WO2026000051A1 - Dynamic roller sieve with self-cleaning star for classifying and cleaning iron ore, with anti-impact device, rollers with independent motors, quick-change shaft system and anti-clogging device - Google Patents

Abstract

The present invention relates to a dynamic roller sieve with a self-cleaning star for classifying and cleaning iron ore, with anti-impact device, rollers with independent motors, quick-change shaft system and anti-clogging device, characterised in that it comprises a plurality of metal grids (7), an automatic lubrication system (10), self-cleaning stars (20), independent speed adjustment per module, an anti-impact device (40) and flexible coupling system for motors (50), an inclination control system (60), drive units (100) with an electric motor, a shaft (110) with bearings (115), an anti-clogging device (120) and a quick-change shaft system (130).

Description

Dynamic roller screen with self-cleaning star for iron ore classification and cleaning, with anti-impact device, rollers with independent motors, quick-change shaft system and anti-fouling device.

Field of invention

[01] This invention patent refers to a dynamic roller screen with a self-cleaning star for classifying and cleaning iron ore, with an anti-impact device, rollers with independent motors, a quick-change shaft system and an anti-fouling device, the field of application being the selection of solid materials, rotary screens, and toothed discs.

Fundamentals of the invention

[02] The mining sector has been suffering for many years from low production during rainy seasons. The technologies currently in use are outdated and have not evolved significantly, a fact that means the problem that the present invention proposes to solve is still part of the daily routine of mining companies.

[03] The methods used for mineral processing, which involve classification and screening of material, aim to separate a material into two or more fractions, with particles or fragments of different sizes, and vibrating screens are generally used for this purpose.

[04] In general, vibrating screens are composed of a suspension, drive, transmission, housing (or structure), and can be supplied with one to three decks, where the screening screens are placed. Basically, the vibrating screen for mining works by means of rotary motion, in which the ore placed in the machine moves between the perforated surfaces for separation and screening.

[05] Sieving is the separation of a material into two or more classes, these being limited to an upper and a lower class. In wet sieving Water is added to the material to be sieved in order to facilitate the passage of fines through the sieve screen. The material retained on the sieve screen is called oversize, and the material that passes through is called undersize.

[06] According to CORREIA and COUTO, (CORREIA, Julio Cesar Guedes; COUTO, Hudson Jean Bianquini. Classification and screening), during screening the separation of the material occurs, taking into account the geometric size of the particles, while in the classification method, the separation is carried out based on the concept of the speed at which the grains pass through a fluid medium. In mineral processing, the most commonly used fluid medium is water. In their studies they indicate that wet classification is normally applied to particles with very fine granulometry, where screening does not work efficiently.

[07] The systems used for ore classification and cleaning are robust equipment made of high-hardness material, given the possibility of use with different types and weights of materials. In general, they are used for ores and ductile materials; however, they can be applied to more fragile materials where there is no demand for high-hardness and high-cost construction materials, or even simply for the separation of material by weight.

[08] In an excerpt from a USP lecture: Equipment, dynamics, process quantification and dimensioning, from October 28, 2020, the professor presents a graph that, in his studies, points to the influence of humidity in relation to sieveability: https://edisciplinas.usp.br/pluginfile.php/5776562/mod_resource/content/1/Aula%2009%20-%20Peneiramento.pdf.

[09] According to theory, with moisture between approximately 8 to 33%, it is impossible to work with or perform the process efficiently using a sieve.

[010] When purchasing a screen and sorter, the customer wants an economical alternative to the process, thereby optimizing the use of their equipment so that it can have greater durability and functionality. They also seek to acquire a technological and innovative product that can solve their problem and, in addition, make them competitive against the competition. [011] We found on the market several models of sieves or sorters used in iron ore, and discs suitable for the purpose, which work dry or with high humidity.

[012] As a state of the art we can cite patent BR 112021022213-8 - Disc, spacer and conveying assembly, which refers to a disc, a spacer and a conveying assembly arranged to cooperate for the transport of materials on a roller grid (sieve, conveyor belt) and in particular, although not exclusively, to a disc and a spacer having wear-resistant areas for contacting the materials for transport.

[013] US Patent 5163564 - Disc screen with controlled interfacial openings, discloses a disc screen with limited compressibility spacers having an elongated metal shaft member with a plurality of screen discs mounted co-rotatingly on the shaft member. The screen discs have central shaft receiving openings through which the shaft extends coaxially. The screen discs are separated and spaced on the metal shaft member by a plurality of non-resilient and non-metallic resilient spacers located between and coaxial with adjacent screen discs.

[014] US Patent 2011094944 - Screening disk, roller, and roller screen for screening an ore feed, being an invention relating to the screening and feeding of ore using a roller screen and more particularly to a screening disk and roller for use in a roller screen for screening an ore feed.

[015] US patent 5405092 - Screen crusher for soil materials, where the present invention refers to a screen crusher for soil materials to be used in the bucket of an excavator.

[016] Patent WO9420227 - Roller screen with eccentric discs, refers to a separating blade for crushing and separating fragile materials, namely for preparing land and soil, preparing compost and using a large A variety of materials are used in the recycling sector to obtain secondary raw materials.

[017] The drawback of current vibrating screens lies in the fact that they are not effective with wet materials, as shown in the study graph, causing the lines to stop during rainy periods, as the vibrating screens become clogged when the moisture content of the material increases, reaching 17%. It is already known that vibrating screens only work well with very dry material.

[018] Due to these characteristics, a drop in productivity is expected during rainy periods, or as a palliative measure, the need to construct and use large sheds, generating high costs for the production process.

[019] Current equipment does not have variable shaft speeds, meaning they all operate at the same speed, contributing to a drop in wet screening performance, as the shafts working at the same speed contribute to clogging of the system during wet work, and this increases the need for downtime for maintenance.

