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Ball Mill Level Smart Mill Control
Ball Mill Level Smart Mill Control
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| Smart Mill Control |
 SmartMill Control is a modern control system for grinding plants. The Fuzzy-Expert-system performs much better than the “classical“ closed loop controls (PID) or even rule based expert systems. SmartMill Control enhances efficiency and durability of grinding systems significantly. A single control block can take several inputs and outputs into account,leading to much better control results. Smooth and stable operating conditions and optimisation of throughput are primary goals of control startegies. SmartMill Control is based on highly developed software tools and building blocks. Data exchange to the process / grinding plant is performed by means of standardized industrial interfaces. Consistent and consequent usage of open system interfaces enables easy connection to all automation systems being used in todays‘ cement industry .Due to the highly modular design of SmartMill Control investment is kept low. The fuzzy expert system "SmartMill Control" combines the easy handling of a PID controller with the flexibility and strength of an expert system.
SmartMill Control is based on a database, which inherits Fuzzy-technologies for process optimisation. Based on an ongoing rating of the process, the current state of the facility is evaluated. Sophisticated algorithms, which inherit KIMA‘s and the customers experience, then calculate new parameters for subordinate control systems. For the acquisition and long term storage of process data, the database is used also. A flexible and very easy to use software system for the management of process data, display of trends analysis and reporting is available.As an option a recipe management system can be added. No special prerequisites are necessary for the integration of SmartMill Control. The software is running on a standard PC, which can very easy be connected
to all automation systems, which are used in plants. There is only a low effort to connect SmartMill Control to the automation system. The investment is significantly lower as compared to competing systems.
 Due to the fact that SmartMill Control is designed as a configurable Fuzzy Expert system, new possibilities to control grinding plants arise (e.g. use the separator to control returns, which then influences the level in the mill)
Simple PID-controller can only use a single input to calculate a single output only to be used for the loop control. SmartMill Control‘s Fuzzy-technology processes a multitude of inputs. The system can be tuned to follow different targets. This flexibilities facilitate new innovative solutions for grinding plant controllers, which render much better results, than classical PID-controllers. Of course, modern versions of the “classical“ strategies:
Feed = constant returns = constant can be chosen. When doing so, the advantages of the Fuzzy-Expert system are preserved, namely the consideration of several inputs, which might be contradictory. 
Applications:
Thermo Link  Direct and easy measurement of cement temperature in ball mills. As the ball mill grinding process insert a large amount of energy into the material being ground the cement heats up during grinding, temperatures above 120 °C will affect additives like gypsum.. The situation is even worse, if hot clincker is fed to the mill. The scavenging air flow can not be increased without sacrificing the grinding result.The most efficient cooling is achieved, if water is spayed into the second compartment of the mill in such a manner, that it directly vapourizes without wetting the material, this means, the temperature should be above 100 °C. Keeping the temperature in the desired range needs a precise measurement of the cement temperature inside of the mill. ThermoLink uses a temperature sensor and very low power electronics to measure the temperature directly in the diaphragm and transmit the results wireless. The low power requirement of the electronics enables the usage of a pendulum driven generator, which supplies all equipment on the mill. Thus the installation is very easy and straight forward. a) Features
b) Elements of ThermoLink
Thermocouple or PT-100 resistor in a heavy duty housing, which can resist abrasive wear.
Both types of sensor produce very low level signals. In order to avoid external interference of these signals, they are directly amplified and converted to safe levels. In order not to load the on board power supply the conditioners consume extreme low power.
The On Mill Unit contains a microprocessor, a wireless transmitter and its own energy supply, which gains its energy out of the rotation of the mill. This completely avoids regular change of batteries or complex installations (inductive loops or the like). One Unit can serve up to three sensors on the same mill.
A small receiver to be located somewhere next to the mill (3 - 10 m). Receives the signals from the mill, amplifies and forwards them to the Base Unit. Base Unit The Base Unit contains an industrial PC, which evaluates and translates the signals back to temperature values. These values are then available as current loop signals 4 . . . 20 mA, which can be easily connected to all PLC or SCADA systems.
 c) Specifications Technical Data
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Smart Mill(Smart Mill)