Echographic Bolt Sensor for Continuous Mill Wear Monitoring
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Solution Overview
Problem
Current methods for measuring the wear state of the inner mill coating and tightening stress of bolts in industrial mills are costly and require mill stoppage, making them impractical for continuous operation.
Innovation Solution
Incorporating an echographic device at the threaded end of the bolts to measure bolt length and estimate wear state and tightening tension, using acoustic wave trains and a radio frequency communication system for real-time data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical instruments or optical instruments are used to measure wear and bolt tension, then measurement accuracy is improved, but mill stoppage is required which increases operational cost and reduces productivity
Solution Approach 1:
The patent replaces mechanical measurement instruments with an acoustic echographic system. The echographic sensor sends acoustic waves through the bolt to measure its length, which indicates both wear of the lining and tension state of the bolt. This acoustic-based measurement system eliminates the need for mechanical contact and mill stoppage, allowing continuous operation while maintaining measurement accuracy.
Solution Approach 2:
The patent introduces an echographic sensor as an intermediary device that can measure bolt properties remotely through acoustic wave transmission. The sensor is positioned at the threaded end of the bolt and uses acoustic waves as a mediator to obtain measurement data without requiring physical disassembly or mill stoppage, thus enabling continuous monitoring.
2Measurement precision
If drilling is performed on bolts to insert wear indication elements, then wear measurement capability is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent extracts the measurement function from the bolt manufacturing process itself. Instead of modifying the bolt during manufacturing by drilling and inserting elements, the measurement capability is added through a separate echographic sensor that attaches to the existing bolt structure. This separates the manufacturing process from the measurement function, maintaining manufacturing simplicity while adding measurement capability.
Solution Approach 2:
The echographic sensor serves multiple functions: it measures both the wear of the lining and the tension state of the bolt using the same device and measurement principle. This multi-functionality eliminates the need for separate measurement systems and complex bolt modifications, providing comprehensive monitoring through a single added component.
3Measurement precision
If strain gauges or hooks are applied to measure bolt tightening stress, then tension measurement capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the wear measurement function and tension measurement function into a single echographic measurement system. By measuring the bolt length through acoustic waves, the system simultaneously provides information about both the wear of the lining (through bolt length change) and the tension state (through elastic deformation), eliminating the need for separate measurement devices and reducing overall system complexity.
Solution Approach 2:
The patent replaces complex mechanical strain gauge systems with an acoustic echographic system. The echographic method uses acoustic wave transmission through the bolt to measure its length and infer tension state, replacing the need for electrical strain gauges, hooks, and associated wiring, thereby significantly reducing device complexity while maintaining measurement capability.
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 direct, continuous measurement of wear and tension without stopping the mill, providing reliable operational data and predictive insights into mill stability and fault diagnosis.
Implementation Method 1
an echographic instrument capable of measuring directly and transmitting on line, the length of the bolts
Implementation Method 2
measuring directly and transmitting on line, the length of the bolts and thereby estimating the wear state
Implementation Method 3
measuring directly and transmitting on line, the length of the bolts and thereby estimating the wear state of the inner lining
Implementation Method 4
using acoustic wave trains and a radio frequency communication system for real-time data transmission
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a system for the in-line measurement of mill liner wear and mill bolt tension, which includes: an acoustic-wave emitter, an acoustic-wave receiver, an electronic circuit, an energy source and a communication device, all at the threaded end of a certain number of bolts; a device in the vicinity of the mill for administering communication and gathering data; and a system in a remote position for processing and displaying data.