[020] Regarding water use in the process, current equipment on the market, because it is not suitable for working with material with a high moisture content, requires constant stops for cleaning, and this is done manually or by means of water jets to remove the accumulation between the separation and selection devices. This results in a waste of natural resources and electrical energy.

[021] Another drawback is the weight provided by equipment whose discs and separation and selection devices are made of high-hardness steel, which leads to increased motor power, more robust drive elements, and consequently greater wear on the system and higher maintenance costs. Lighter materials would contribute to the efficiency and durability of the system, as well as savings on electricity. [022] As a consequence of a more robust and heavier machine, there is difficulty in transport, assembly and storage, thus increasing the costs associated with them, since they are generally calculated based on weight and dimensions.

[023] In addition to these factors, during the transport, assembly and maintenance process, the operator needs to exert more effort due to the weight and the risk of accidents with heavier devices.

[024] Similar solutions belonging to the state of the art fail to provide a solution to the related technical problems.

[025] To remedy the aforementioned inconveniences and present a solution to the problems found in the state of the art, we present the dynamic roller screen with self-cleaning star for classification and cleaning of iron ore with anti-impact device, rollers with independent motors, quick-change shaft system and anti-fouling device.

[026] Unlike the equipment presented, and studies that point to the difficulty or impossibility of carrying out the process with materials with high moisture content, the present patent application has the characteristic of screening wet materials with high performance, being distinct in its method, applicability, benefits to the investor, combined with safety in use and maintenance, and especially because there are no current equipment used to classify ores with 20% moisture content with the same productive capacity.

Brief description of the drawings

[027] Figure 1 shows a perspective view of the assembled sieve;

[028] Figure 2 shows a detailed view of the automatic lubrication system (10), its positioning and enlarged detail of the main components and connection means;

[029] Figure 3 shows a perspective view of the tilt control system (60); [030] Figure 4 shows a perspective view of a shaft with the mounted stars, bearing and drive gears;

[031] Figure 5 shows a perspective view of a shaft with a half-star mount at each end;

[032] Figure 6 shows a perspective view of the assembly formed by the conventional shaft and the shaft with a half-star mount at each end;

[033] Figure 7 shows a perspective view of the polymer pointed star;

[034] Figure 8 shows a side view of the polymer pointed star;

[035] Figure 9 shows a perspective view of the star with notched tips, or groove model;

[036] Figure 10 shows the side view of the star (20) with tips (21) equipped with notches or grooves (23), or groove model;

[037] Figure 11 shows the detail of the groove model tip, with grooves (23);

[038] Figure 12 shows the perspective view of the star (20) with interchangeable points (26);

[039] Figure 13 shows the detail of the interchangeable tip (26);

[040] Figure 14 shows a perspective view of the central star assembly of the anti-impact module;

[041] Figure 15 shows a front perspective view of the star with polymer points, showing the ceramic or Hardox circular inserts at the points;

[042] Figure 16 shows a rear perspective view of the star with polymer points, showing the ceramic or Hardox circular inserts at the points; [043] Figure 17 shows an exploded front perspective view of the split star;

[044] Figure 18 shows a perspective view of the assembled split star;

[045] Figure 19 shows the front perspective view of the right-hand half star;

[046] Figure 20 shows the rear perspective view of the Half Star (24a) right side;

[047] Figure 21 shows the front perspective view of the Half Star (24b) left side;

[048] Figure 22 shows a perspective view of the anti-impact device;

[049] Figure 23 shows a side view of the anti-impact assembly as a sieve;

[050] Figure 24 shows a perspective view of the anti-impact assembly as a sieve;

[051] Figure 25 shows a perspective view of the anti-impact device showing the arrangement of the bearings and shafts;

[052] Figure 26 shows a perspective view of the axes of the anti-impact device, arrangement and mounting of the stars.

[053] Figure 27 shows the perspective view, representing the reverse unlocking system (70), represented by a line, which is obtained by means of the arrangement of the sieves, aligned and synchronized, in order to form a “V” set from the smallest, on the inside, to the largest, which ends at the extremities, a shape that occurs by means of the synchronization of the salient projections of the self-cleaning stars;

[054] Figure 28 shows a perspective view of the flexible coupling (80); [055] Figure 29 shows a perspective view of the dynamic roller screen with independent motors;

[056] Figure 30 shows detail “A” of the drive system of the dynamic roller screen with independent motors;

[057] Figure 31 shows the front view of the dynamic roller screen with independent motors;

[058] Figure 32 shows a perspective view of the star assembly (20) with quick-change shaft coupling system (130);

[059] Figure 33 shows an exploded perspective view of the star assembly (20), quick-change shaft coupling system (130), bearings (134) and traction (133) and fastening (132) elements;

[060] Figure 34 shows the side view of the star assembly (20) with quick-change shaft coupling system (130);

[061] Figure 35 shows a perspective view of the quick-change shaft coupling system (130), mounted on the left side of the roller or star assembly (20);

[062] Figure 36 shows an exploded perspective view of the quick-change shaft coupling system (130);

[063] Figure 37 shows a perspective view of the quick-change shaft coupling system (130) when mounted on the right side of the star assembly (20);

[064] Figure 38 shows an exploded perspective view of the quick-change shaft coupling system (130);

[065] Figure 39 shows the front view of the anti-fouling device in a first format; [066] Figure 40 shows a side view of the anti-fouling device in a first format;

[067] Figure 41 shows a perspective view of the anti-fouling device in a first format;

[068] Figure 42 shows the front view of the anti-fouling device in a second format;

[069] Figure 43 shows a side view of the anti-fouling device in a second format;

[070] Figure 44 shows a perspective view of the anti-fouling device in a second format;

[071] Figure 45 shows the front view of the anti-fouling device in a third format;

[072] Figure 46 shows a side view of the anti-fouling device in a third format;

