Embedded Mill Sound Analyzer Using FPGA and Microphone Array

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Solution Overview

Problem

Current sound analysis systems in mills are complex, costly, and inefficient, relying on centralized servers and analog signal processing, which limits their ability to provide detailed insights into mill operation and requires extensive maintenance, making them unreliable and difficult to implement in industrial settings.

Innovation Solution

An embedded system with a microphone array that performs real-time sound analysis in the time and frequency domains, using industrial microphones and a processor with FPGA for digital signal processing, communicating via Ethernet/IP protocol to optimize load and water addition, and estimate wear of mill components, reducing the need for centralized servers and improving reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If centralized servers with special hardware are used for sound analysis, then advanced analysis algorithms can be executed, but the system becomes complex, costly, and requires large memory space and high speed

Engineering Contradiction:

Improvesound analysis precisionVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts the sound analysis functionality from centralized servers and implements it directly in the mill's control system using embedded processors. This removes the need for separate server infrastructure while maintaining analysis capabilities, thereby reducing overall system complexity and cost.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the sound analysis functions with the existing mill control system by integrating the embedded processor and microphone array into the mill's control architecture. This merging eliminates the need for separate centralized servers and reduces system complexity while maintaining analytical precision.

Inventive Principle:

Principle #5Merging (Combining)

2Loss of information

If centralized systems with servers and databases are used, then data can be saved and analyzed, but the system requires extensive maintenance and is difficult to implement

Engineering Contradiction:

Improvedata storage and analysisVSAvoidimplementation ease

Core Design Contradiction:

Loss of informationVSEase of manufacture

Solution Approach 1:

The patent extracts data processing and storage functions from complex centralized systems and implements them directly in the embedded controller. This eliminates the need for separate servers and databases, significantly simplifying implementation while maintaining data management capabilities.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If analog signal processing is used, then sound signals can be processed, but the system is unreliable and requires extensive maintenance

Engineering Contradiction:

Improvesignal processing capabilityVSAvoidsystem reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces analog signal processing with digital signal processing using embedded processors. This substitution eliminates the unreliability and maintenance issues associated with analog systems while maintaining signal processing capability, thereby improving system reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If the mill operates continuously to maximize productivity, then energy consumption increases, but stoppages for repairs reduce efficiency

Engineering Contradiction:

Improvecontinuous operationVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent implements real-time monitoring of mill conditions through the microphone array and embedded processor, providing feedback on ball wear, lining condition, and grinding efficiency. This feedback enables predictive maintenance, allowing the mill to operate continuously with optimized energy consumption by scheduling maintenance only when truly necessary.

Inventive Principle:

Principle #23Feedback

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 system provides precise and efficient analysis of mill operations, optimizing energy consumption, extending the lifespan of steel balls and inner linings, and reducing stoppages, while being compact, robust, and deterministic, with direct communication to control systems for uninterrupted processing and communication.

Implementation Method 1

a microphone that captures sound signals from the cascade of mineral and steel balls

Methodology Applied

Scientific EffectSound: Sound

Implementation Method 2

an embedded system for their analysis in real-time

Methodology Applied

Scientific EffectAcoustic emission: Acoustic Emission

Data Source

PatentUS10546097B2Analyzer system of sound generated in mills based on embedded systems and a microphone array

Publication Date: 2020.01.28 ELECTRO CONTROLES DEL NOROESTE S A DE

AI summary

This invention consists of a new analyzer system of the sounds generated in mills that capture the signals issued by the mineral and steel balls cascade that perform grinding. These signals are processed in an embedded system (2) formed by a field programmable gates array (FPGA) and a processor. The system is comprised of an industrial microphone array (1) that captures the sound signals that are converted from analog to digital through and acquisition system (3) specialized in sound signals, processed by a FPGA capable of performing parallel operations at high speed due to the customized hardware developed for this application, and sent to the processor through a high-speed data bus.