Polysius
To true up the surfaces
that carry everything.
Key figures strip
- Mobile
- The machine comes to your plant
- 2 machines
- Rotary kilns and shell-supported ball mills
- Documented
- Electronic diameter and concentricity monitoring
- Worldwide
- Universal electrical devices ensure compatibility
- Before & after
- Roundness measured, documented and evaluated twice
The Problem
A kiln tyre, a supporting roller and a mill slide ring have the same job and the same fate: they absorb large forces continuously, and there is no wear part between them and the load. Whatever happens to them happens to the running surface itself. Geometric defects and damage therefore occur on their surfaces over time — on a kiln through the forces themselves, on a mill through irregularities in operation.
| 1 — A defect appears | A groove, a spot of pitting, a flat, a roughened band |
| 2 — The contact becomes uneven | Load concentrates where the surface is still high, and the defect grows faster than the rest |
| 3 — The machine reacts | Unevenness and damage spread to what runs against it — the roller, the bearing, the shell |
| 4 — Something expensive gets replaced | Which is the outcome polgrind® exists to prevent |
Two Machines, One Service
Rotary kiln — tyres and supporting rollers
Races and rollers on rotary kilns must continuously absorb large forces. Geometric defects and damage therefore occur on their surfaces over time. This leads to irregularities and damage on the machines. With our mobile polgrind® machining, we ensure that the surfaces become flawless again. This significantly improves the operational reliability of the rotary kiln.
Effective elimination of faults and surface damage of tyres and supporting rollers
Significantly increased service life and production time
Machined on site, in the roller station
Ball mill — slide rings
Slide rings for shell-supported ball mills are exposed to extreme forces on an ongoing basis. Due to irregularities in mill operation, the surfaces of these components are damaged over the course of time. This leads to unevenness and damage to the machines. Our mobile polgrind® machining service ensures that the surfaces are returned to a pristine condition. This means that your mill can once again run smoothly.
Effective elimination of defects and surface damage to slide rings
Significantly increases the service life of slide rings and ball mill bearings
Slide ring lift values and oil temperature documented
The Process
The centrepiece of our service is the systematic grinding process. What makes it a service rather than a repair is that the condition is recorded on both sides of the work.
| 1 — Preliminary inspection | Recommended before the work is carried out, to avoid any unnecessary downtime when performing the grinding work |
| 2 — Measure and document | Roundness is measured, documented and evaluated before grinding. On a mill, the slide ring lift values and the oil temperature are documented as well |
| 3 — Systematic grinding | Surfaces are carefully machined using grinding belts with different grit sizes, eliminating all unevenness, damage and roughness |
| 4 — Measure again | Roundness is measured, documented and evaluated after grinding too. The surfaces are returned to a first-class condition |
polscan® Finds It, polgrind® Fixes It
These two services are the natural pair in the Field Services portfolio, and on a rotary kiln they are frequently the two halves of the same job.
| polscan® — the diagnosis | polgrind® — the correction | |
| What it does | High-precision optoelectronic measurement of the rotary kiln during operation: axis deviation, shell deformation, eccentricity, ovality | Mobile machining that returns those same surfaces to a flawless condition |
| The relevant options | Option 1 detects the dimensions of the tyres and supporting rollers; option 2 records the axial runout of the tyres | Machining of exactly those surfaces, with electronic diameter and concentricity monitoring |
| What you learn | Which surfaces are out of tolerance, and by how much | That they are back inside tolerance, proven by a measurement |
Grind or Replace?
Machining is the cheap option. It is not always the right one, and the page says so.
| First choice — machine the surface | Surface damage, unevenness, roughness, loss of concentricity. The component stays where it is and comes back into tolerance |
| When the axle is the issue — refurbish the roller | The main load on a supporting roller is the shearing in the axle. In the event of a fault, the roller can be refurbished in one of our worldwide service workshops and fitted with a new axle |
| When the station is the issue — replace it | For hot bearings or broken axles, roller stations of any make can be modified to the proven polysius® roller station, connected to the existing baseplate via an adapter plate |
Your Added Value
Significantly increased service life and production time
Effective elimination of faults and surface damage of tyres and supporting rollers
Process documentation through electronic diameter and concentricity monitoring
Available worldwide
The grinding and lathe machine easily eliminates unevenness, damage and roughness, and makes sure your tyres and supporting rollers are trued up again.