[073] Figure 47 shows a perspective view of the anti-fouling device in a third format;

[074] Figure 48 shows the front view of the anti-fouling device in a fourth format;

[075] Figure 49 shows a side view of the anti-fouling device in a fourth format;

[076] Figure 50 shows a perspective view of the anti-fouling device in a fourth format;

[077] Figure 51 shows the front view of the anti-fouling device in a fifth format; [078] Figure 52 shows a side view of the anti-fouling device in a fifth format;

[079] Figure 53 shows a perspective view of the anti-fouling device in a fifth format;

[080] Figure 54 shows a side view of an example of the application of the anti-fouling device (120) between two stars (20);

[081] Figure 55 shows a side view of an example of the application of the anti-fouling device (120) between two stars (20);

Description of the invention

[082] This patent application was developed to solve the problem of screening iron ore with high moisture content, by using a set of self-cleaning stars, together with an anti-impact device, rollers with independent motors, a quick-change shaft system and an anti-fouling device.

[083] The main objective is to present a dynamic screening system using rubber stars with a self-cleaning system and variable shaft speeds, with an anti-impact device and rollers with independent motors, each shaft having its movement carried out by an individual electric drive system, possessing a quick-change shaft system and anti-fouling device, providing better wet screening performance, but not limited to this, when compared to current vibrating screens, thus providing better wet screening performance when compared to current vibrating screens.

[084] Another objective is to allow work to be done with ore cleaning as well as classification by desired size.

[085] The overall objective is to provide the user with more economical, optimized, technological and innovative equipment, but mainly one that can To solve the described technical problems and, in addition, to make it competitive against the competition.

[086] Among the benefits of its use are low electricity consumption, since the complete system is lighter, requiring less rotational effort, thus allowing the use of lower power and energy consumption motors. The maintenance process is simpler and safer, as the rubber parts are lighter. The lighter weight facilitates transport and assembly, thus reducing costs, and it processes even wet material up to 3 times faster compared to vibrating screens, once again allowing the owner to become competitive against the competition.

[087] With regard to safety and ergonomics, the use of elastomer (rubber) stars makes handling, transport and assembly easier than those made of steel, thus reducing the risk of accidents and repetitive strain injuries.

[088] Another benefit is the reduction in machine downtime for cleaning, whether done manually or using water jets. In the latter case, this leads to a reduction in water resources, electricity consumption, and consequently direct financial savings for the company.

[089] The focus is on providing users with an innovative, efficient, economical, safe, practical, low-cost and environmentally friendly product due to the fact that the stars are made of recyclable material.

[090] The dynamic roller screen with self-cleaning star for classifying and cleaning iron ore with self-cleaning star, anti-impact device and rollers with independent motors is made up of a metal structure, equipped with motors, geared motors, frequency inverters, traction and movement devices, control panel, tubular shafts, polymer stars and fastening means. [091] The set of geared motors are controlled by frequency inverters, and these in turn are controlled by an electrical panel with a control and protection system.

[092] The said Sieve has a set of tubular shafts, mounted with toothed wheels, encapsulated with polymer or elastomer stars, compacted by pressure, flexible coupling for the motors, an automatic lubrication system for chains and bearings. The automatic lubrication system is distributed to each point of the bearings of the traction devices.

[093] The application of modules with independent frequency inverters contributes to the possibility of the system working with shafts of different speeds, increasing the agitation process of the processed material, in order to increase the disaggregation of particles that tend to adhere to the material.

[094] Basically, the sieve works with independent rubber star rollers, each star is formed by a plurality of points and some of these points have a projection that functions as a self-cleaning scraper. The points with projection scrape against the body of the other stars, removing the aggregated material and keeping the sieve deck always clean, preventing clogging or accumulation when the processed material is very wet.

[095] Screening or classification works by moving star rollers that are specific to iron ore, transporting material larger than desired and allowing fines to pass between the points of the stars. The size of the screened particle can vary or be obtained by varying the speed of the motors and also by the inclination of the screen.

[096] As the stars have 2 or 4 points equipped with tips, these clean the neighboring shafts during the processing of the material by the screen deck, that is, the tips or fingers prevent the accumulation of material between the shafts, causing the screening deck to remain open throughout the process. [097] Each 2 or 3 meter module can work with independent speed variations; this process improves the efficiency of the sieve and it can be regulated according to the moisture content of the material. The number of tips and the dimensions of the modules are in accordance with the project and need, as well as the type and shape of material to be treated.

[098] The screening system features tilt and speed control for the classification system. Speed and tilt control are important for the equipment's good performance. With this control, the operator can adjust the efficiency level up or down during operation. The control is performed via a PLC (Programmable Logic Controller), an electronic device used in industrial automation to control machines and processes, programmable so that it can be configured to perform various tasks, such as monitoring sensor inputs, processing data, and activating outputs to control motors, valves, and other devices, forming an intelligent integrated control system for speed adjustments and a reverse system for unlocking and simultaneous dual-speed control.

[099] Compared to equipment on the market, it stands out for being equipment with technology to process iron ore (mining in general) with high moisture content, that is, up to 22% moisture.

[0100] One example of an application of this Sieve is that it can be mobile, mounted on an off-road road trailer with a proprietary braking system, in order to connect the hydraulic system to pneumatic, thus maintaining safety during transport within the customer's area, or it can also be used in a roll-on roll-off system.

[0101] This patent presents a plurality of star configurations, which have distinct self-cleaning solutions, maintaining the same principle, being smooth stars, with grooves and interchangeable tips made of ceramic or hardox material. The stars are made of polymer, such as natural rubber or polyurethane with a minimum hardness of 80 and a maximum of 90 Shore, but not limited to these. These star-shaped screens, specifically designed for iron ore screening processes, are designed for high impact and abrasion, as both the material and the process involve significant impact. These screens feature multiple self-cleaning tips to prevent excessively wet material from accumulating on the rotating shafts. The screens, with their multiple tips, have either 2 or 4 distinct points (though not limited to this number) responsible for the self-cleaning process.

