especially of the roller surfaces. In abnormal circumstances, it can also result in more significant damage to the roller itself. The Roller Press Scanner detects both. Current status is then automatically reported against historical data for a detailed insight into the changing condition of your rollers. With this insight, you can better plan maintenance to limit disruption, extending periods between shutdowns – without risking the overall health of the roller press. When intervention is required, we are also your reliable partner for roller maintenance, repair and optimization.
We introduced roller press technology to the cement industry over 35 years ago. That revolutionary spirit lives on today in our Roller Press Scanner.
Roller monitoring redefined
Conventional surface measurement and reporting takes many hours and is of limited accuracy. Only a couple of hundred data points are ever recorded from the same prescribed spots. This means only certain areas of the entire surface are inspected properly. The chances of missing progressive wear patterns or abnormal damage are therefore high.
In contrast, the Roller Press Scanner is much more thorough! Measurement is conducted inside the machine, while the roller is moving, and covers the complete roller surface – many millions of data points! The result is a scanning process that is much quicker and produces a surface model that is substantially more accurate – all without disrupting production.
- Traditional surface measurement by hand
- Fully-automatic measurement with KHD’s RP Scanner
The process: four easy steps
The Roller Press Scanner really is a smart device. It’s easy to operate via smartphone or tablet and can be installed quickly and easily by just two employees. It’s as easy as 1-2-3-4. Here’s how:
Place and lock the scanner on dedicated mountings. Machines without pre-installed mountings can be retrofitted easily.
Insert USB flash drive, energize and power up the scanner.
Connect the scanner to your mobile device, open the Roller Press Scanner app, and start the scan. Simple.
Remove the USB flash drive and upload the data to KHD. We then automatically create a report, which is sent to you the same day via email.
Next level reporting
Our reports reveal even the smallest irregularities and damage to your roller surface. Crucially, they also compare the current condition of your rollers against historical data to show the rate of wear over time. That gives you the information you need to be proactive with your refurbishment and to select the ideal timing of maintenance work.
This brings two crucial benefits. Firstly, you prevent unplanned stoppages and related production loss. Secondly, you can get as much life out of your rollers as possible, without risking damage to the machine. Which means higher productivity and, in the long run, reduced production and maintenance costs.
Maintenance that makes sense
Understanding the progression of wear is the vital piece of information you need to plan maintenance effectively. Without it, any maintenance plan is effectively a best guess. By giving you that information, the Roller Press Scanner therefore takes away that guesswork and allows you to schedule maintenance at the point it most makes sense.
Our Roller Press Scanner helps tell you when maintenance is needed. But we are also your partner when it comes to executing maintenance, repairs and more.
Count on the experts
As the authority in the use of roller presses in cement-related applications, we are the trusted choice for your repair and maintenance needs, as well as for optimization projects and troubleshooting.
When you come to us, you can expect first-class service and the highest‑quality workmanship, every time. We can execute partial or complete refurbishment of your equipment. And if you need new rollers, we can procure and supervise the installation of those for you too.
When and how to act
We recommend surface scans every 1000 operating hours or every eight weeks in order to effectively track roller surface condition. Small deficiencies can then be fixed by your personnel, according to our repair instructions. If you see the need for support, we can guide you remotely or provide an expert that oversees the work onsite. In cases of more substantial damage or progressive wear, we take over and execute the repair process for you. That can be done in-situ (to reduce disassembly work) or in a local workshop.
Roller surfaces and refurbishment: hard facing
The most common type of surface is hard facing. This is a welded surface of various material layers that all have different mechanical properties. The welding process creates a hardened protective wear layer on the roller surface.
The refurbishment of hard-faced surfaces is a multi-stage process. The remaining wear layer must first be removed with the help of grinders or plasma cutters to reestablish a true and level base. In the subsequent steps, multiple protective layers are rewelded to form the new hard-faced surface. It’s a technical job that should only be undertaken by skilled welders with the right training – such as those found at KHD workshops.
Roller surfaces and refurbishment: stud lining
The second roller surface type from KHD is stud lining – and is far more sophisticated. Extremely dense tungsten carbide material is sintered into studs, which are glued into pre-drilled holes in the roller surface. Due to the height difference between the studs and the roller surface, an autogenous wear layer is created by the ground material that settles between the studs on top of the roller surface.
Although studs are extremely dense and tough, they are still subject to wear. However, the rate of wear rate is considerably lower than hard faced surfaces for any given material composition and process conditions.
When the stud lining surface shows progressive concave wear, it can be refurbished with the help of a special grinding application that was developed and perfected by KHD. This grinding process is conducted in-situ, allowing us to execute the work as quickly and efficiently as possible, reducing machine downtime to a minimum.
New high-chrome wear protection
Our latest development is a high-chrome bandage (HCB) made from a compound casting. HCB combines lower maintenance requirements with a convincing extra-long service life. The new surface option has already run successfully for over two years in real-world conditions. Plus two more installations are in operation since the beginning of 2022.
The specialty of our HCB is the mechanical insertion of the profiling. Instead of welding the profile, which causes tiny surface cracks that can lead to problems, we mechanically grind the profile into the surface. This makes the surface also more reliable and longer lasting in direct comparison to other compound castings available in the market. Quite ingenious, right?
Interested in learning more about this promising new development? Let us know and we’ll arrange a call with one of our experts.