Embedded Mill Liner Sensors for Wear and Vibration Monitoring
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Solution Overview
Problem
Grinding mills face challenges in optimizing operating conditions due to the hard-wearing nature of materials used for liners, which prevents operators from viewing the interior during operation, making it difficult to improve efficiency and extend the life of the mill, leading to increased operating costs and reduced output.
Innovation Solution
Integration of a vibration sensor and a wear sensor within the mill liner to monitor vibration and wear, respectively, allowing for more accurate data collection and transmission of operational parameters, such as charge toe positions, rotational speed, and wear levels, to improve mill efficiency and extend liner life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If hard-wearing materials are used for liners to protect the drum, then the life of the mill is extended, but operators cannot view the interior during operation making it difficult to improve operating conditions
Solution Approach 1:
The patent replaces mechanical visual inspection methods with electronic sensing systems. Vibration sensors and wear sensors are embedded in the liners to electronically monitor interior conditions, allowing operators to view data remotely without needing to physically access or see inside the operating mill.
Solution Approach 2:
The patent introduces sensors as intermediary devices between the liner and the operator. These sensors act as mediators that convert physical conditions (vibration, wear) into measurable signals that can be transmitted to operators, enabling indirect observation of interior conditions without compromising the protective function of the hard-wearing liners.
2Measurement precision
If vibration sensors are disposed within the mill liner, then more accurate vibration readings are obtained, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into the liner structure itself. The liner serves both as a protective wear component and as a mounting structure for sensors. By integrating the sensors within the liner during manufacturing, the patent reduces overall system complexity compared to adding separate monitoring structures.
Solution Approach 2:
The mill liner is designed to serve multiple functions: it provides mechanical protection against wear, structural support for the drum, and housing for the vibration and wear sensors. This multi-functionality reduces the need for separate components and simplifies the overall system architecture.
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
The embedded sensors provide real-time data on mill operation and wear, enabling operators to adjust parameters like rotational speed and charge size, thereby enhancing efficiency and reducing maintenance costs by extending the life of mill components.
Implementation Method 1
a vibration sensor sensing vibration of the liner in use of the mill
Implementation Method 2
a wear sensor to sense wear of the wear surface of the liner during use
Data Source
AI summary
Disclosed herein is a mill liner assembly for a grinding mill, comprising: a mill liner which comprises a wear surface and an opposite inner surface that is arranged in use to be mounted in opposed relation to an interior surface of a shell of the grinding mill, a liner sensor which is embedded within the mill liner; and a control or power arrangement configured to control or power the liner sensor, the control or power arrangement being also embedded in the mill liner.