[0102] In addition to the stars distributed along the shaft, in order to complement the system, we also have the side finishes, called "Half Star", which are installed at the ends of the shafts, being specifically developed to improve cleaning in the corners of the screening deck. These areas are critical, as they are regions where ore tends to accumulate, causing accelerated wear of the stars located at the ends, affecting both the left and right sides.

[0103] A low-carbon steel assembly can exhibit premature and significant wear in less than 30 days of operation, with the main culprit being the hexagonal steel part next to the housing. This part not only fails in its cleaning function but also accumulates material that contributes to the premature wear of the star on the opposite axis, which is circled. The Half-Star model, presented in this patent application, not only performs cleaning effectively but also prevents system blockage.

[0104] In the preferred form of a self-cleaning smooth-tip star, each star has 2 or 4 tips, a device that cleans the subsequent shaft, enabling the cleaning of the deck system through the movement of the shafts. In this way, the stars with tips, or fingers, provide gentle friction on the stars of the other shaft, loosening accumulated wet material.

[0105] A second preferred form consists of a star with self-cleaning grooves, which performs the same function as the previous model, but with a different shape, causing the material to accumulate at the tip of the star, thus creating a layer of the same processed material. Because the material being processed accumulates on the tips and has the same physical resistance to wear, the star tips resist wear better, thus extending their lifespan.

[0106] Another preferred form is stars with interchangeable ceramic or hardox tips, or similar, a model developed to provide greater durability to star shafts in mining. Ceramic and hardox are materials widely used in mining due to their mechanical resistance to wear. The fact that these tips are interchangeable greatly reduces the cost of acquiring spare parts, because with this star model the customer can replace only the tips and keep the stars in operation for longer.

[0107] Commonly, damage to a single star on the shaft can lead to contamination of the system, thus requiring the replacement of the entire shaft. This is a process that demands considerable time, delays the production process due to machine downtime, and additional expenses for machinery and specialized personnel.

[0108] To solve this problem, the present patent presents the split star, allowing the customer to replace only the damaged star without the need to disassemble the entire shaft. This process requires the use of only one wrench and a few minutes to change the star, representing a major step towards optimizing maintenance time and reducing unscheduled downtime, ensuring more efficient and continuous operation.

[0109] Another preferred form, in the same style as the stars already mentioned, is distinguished by being split in two, joined by fastening elements. The star has an identical design to the previous ones, but with the added advantage regarding assembly and maintenance.

[0110] Another preferred form is the use of a half-star, distinct from the previous ones by containing a backing disc in the same body, being positioned either on the right or left side of the equipment axis, and which for this purpose has a shape for each side, It may or may not be equipped with inserts, and like the previous ones, it has a self-cleaning system in a variety of tips.

[0111] Another complementary form adopted by the stars is that they can be equipped with a plurality of circular inserts on their lateral faces, which inserts can be made of ceramic, hardox or similar material. These circular inserts help in removing debris and excess material, which gives the system greater durability and reduces downtime for maintenance.

[0112] The stars are mounted on the roller shaft, in line, forming a deck for transporting and screening the material. These shafts are interconnected by double gears, which are driven by a chain system through a geared motor. Unlike current models, the Half Star models are mounted on these shafts in the same way, at the ends, since the current system only uses one fixing piece, and this generates premature wear of the adjacent star.

[0113] In addition to the implementations mentioned, there is the possibility of attaching to the screen a device to absorb, dissipate or dampen the energy from particles due to direct or indirect impact, called an anti-impact device, intended to optimize the performance and durability of dynamic screens used in ore processing. The device was developed to absorb impacts from particles larger than 100 ^mm² , but not limited to this dimension. This system is essential to reduce premature wear of the rubber stars caused by the direct deposition of iron ore.

[0114] The anti-impact device consists of a robust metal structure supporting a deck with multiple axles, the preferred configuration being five axles. These axles are coated with Hardox discs, a wear-resistant steel, or similar material, available in at least two different diameters. Each axle has a pair of stars made of polymer, preferably rubber or TPU (thermoplastic polyurethane), which may optionally be fitted with Hardox inserts. It has at least one octagonal spacer, also made of Hardox TUF 600, installed between each pair of stars and discs. This material is chosen because of Its exceptional hardness and abrasion resistance are essential characteristics for mining applications. However, it is not limited to this material.

[0115] The functionality of this device is ensured by means of a plurality of rollers, preferably five, of robust build, coated with stars made of polymer, preferably thermoplastic polyurethane (TPU), complemented by discs and spacers made of metal, preferably Hardox steel, already known for its high wear resistance. These rollers are synchronized to rotate unidirectionally, driven by a geared motor connected to the main drive shaft. The motor is regulated by a frequency inverter, which is synchronized with the system feeder, ensuring efficient and continuous operation, being a system that emulates the operational mechanism of conventional screen decks.

[0116] The main objective of this anti-impact system is to mitigate damage caused by falling particles, for example from a height of 2 meters or more, onto the main deck of the screen, protecting the stars from impacts that could compromise their integrity and functionality.

[0117] A second objective is to play a crucial role in pre-screening, preventing large particles from directly impacting the rubber stars, which not only preserves their structural integrity but also significantly extends the screen's lifespan, increasing the efficiency of the overall screening process.

[0118] Designed to withstand loads of several tons of material simultaneously, the anti-impact device is particularly effective in high-load scenarios, where the risk of overload and consequent screen stoppage is high, due to imbalance in ore feed.

