Grinding Mill Drum Strain Sensor Weight Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for measuring the amount of material inside a grinding mill, such as those using microphone systems or strain gauge weight sensors, are not accurate due to interference from adjacent grinding mills and do not provide instant and reliable weight information, which is crucial for energy efficiency and process optimization.
Innovation Solution
A grinding mill equipped with a strain sensor mounted on the outer periphery of the drum, connected to a transmitter with a wireless signal module, which transmits data to a receiver for accurate weight measurement by detecting deflection caused by the material and balls, allowing for real-time monitoring and optimization of the grinding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If microphone systems are used to measure material amount inside the grinding mill, then the measurement system can be implemented, but the measurement accuracy deteriorates due to interference from adjacent grinding mills and other noises
Solution Approach 1:
The patent introduces strain sensors as an intermediary measurement mechanism that directly measures mechanical deformation of the mill shell caused by material weight, bypassing the noisy acoustic environment. The strain sensors convert mechanical stress into electrical signals, providing a direct physical measurement pathway that is immune to acoustic interference from adjacent mills.
2Measurement precision
If strain gauge weight sensors are mounted inside the grinding mill, then weight measurement can be performed, but the device complexity and installation difficulty increase
Solution Approach 1:
The patent creates a simplified copy of the measurement function by mounting strain sensors on the external outer periphery of the mill shell rather than inside. This external mounting position replicates the weight measurement capability while avoiding the complex internal installation environment, making the system easier to install and maintain.
3Ease of manufacture
If the strain sensor is mounted on the inner periphery of the drum, then the installation is simpler, but the measurement accuracy decreases due to lower deflection values
Solution Approach 1:
The patent transitions the sensor mounting location from the inner periphery to the outer periphery of the drum, utilizing the external dimension of the mill shell. This dimensional change allows the strain sensors to capture greater deflection values during operation, significantly improving measurement accuracy while the external mounting remains accessible for installation.
4Ease of operation
If wireless transmission is implemented for real-time weight monitoring, then the operational flexibility increases, but the power consumption and device complexity increase
Solution Approach 1:
The patent employs a power module that dynamically manages electrical parameters to enable wireless transmission while controlling power consumption. The system adjusts transmission power levels and data sampling frequencies based on operational conditions, optimizing the balance between real-time monitoring capability and energy consumption from the power source.
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 solution provides instant and accurate weight information, enabling better energy management and process optimization by reducing maintenance requirements and improving the reliability of material quantity measurements within the grinding mill.
Implementation Method 1
A strain sensor (80) is adapted to the drum (10) so that providing a data to determine weight information of the drum (10). Strain sensor will determine any weight changes on the drum (10) by measuring deflection of the drum (10) due to the loads, e.g. balls (30) or the material to be grinded.
Data Source
Figure 1~3
AI summary
The invention relates to a grinding mill comprising a drum (10) wherein a plurality of balls (30) are disposed in a freely movable manner having an inlet (12) to fed particulate material inside the drum (10) and an outlet (14) to transfer fine material after grinding. The grinding mill is comprising a strain sensor (80) adapted to the drum (10) so that providing a data to determine a weight information of the drum (10).