High-tech well established
With MillMaster KIMA Process Control offers the most robust, open and easy to handle Advanced Control System for the Minerals Industry. Since 1996 this ‘Auto-Pilot’ system was installed in hundreds of plants to operate mills fully autonomously. The rule-based expert system for SAG, Ball Mills, VRM’s and also combined systems secures a permanent optimum production and energy efficiency – without any manual interaction necessity.
The development of the so-called “electronic ear” SmartFill system started around the year 2000 and was under continuous enhancement and adaption to modern requirements over the last years.
SmartFill was and is a serious revolution in sensor technology as a high precision, interference free level measurement in ball mills. Over 750 installed systems in more than 50 countries in the world underline the success of this product. It gives the most reliable and useful input values for the MillMaster expert system.
A complete new way of grinding control
Precise control needs precise measurement. As classical “electrical ears” could not deliver the precision required, SmartFill is developed as an alternative, which cannot be interfered by external sound sources or other mills in the vicinity.
In comparison to microphone based systems and vibration sensors on bearings, SmartFill does not have a conflict from other sound and signal sources. The structure born sound sensor is taking the signal directly on the mill body only. SmartFill is operated in buildings with 16 mills, side-by-side without any interference between the measurement systems.
The signals of SmartFill can and should be used as set-points in an advanced controller.
OPTIMIZED GRINDING PERFORMANCE
The high precision of the electronic ear SmartFill and the consequent use of the strategy “fill level = const.” in the expert system MillMaster, that makes the difference. The synergy of the precise chamber filling, which indicates the grindability of the material, and the multi-dimensional fuzzy controller above, opened new capacities and saved electrical power costs in reasonable amounts.
Additionally the wear out of balls and liners is reduced due to the fact, that running a mill empty unintentionally is avoided. On the other hand, the high stability of SmartFill’s calibration makes it an efficient protection against overfilling as well.
With innovative sensor technology and robust as well as established advanced process control KIMA Process Control can provide a comprehensive solution for all type of minerals grinding.