[0119] Additionally, the system is calibrated to operate at speeds compatible with those set for the screen, ensuring efficient integration and improving the overall effectiveness of the screening process. [0120] This device is a strategic solution, not only increasing operational efficiency but also reducing the need for frequent maintenance, thus representing a valuable contribution to the mineral processing industry.

[0121] With regard to tests and trials, the objective was to ascertain whether the technology allowed for sieving and to check if it was possible to obtain an undersize with a topsizer below 19m (specification of Mutuca's common fine).

[0122] The study aimed to explore 3 critical processing moisture contents (20%, 20.5% and 21%), given that the material in the mine already has a moisture content close to 16% (intrinsic to the material). It was carried out with a prototype screen, adapted to receive the material with 21% moisture. The system was fed by a Bobcat machine, using Undersize and Oversize residues from the processed material. It showed excellent results in laboratory tests.

[0123] Another example of implementation is the dynamic roller screen with independent motors, where each shaft is controlled by its own electric motor, i.e., individually, and the use of adjustments in the current voltage in order to avoid uneven wear between the components, improving operating efficiency and reducing maintenance costs.

[0124] In this variation of the system, the objective is to present a dynamic roller screen with independent motors, with each axis having its movement carried out by an individual electric drive system, providing better wet screening performance, but not limited to this, when compared to current vibratory screens.

[0125] This variation offers greater speed and torque control, reduced mechanical wear, greater operational flexibility, automated monitoring and real-time diagnostics, and as a result, increased system durability and safety. [0126] Greater speed and torque control is achieved through the use of individual motors, where each shaft can operate at different speeds as needed for the process, providing more efficient and adjustable screening. Unlike the chain/sprocket system, where speed variation requires complex mechanical adjustments, electric drive allows for dynamic changes via automated control.

[0127] The reduction of mechanical wear occurs by eliminating the chain and sprocket, thus decreasing wear due to friction and the need for constant local lubrication, minimizing maintenance costs and equipment downtime.

[0128] Greater operational flexibility is evident, as the system allows the equipment to be adapted to different types of materials and operating conditions, optimizing separation efficiency. The star configuration can be adjusted according to process demand, something more difficult to achieve in a fixed mechanical transmission system.

[0129] Automated monitoring and real-time diagnostics are achieved through the inclusion of an automated control system that allows continuous supervision of equipment performance, identifying load variations and adjusting parameters to maintain maximum efficiency.

[0130] Increased durability and safety are achieved through enhanced safety devices, such as emergency stops and protections to prevent accidents during operation.

[0131] The dynamic sieve with variation using rollers with independent motors was developed for the efficient separation of solid materials of different sizes, using rotating polymer stars that promote the movement and classification of materials.

[0132] This enhancement is effective in applications where precision in separation is crucial, being constructed of high-strength steel, which ensures durability and Abrasion resistance. The structure is designed to withstand vibrations and dynamic loads during operation.

[0133] In a variation of this improvement, each axis of the equipment has an independent drive unit per axis, where dynamic stars are coupled. This unit is equipped with an electric motor, allowing precise control of speed and torque. Because it has an independent unit, it allows the equipment to be adapted to different types of materials and grammages, improving screening efficiency. The arrangement of the motors is preferably alternating, that is, to the right and left of the equipment, in relation to its longitudinal axis. They may be of equal number or not, according to the dimensions and needs of the device.

[0134] In a second variation, the drive assembly, its axles, stars and other couplings, can be mounted on only one side of the structure.

[0135] The stars are manufactured from materials that offer high wear resistance and are designed to optimize material flow. Their configuration can be adjusted according to process needs, allowing for customized separation.

[0136] The Sieve also consists of shaft couplings with a quick-change system, which is a modular system where the main shaft has chamfers at both ends, equipped with holes. These chamfers or cuts are concentric and fit into shafts mounted on both bearings (right and left) and joined by fasteners. At least one gear wheel is mounted concentrically at the end of one of the bearing shafts. In this system, the two main parts fit together by means of their cutout and fasteners, allowing for quick and efficient assembly and disassembly of the unit, unlike current models where complete disassembly of the bearing is necessary to remove the entire assembly.

[0137] The anti-fouling device consists of a system of freely moving circular rings, with at least two rings, used between the stars. This system consists of loose rings or hoops, positioned to move concentrically and freely between the stars during the sieving process.

[0138] The main function of free rings or anti-stick rings is to prevent material with a high clay content (high concentration of manganese and alumina in the ore) or high moisture content from adhering to the walls of the star screens, which usually results in blockages and loss of equipment efficiency. With the constant movement of the rings, the clayey material is continuously dislodged from the surfaces of the star screens, keeping the screening system unobstructed and in constant operation. This self-cleaning mechanism is efficient and reduces downtime for maintenance, increasing productivity and extending the lifespan of the equipment.

[0139] The equipment's features allow for high processing capacity, making it ideal for applications in industries such as mining, construction and recycling, but not limited to these.

[0140] The dynamic roller screen with independent motors per shaft presents a robust and efficient solution for material separation, offering flexibility and control to meet the specific demands of each application, facilitating maintenance through simplified access to the main components, reducing downtime and increasing operational efficiency.

[0141] As an example of expanded use, there are the crushing and classification sectors of mining companies in general, phosphate mining plants for fertilizer production, ore loading ports, in the cleaning and classification of ore for export, and it can be applied to companies processing construction debris for landfills and also cleaning and classifying soil in general, among other segments, not limited to iron ore.

[0142] In accordance with the related figures, the dynamic self-cleaning star roller screen for classifying and cleaning iron ore with self-cleaning star, anti-impact device, rollers with independent motors, quick-change shaft system and anti-fouling device, consists of a metal structure (1), equipped with motors (2), geared motors, frequency inverters, traction (3) and movement devices, rotating tubular shafts (4) and fastening means.

