Grinding Tube Torque Monitoring for Frozen Charge Release
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Solution Overview
Problem
Existing monitoring systems in tube mills fail to accurately detect the presence of frozen charges, leading to unnecessary shutdowns and potential damage due to material detachment during startup, especially in mills without steel balls.
Innovation Solution
A method that involves measuring torque at two different angles of rotation, calculating a target torque based on the first actual torque, and using a threshold range to determine if the charge has been released from the grinding tube's interior wall, allowing for a reliable distinction between grinding and charge release modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If monitoring function is used to detect frozen charges, then reliability of detecting frozen charges is improved, but false shutdowns occur in mills without steel balls
Solution Approach 1:
The monitoring function is segmented into two distinct modes: grinding mode and charge release mode. The system determines which mode is active by measuring torque at multiple angles of rotation and comparing the results. This segmentation allows the monitoring function to distinguish between normal grinding operations and actual frozen charge conditions, preventing false shutdowns while maintaining detection reliability.
Solution Approach 2:
The monitoring function dynamically adapts its behavior based on the operating mode. By continuously measuring torque at different angles of rotation and adjusting the evaluation criteria accordingly, the system can reliably detect frozen charges during charge release mode while avoiding false positives during grinding mode, thus maintaining both detection accuracy and mill availability.
2Measurement precision
If torque monitoring is used to detect frozen charges, then detection capability is improved, but unnecessary shutdowns occur
Solution Approach 1:
The monitoring function is segmented into two distinct modes: grinding mode and charge release mode. The system determines which mode is active by measuring torque at multiple angles of rotation and comparing the results. This segmentation allows the monitoring function to distinguish between normal grinding operations and actual frozen charge conditions, preventing false shutdowns while maintaining detection reliability.
Solution Approach 2:
The system continuously measures torque at different angles of rotation and uses this feedback to determine the operating mode. Based on the feedback from multiple torque measurements, the system dynamically adjusts the monitoring criteria to accurately distinguish between grinding and charge release modes, ensuring shutdowns only occur when truly necessary.
3Reliability
If monitoring function is activated, then frozen charge detection is improved, but system complexity increases
Solution Approach 1:
The monitoring function is designed to perform multiple functions within a unified framework. It can operate in both grinding mode and charge release mode, distinguishing between the two through torque measurements at multiple angles. This multi-functionality reduces the need for separate monitoring systems for each mode, thereby reducing overall system complexity while maintaining reliable frozen charge detection.
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
Ensures high reliability in detecting frozen charges, preventing unnecessary shutdowns and maintaining mill availability by accurately distinguishing between sliding and frozen material, thus avoiding damage and ensuring safe operation.
Implementation Method 1
measuring torque at two different angles of rotation
Data Source
AI summary
A method for starting a grinding tube with an assigned drive device, wherein during the operation of the grinding tube a grinding mode and a charge release mode can be set such that a particularly reliable monitoring of the state of charge located in the grinding tube is ensured, where the grinding tube is rotated and, at a first rotational angle, a first actual torque is detected, a setpoint torque is calculated for a second, relatively large rotational angle based on the first actual torque, an actually occurring, second actual torque is detected when the second rotational angle is reached, an investigation is performed to determine the difference of the second actual torque from the setpoint torque, and the charge release mode of the grinding tube is set when the second actual torque is within the threshold range, otherwise the grinding tube is operated in the grinding mode.