Gebr. Pfeiffer roller repair and production

1. Product positioning
Vertical roller system full-cycle service expert
CNBM Qinhong relies on carbon nano-polymer composite repair technology and intelligent remanufacturing process to provide damage repair-preventive maintenance-customized manufacturing integrated solutions for the extraordinary series of vertical mills (MPS/MLS and other models). Through the independently developed gradient composite materials and digital detection system, the service life of the roller body is extended by 3-5 times after repair, and the comprehensive operation and maintenance cost is reduced by 50%. It is suitable for the full range of extraordinary grinding roller systems from Φ1.8 to 5.4m, and overcomes the industry pain points such as easy cracking and long return cycle of traditional surfacing repair.

2. Core technology analysis

1. Four-dimensional composite repair system

Gap filling and strengthening:
Using carbon nano-polymer materials (compressive strength 179MPa, temperature resistance 250℃), the gap between the roller body and the liner is accurately filled to an accuracy of 0.05mm, and the matching area is >98%, eliminating the risk of micro cracks caused by hard metal impact.
Surface cladding upgrade:
Laser cladding of tungsten carbide layer (Hv2200) and high chromium alloy transition layer (Cr26, HRC62-65), wear resistance increased by 60%, bonding strength> 550MPa.
Stress field reconstruction:
Based on ANSYS simulation reverse modeling, the stress distribution of the roller body is optimized, the residual stress is reduced by 35%, and the risk of plastic deformation is avoided.
Sealing system innovation:
Ceramic matrix composite sealing ring, temperature resistance increased to 220℃, blocking dust from invading the bearing cavity.
2. Intelligent remanufacturing process

3D scanning modeling:
Laser reverse engineering achieves 0.3mm level adaptation accuracy for old parts and supports rapid repair of non-standard roller bodies.
Gradient heat treatment:
Five-stage temperature control (including deep cold process), hardness uniformity error <1.5HRC, avoiding secondary damage caused by thermal stress.
Dynamic balance calibration:
Laser positioning assembly technology, grinding roller running eccentricity <0.1mm/m, vibration value stable within 5mm/s.
3. Preventive maintenance system

Intelligent lubrication monitoring:
Real-time monitoring of oil return temperature (fluctuation value <3℃), vacuum negative pressure (-0.45~-0.25bar), and early warning of abnormal bearing wear.
Wear life prediction:
Based on vibration spectrum analysis (sampling rate 100Hz), predict the risk of liner cracks, with an error of <3 days
III. Full-cycle service scenarios
1. Damage repair service

Roller wear:
Filling grooves with unilateral wear >6mm (100% contact surface fit after repair), with a compression recovery rate of 98%.
Liner cracks:
Treatment of stress cracks with a depth of ≤50mm, combined with polymer material filling + cladding layer strengthening, with a fracture rate of <0.3%.
Bearing failure:
Quickly replace SKF/FAG customized bearings (installation accuracy ±0.02mm), 48-hour emergency response.
2. Customized manufacturing service

Gradient composite roller body:
Surface tungsten carbide cladding (Hv2200) + middle layer high chromium alloy (Cr26) + bainitic steel matrix (impact toughness ≥ 25J/cm²), suitable for harsh working conditions such as high sulfur corrosion and superhard materials.
Intelligent monitoring roller sleeve:
Integrated stress sensor (data sampling rate 100Hz), real-time transmission of wear, temperature and other parameters to the central control system.
3. Preventive maintenance service

Lubrication optimization package:
8000h oil replacement cycle, real-time monitoring of filter element dirtiness, and annual maintenance cost reduction of 30%.
Sealing system upgrade:
Quarterly addition of high-temperature grease (temperature resistance > 200℃) to block more than 80% of dust intrusion.
IV. Service guarantee system
1. Quality commitment

ISO 9001/GB/T 33947 dual certification, warranty period 18 months
Each batch comes with a metallographic test report