Milling Facility Flow Monitoring for Abnormality Localization
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Solution Overview
Problem
Conventional milling facilities face challenges in identifying specific abnormal spots within the grinding and pulverizing steps due to the configuration of multiple tiers of roll mills and sifting machines, leading to inefficient detection of abnormalities.
Innovation Solution
A monitoring system is implemented, featuring flow rate measuring devices on discharge paths from grinders and pulverizers, along with a monitoring device that compares measurement results to reference values and displays anomalies, enabling operators to easily locate abnormal spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple tiers of roll mills and sifting machines are combined to form grinders and pulverizers, then the milling capability and productivity are improved, but the complexity of identifying specific abnormal spots increases
Solution Approach 1:
The patent divides the milling facility into multiple grinders and pulverizers, each consisting of specific roll mills and sifting machines. Flow rate measuring devices are installed at the discharge of each sifting machine to monitor individual component performance. This segmentation allows operators to identify which specific grinder or pulverizer has an abnormality by checking which unit's discharge flow rate deviates from the total, thereby resolving the contradiction between improved milling capability through combination and the complexity of identifying specific abnormal spots.
2Ease of operation
If conventional weight-based monitoring is used to detect abnormalities, then the overall facility monitoring is simple, but the specific abnormal spot cannot be identified
Solution Approach 1:
The patent introduces flow rate measuring devices as intermediaries between the sifting machines and the monitoring system. These devices measure the discharge flow rates of individual sifting machines, providing detailed information about each component's performance. The monitoring device compares the sum of individual flow rates with the total discharge flow rate, enabling both simple overall monitoring and precise localization of abnormalities without losing information about specific problem areas.
3Measurement precision
If flow rate measuring devices are installed on all discharge paths, then the precision of abnormality detection is improved, but the device complexity and cost increase
Solution Approach 1:
The patent implements a feedback mechanism where the monitoring device continuously compares the sum of discharge flow rates from individual sifting machines with the total discharge flow rate. When a discrepancy is detected, the system provides feedback to operators about which specific grinder or pulverizer has an abnormality. This feedback approach achieves high measurement precision for abnormality detection without requiring complex intervention, as the system uses existing flow rate data in a comparative feedback loop to identify issues efficiently.
Data Source
AI summary
Provided is a monitoring system for a milling facility, which includes a plurality of grinders including roll mills for grinding a material to be milled and sifting machines for sifting, according to grain size, the material to be milled as ground by the roll mills; and a plurality of pulverizers including roll mills for pulverizing the material to be milled and sifting machines for sifting, according to grain size, the material to be milled as pulverized by the roll mills. The material to be milled is milled by each of the grinders and pulverizers. A plurality of flow rate measuring devices are provided on respective flow paths for product flours discharged from the respective sifting machines in the respective grinders and pulverizers, and a monitoring device capable of monitoring presence or absence of an abnormality based on measurement results on respective flow rates of the product flours is provided.