[0143] In one embodiment, the dynamic roller screen with self-cleaning star for classifying and cleaning iron ore with self-cleaning star, anti-impact device, rollers with independent motors, quick-change shaft system and anti-fouling device, consists of a metal structure (1), equipped with a set of motors, gearmotors, frequency inverters (2), traction devices (3) and movement, bearings (4), shafts (5), fastening means, and toothed wheels (6), the screen being characterized by containing a plurality of detachable metal grids (7) mounted on the structure (1), an automatic lubrication system (10) for the traction devices (3) and bearings (4), a plurality of self-cleaning stars (20), independent speed adjustment by module controlled via control and operation panel, anti-impact device (40), flexible coupling system for the motors (50), inclination control system (60), a plurality of drive sets (100) with electric motor, where in each assembly is mounted a shaft (110) with bearings (115), independently, and dynamic stars and rollers are coupled to these shafts, and that by means of this arrangement, each shaft (110) can operate at a different speed, based on the needs of the process; and that the sieve is equipped with an anti-fouling device (120), and a quick-change shaft system (130);

[0144] In another embodiment, the Sieve is distinguished by the fact that it is modular, with tilt control (60) by means of a lifting system (64), reverse unlocking system (70), simultaneous speed adjustments of the classification system, control by Programmable Logic Controller, and that each module works with the variation of speeds independently, this being regulated according to the moisture content of the material;

[0145] In another embodiment, the Sieve is distinguished by the reverse unlocking system (70) being obtained by the arrangement of the sieves, aligned and synchronized, so that the assembly can visually present the shape of a “V”, from the smallest, on the inside, to the largest, which ends at the extremities; shape this occurs through the synchronization of salient projections of self-cleaning stars (20);

[0146] In another embodiment, the Sieve, differs in that the size of the sieved particle is obtained by varying the speed of the motors (2) and also by the inclination of the sieve;

[0147] In another embodiment, the Sieve differs by containing a flexible coupling system (80) for the motors, this being a cylindrical body, where in the proximal part there is a flange (81) with a circular opening for fitting with a key system (82), fixed by means of fastening elements to a split intermediate portion (83), which has an annular body (84), and a fastening element; at the other end, there is another flange (85), and in this a flanged gear (86);

[0148] In another embodiment, the Sieve, differs in that the automatic lubrication system (10) is equipped with an automation system (11), connectors, cables (12) and hoses (13) and these are connected to the lubrication points of the bearings (4) and traction devices (3);

[0149] In another embodiment, the Sieve is distinguished by the possibility of being mounted on a trailer platform, or implement, with a braking system, in order to connect to the same system;

[0150] In another embodiment, the Sieve is distinguished by the possibility of having an anti-impact device (40) mounted on its upper part, and as a base, a lifting system (60), which in turn is a metallic structure, equipped with a plurality of supports, and a “U” shaped profile on the upper part; the central supports (61) have an articulation on the upper part, while the supports (62) of the proximal ends have upper and lower articulation and a height adjustment system; the distal supports (63) have a lifting system (64) and lower articulation.

[0151] In one embodiment, Self-Cleaning Star stands out for being manufactured from polymer, which may be elastomer, polyurethane or similar; [0152] In another embodiment, the Self-Cleaning Star, differs in that the salient projections (22) are of the same material as the star (20), and these can be shaped to the main body, or fixed to it;

[0153] In another embodiment, the Self-Cleaning Star, it differs in that the salient projections (22) are interchangeable;

[0154] In another embodiment, the Self-Cleaning Star, is distinguished by the fact that the salient projection (22) is provided with grooves (23);

[0155] In another embodiment, the Self-Cleaning Star is distinguished by the fact that the tips are made of ceramic, Hardox or similar material, metallic or other material with greater hardness than polymer;

[0156] In another embodiment, the Self-Cleaning Star is distinguished by being split in two, joined by fastening elements, a snap-fit system, or other means of joining;

[0157] In another embodiment, the Self-Cleaning Star differs in that the half-star (24a) and (24b) have a backing disc (25) shaped like a star (20), arranged next to the equipment housing, so that the star (20), its points (21), protruding projections (22) or inserts (26), face inwards, and can be mounted on either the right or left side.

[0158] In another embodiment, the Self-Cleaning Star, is distinguished by the fact that a plurality of points (21) of the stars (20) are provided with inserts (26) shaped in accordance with the points (21) where they are incorporated, and a plurality of insert plates (27), arranged on their inner, outer or both lateral faces, of a plurality of points (21); these inserts (27) may be made of ceramic, hardox or similar material, metallic or other material of greater hardness than the polymer;

[0159] In another embodiment, the Self-Cleaning Star, differs in that the number of points (21), salient projection (22), inserts (26) and insert plates (27), as well as their arrangement, can vary according to the dimensions and shape of the shaft (5), type of equipment where it will be mounted, as well as the material to be processed. [0160] In another embodiment, the Self-Cleaning Star stands out because it is manufactured from recyclable materials.

[0161] In another embodiment, the Sieve differs in that the half stars (24a) (24b) are mounted alternately between the rollers, so that one roller has two, one mounted on the right and the other mounted on the left, and the parallel roller, in sequence, does not contain said half stars.

[0162] In one embodiment, the Anti-Impact Device is distinguished by being a metallic structure equipped with side access openings (41), a top cover with a detachable grid (7), lifting eyelets (42), a plurality of axles (43) mounted in bearings, and arranged parallel to each other; they are mounted on a support (44), and with an inclination from the rear to the front, receiving movement and synchronization by a drive system, composed of a motor and geared motor (2), and a drive assembly; these axles (42) in turn have mounted concentrically, a plurality of polymeric stars (20);

[0163] In another embodiment, the Anti-Impact Device differs in that the stars (20) are mounted in pairs, separated by means of a larger spacer disc (45) and the assembly in turn is provided with two smaller spacers (46) and a coupling (47); and that the mounting of the stars is staggered between the axes.

