Acoustic Clinker Hardness Detection
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Solution Overview
Problem
Current methods for determining cement clinker hardness in cement plants are time-consuming and prone to inaccuracies, leading to significant delays and waste due to the inability to immediately adjust production parameters in response to hardness fluctuations, resulting in unusable cement clinker production.
Innovation Solution
A device and method utilizing acoustic signals generated when cement clinker impacts a base to determine hardness through sensors and an evaluation unit, converting the signals into frequency distributions for real-time analysis, allowing for immediate adjustments to production parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If volumetric density method is used to determine clinker hardness, then measurement can be performed, but the process is time-consuming and causes loss of time
Solution Approach 1:
The patent replaces the mechanical volumetric density measurement method with an acoustic signal-based detection system. Sensors detect acoustic signals generated when clinker impacts a base, and an evaluation unit analyzes these signals to determine hardness in real-time, eliminating the need for time-consuming laboratory measurements.
Solution Approach 2:
The clinker itself generates the acoustic signal through its impact on the base, utilizing its own physical properties (hardness affecting impact characteristics) for self-detection. This eliminates the need for separate measurement apparatus and procedures, enabling immediate hardness determination at the point of production.
2Measurement precision
If volumetric density method is used to determine clinker hardness, then measurement can be performed, but measurement inaccuracies occur due to gas inclusions
Solution Approach 1:
The patent replaces the volumetric density method with acoustic signal analysis. The acoustic signal captured during impact naturally accounts for gas inclusions and internal clinker structure, providing reliable hardness measurement without the inaccuracies caused by gas bubbles affecting density measurements.
3Measurement precision
If clinker hardness is determined after production, then measurement can be performed, but production efficiency decreases due to inability to immediately adjust parameters
Solution Approach 1:
The system performs hardness determination in advance of any potential production adjustments by continuously monitoring clinker hardness at the point of production. This enables proactive adjustment of kiln parameters before batches are completed, maximizing production efficiency.
Solution Approach 2:
The acoustic signal detection system provides real-time feedback on clinker hardness to the control system. This feedback loop enables immediate adjustment of rotary kiln operating parameters based on actual hardness measurements, maintaining optimal production efficiency and minimizing waste.
4Productivity
If incorrect clinker hardness measurement is used, then production continues, but unusable cement clinker is produced due to inability to readjust process
Solution Approach 1:
The real-time acoustic signal-based hardness measurement provides continuous feedback to the production control system. This enables immediate detection and correction of hardness deviations, preventing the production of unusable clinker while maintaining continuous operation.
Solution Approach 2:
The system detects hardness issues in advance before they result in unusable product. By monitoring hardness continuously and enabling prompt adjustments, the system prevents rather than corrects defects, minimizing loss of substance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables real-time determination of cement clinker hardness, reducing waste and improving production efficiency by allowing for immediate adjustments to the rotary kiln process parameters, thereby maintaining desired hardness levels.
Implementation Method 1
the cement clinker impacting a base, with the cement clinker setting the base into vibration as a result of the impact
Implementation Method 2
the cement clinker setting the base into vibration as a result of the impact, with an acoustic signal resulting therefrom
Data Source
Figure 1
Figure 2~3(b)
Figure 4(a)~4(b)
AI summary
The invention relates to a device (50) for determining the hardness (H) of cement clinker (ZK) in a cement plant (20) by evaluating an acoustic signal (AS) upon impact of the cement clinker on a substrate (12) after leaving a rotary kiln (9), a cement plant with such a device, a corresponding method (200) using this device, and a data carrier (300) with a software program (301) stored thereon for installation in an evaluation unit (70) of such a device for at least partially carrying out such a method.In the cement plant, the cement clinker falls from the rotary kiln onto a base and sets it into vibration upon impact, resulting in an acoustic signal (AS) characteristic of the respective hardness, comprising at least one frequency distribution (FV) or frequency-time distribution (FZV) or time signal (ZV) characteristic of the hardness, wherein the device (50) comprises one or more sensors (60) and an evaluation unit (70), wherein the sensors (60) are provided to record the respective acoustic signal (AS) and the evaluation unit (70) is provided to determine at least the hardness (H) of the cement clinker (ZK) from the recorded frequency distribution (FV) or the recorded frequency-time distribution (FZV) or the recorded time signal (ZV).