[0164] In one embodiment the Sieve has a plurality of drive sets (100) with electric motor, where in each set is mounted a shaft (110) with bearings (120), independently, and dynamic stars and rollers are coupled to these shafts, and by means of this arrangement, each shaft (110) can operate at a different speed, based on the needs of the process.

[0165] In another embodiment, the Sieve is equipped with automated monitoring and real-time diagnostics, which means that monitoring and operation can be carried out remotely, as well as being activated or operated in emergency shutdowns. [0166] In another embodiment, the drive assemblies (100) and their respective axles (110) are mounted alternately with each other.

[0167] In another embodiment, the arrangement and quantity of drive assemblies (100) and axles (110) are based on the dimensions of the assembly where they will be mounted.

[0168] In another embodiment, the anti-fouling device (120) is composed of a plurality of concentric spacers, which in turn are ring-shaped bodies, used between stars (20) that are mounted on the shaft, forming a set, with the spacers having free movement and rotation between the stars during the screening process;

[0169] In another embodiment, the anti-fouling device (120) is characterized by the fact that the spacers (121) and (122) have a corrugated cross-section and a circular profile, both the inner spacer (121) and the outer spacer (122);

[0170] In another embodiment, the anti-fouling device (120) is characterized by the fact that the outer spacer (121) is oval in shape, and the inner spacer (122) is circular;

[0171] In another embodiment, the anti-fouling device (120) is characterized by the fact that both spacers (121) and (122) are circular in shape, concentric, both the inner and outer spacer;

[0172] In another embodiment, the anti-fouling device (120) is characterized by the fact that the spacers (121) are of regular polygonal shape, and the inner spacer (122) is circular; and that this polygon can be 8 sides;

[0173] In another embodiment, the Quick Change Shaft System is characterized as a quick change shaft coupling system (130), comprising a shaft (131) with cutouts at both ends, which in turn have holes and slots for fixing, the cutouts fitting into both shaft couplings (130) mounted at both ends, right and left, of the star assemblies (20), and joined by means of fixing (132) and joining; at the end of one of the shafts (130) the bearings (134) are mounted concentrically at least one toothed wheel (133), a mounting plate (135) and this toothed wheel (133) being connected to a drive assembly;

[0174] In another embodiment, the quick-change shaft system is characterized by the fact that keys, locks, threaded elements, pins or the like can be used as fastening means (132);

Claims

CLAIM 1. DYNAMIC ROLLER SCREEN WITH SELF-CLEANING STAR FOR CLASSIFICATION AND CLEANING OF IRON ORE WITH SELF-CLEANING STAR, WITH ANTI-IMPACT DEVICE, ROLLERS WITH INDEPENDENT MOTORS, QUICK-CHANGE SHAFT SYSTEM AND ANTI-FOUGHT DEVICE, consists of a metal structure (1) equipped with a set of motors, gearmotors, frequency inverters (2), traction devices (3) and movement, bearings (4), shafts (5), fastening means and gear wheels (6), the Screen being characterized by containing a plurality of detachable metal grids (7) mounted on the structure (1), an automatic lubrication system (10) for the traction devices (3) and bearings (4), a plurality of self-cleaning stars (20), independent speed adjustment by module controlled via control and operation panel, device anti-impact (40) and flexible coupling system for the motors (50), tilt control system (60), a plurality of drive assemblies (100) with electric motor, where in each assembly a shaft (110) with bearings (115) is mounted independently, and dynamic stars and rollers are coupled to these shafts, and that by means of this arrangement, each shaft (110) can operate at a different speed, based on the needs of the process; and that the screen is equipped with an anti-fouling device (120), and a quick-change shaft system (130); 2. SIEVE, according to the first claim, characterized by being modular, with tilt control (60) by means of a lifting system (64), reverse unlocking system (70), simultaneous speed adjustments of the classification system, control by Programmable Logic Controller, and that each module works with the variation of speeds independently, this being regulated according to the moisture content of the material; 3. SIEVE, according to the first claim, characterized by the reverse unlocking system (70) being obtained by means of the arrangement of sieves, aligned and synchronized, so that the set can visually present the shape of a “V”, from the smallest, in the inner part, to the largest, which ends at the extremities; this shape occurs through the synchronization of the salient projections of the self-cleaning stars (20); 4. SIEVE, according to the first and second claims, characterized in that the size of the sieved particle is obtained by varying the speed of the motors (2) and also by the inclination of the sieve; 5. SIEVE, according to the preceding claims, characterized by containing a flexible coupling system (80) for the motors, this being a cylindrical body, where in the proximal part there is a flange (81) with a circular opening for fitting with a key system (82), fixed by means of fastening elements to a split intermediate portion (83), which has an annular body (84), and a fastening element; at the other end, there is another flange (85), and in this a flanged gear (86); 6. SIEVE, according to the preceding claims, characterized by the automatic lubrication system (10) being equipped with an automation system (11), connectors, cables (12) and hoses (13), and these being connected to the lubrication points of the bearings (4) and traction devices (3); 7. SIEVE, according to the previous claims, characterized by the possibility of being mounted on a trailer platform, or implement, with a braking system, in order to connect to the SIEVE system; 8. SIEVE, according to the preceding claims, characterized by the possibility of having an anti-impact device (40) mounted on its upper part, and as a base, a lifting system (60), which in turn is a metallic structure, equipped with a plurality of supports, and a “U” shaped profile at the top; the central supports (61) have a joint at the top, while the supports (62) at the proximal ends have upper and lower joints and a system of height adjustment; the distal supports (63) have a lifting system (64) and lower articulation; 9. SELF-CLEANING STAR, comprising a star-shaped body (20), provided with a plurality of points (21), mounted concentrically to the axis (5) of the roller sieve by its central portion, whose housing is of a shape compatible with the axis, being characterized by the fact that the end of at least two points (21) is provided with a salient projection (22), whose shape, angle and lines follow the point (21) where it is mounted; 10. SELF-CLEANING STAR, according to the previous claim, characterized by being manufactured from polymer, which may be elastomer, polyurethane or similar; 11. SELF-CLEANING STAR, according to claims 7 and 8, characterized in that the salient projections (22) are of the same material as the star (20), and these may be conformed to the main body, or fixed to it; 12. SELF-CLEANING STAR, according to claims 7 to 9, characterized in that the salient projections (22) are interchangeable; 13. SELF-CLEANING STAR, according to claims 7 to 10, characterized in that the salient projection (22) is provided with grooves (23); 14. SELF-CLEANING STAR, according to claims 7, 8, 10 and 11, characterized in that the tips are made of ceramic, Hardox or similar material, metallic or other material with a hardness greater than the polymer; 15. SELF-CLEANING STAR, according to claims 7 to 14, characterized by being split in two, joined by fastening elements, a snap-fit system, or other means of joining; 16. SELF-CLEANING STAR, according to claims 7 to 12, characterized in that the half-star (24a) and (24b) have a backing disc. (25) shaped like a star (20), arranged next to the equipment casing, so that the star (20), its points (21), protruding projections (22) or inserts (26), face inwards, and can be mounted on either the right or left side; 17. SELF-CLEANING STAR, according to claims 7 to 15, characterized in that a plurality of points (21) of the stars (20) are provided with inserts (26) shaped in accordance with the points (21) where they are incorporated, and a plurality of insert plates (27), arranged on their inner, outer or both lateral faces, of a plurality of points (21); these inserts (27) may be made of ceramic, hardox or similar material, metallic or other material of greater hardness than the polymer; 18. SELF-CLEANING STAR, according to the preceding claims, characterized by the fact of the number of points (21), salient projection (22), inserts (26) and insert plates (27), as well as their arrangement, may vary according to the dimensions and shape of the shaft (5), the type of equipment where it will be mounted, as well as the material to be processed; 19. SELF-CLEANING STAR, according to claims 9 and 10, characterized by being manufactured from recyclable materials; 20. SIEVE, according to the preceding claims, characterized by the fact that the half-stars (24a) and (24b) are mounted alternately between the rollers, so that one roller has two, one mounted on the right and the other mounted on the left, and the parallel roller, in sequence, does not contain said half-stars; 21. ANTI-IMPACT DEVICE, characterized by being a metallic structure equipped with lateral access openings (41), a top cover with a detachable grid (7), lifting eyes (42), a plurality of shafts (43) mounted in bearings, and arranged parallel to each other; they are mounted on a support (44), and with tilting of the rear part towards the front, receiving movement, and synchronization by a drive system, composed of a motor and geared motor (2), and traction assembly; these axles (42) in turn have mounted concentrically, a plurality of stars (20); 22. ANTI-IMPACT DEVICE, characterized by the fact that the stars (20) are mounted in pairs, separated by means of a larger spacer disc (45) and the assembly in turn is provided with two smaller spacers (46) and a coupling (47); and that the mounting of the stars is staggered between the axes; 23. DYNAMIC ROLLER SCREEN WITH INDEPENDENT MOTORS, characterized by the fact that the equipment has a plurality of drive sets (100) with electric motor, where in each set a shaft (110) with bearings (115) is mounted independently, and dynamic stars and rollers are coupled to these shafts, and that by means of this arrangement, each shaft (110) can operate at a different speed, based on the needs of the process; 24. Dynamic roller screen with independent motors according to the first claim, characterized by being equipped with automated monitoring and real-time diagnostics, and that monitoring and operation can be performed by a remote system; 25. DYNAMIC ROLLER SCREEN WITH INDEPENDENT MOTORS characterized in that the drive assemblies (100) and their respective shafts (110) are mounted alternately with each other; 26. DYNAMIC ROLLER SCREEN WITH INDEPENDENT MOTORS characterized by the fact that the arrangement and quantity of drive assemblies (100) and shafts (110) are a function of the dimensions of the assembly where they will be mounted; 27. ANTI-FOULING DEVICE, characterized by being a device (120) composed of a plurality of concentric spacers, which in turn are ring-shaped bodies, used between stars (20) that are mounted on the shaft, forming a set, with spacers having free movement and rotation between the stars (20) during the screening process; 28. ANTI-FOUGHING DEVICE according to the previous claim, characterized in that the spacers (121) and (122) have a corrugated cross-section and a circular profile, both the inner spacer (121) and the outer spacer (122); 29. ANTI-FOUGHING DEVICE according to claim 27, characterized in that the outer spacer (121) is oval in shape, and the inner spacer (122) is circular; 30. ANTI-FOUGHING DEVICE according to claim 27, characterized in that both spacers (121) and (122) are circular in shape, concentric, both the inner and outer spacer; 31. ANTI-FOUGHING DEVICE according to claim 27, characterized in that the spacers (121) are of regular polygonal shape, and the inner spacer (122) is circular; and this polygon is 8 sides; 32. QUICK-CHANGE SHAFT SYSTEM, characterized by being a quick-change shaft coupling system (130), comprising a shaft (131) with cutouts at both ends, which in turn have holes and slots for fixing, the cutouts fitting into both shaft couplings (130) mounted at both ends, right and left, of the star assemblies (20), and joined by means of fixing (132) and joining; at the end of one of the shafts (130) of the bearings (134) is mounted concentrically at least one toothed wheel (133), a fixing plate (135) and this toothed wheel (133) being connected to a drive assembly; 33. QUICK-CHANGE SHAFT SYSTEM, according to the previous claim, characterized in that keys, locks, threaded elements, pins or the like can be used as fastening means (132);