DESC:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of invention:
SYSTEM AND METHOD FOR ONLINE WEAR MONITORING OF HIGH PRESSURE GRINDING ROLLS

Applicant:
BENVIRA FORWARD ALGORITHMS LLP
A Limited Liability Partnership Firm
Having address as:
No. 12, Third Floor, Block - D, Doshi Gardens No.174,
Arcot Road, N.S.K Salai, Vadapal ani Chennai,
Chennai, Tamil Nadu, 600026, India

The following specification particularly describes the subject matter and the manner in which it is to be performed.
CROSS REFERENCE TO RELATED APPLICATION AND PRIORITY
[001] The present application claims priority to Indian Patent Application No 201941015445 titled “INTERNET OF THINGS IN ROLLER PRESS” filed on 17th October 2019, the entity of which is hereby incorporated by reference.
TECHNICAL FIELD
[002] The present subject matter described herein, in general, relates to a roller press machine, and more particularly, to a system and method for online wear monitoring of high pressure grinding rolls (HPGR).
BACKGROUND
[003] Nowadays, core industries like Cement, Steel, Mining and Power are among the last ones to absorb latest technologies like IOT, AI, Machine learning etc. Typically, application of these new technologies in industrial scale Projects can create substantial value for its users. With suitable sensing, analysis, integration and implementation, significant cost savings can be made that may ultimately help in reducing capital and operating expenditure in plant and machinery.
[004] One such industrial application, which can generate substantial value by implementing IOT concepts to design predictive algorithms for preventing unscheduled breakdowns/stoppages is the area of High Pressure Grinding Rolls or Roll Presses (as more commonly known). Roll Presses have become the preferred type of grinding technology over the conventional Ball Mills and Vertical Roller Mills (VRMs) because they consume roughly 15-20% less power and have proven to be very effective for grinding of raw materials, mineral ores and residuals like Blast Furnace Slag in the Cement and Mineral Industries.
SUMMARY
[005] Before the present system(s) and methods for online wear monitoring of high pressure grinding rolls, are described, it is to be understood that this application is not limited to the particular system(s), and methodologies described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosures. It is also to be understood that the terminology used in the description is for the purpose of describing the particular implementations or versions or embodiments only and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to a system and a method online wear monitoring of high pressure grinding rolls. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
In one implementation a system for online wear monitoring of high pressure grinding rolls is described. The system comprising a processor and a memory coupled to the processor. The memory stores a set of instructions to be executed by the processor. The system further comprises one or more sensors communicatively coupled to the processor and the one or more sensors are connected to the roller press machine for measuring one or more operating parameters of the roller press machine. The one or more operating parameters comprise at least one of surface profile of the roller press machine, metal piece details, undersurface crack details, side plate distance details. Further the one or more operating parameters are sensed by using radar technology and the one or more parameters are received and processed by the processor for generating a working status of the roller press machine in real-time.
[006] In one embodiment method online wear monitoring of high pressure grinding rolls is described. The method comprises measuring by one or more sensors, one or more operating parameters of the roller machine. The one or more operating parameters comprises at least one of surface profile of the roller press machine, metal piece details, under surface crack details, side plate distance details. The one or more operating parameters are sensed by using radar technology. The method further comprises receiving one or more parameters and processing by the processor for generating a working status of the roller press machine in real-time.
BRIEF DESCRIPTION OF THE DRAWINGS
[007] The foregoing detailed description of embodiments is better understood when read in conjunction with the appended drawings. For the purpose of illustrating of the present subject matter, an example of construction of the present subject matter is provided as figures; however, the invention is not limited to the specific method and system online wear monitoring of high pressure grinding rolls disclosed in the document and the figures.
[008] The present subject matter is described in detail with reference to the accompanying. In the figures, the left-most digit (s) of a reference number identifies the figure in which the reference number appears. The number are throughout the drawings to refer various features of the present invention.
[009] Figure 1 illustrates a network implementation of a system for online wear monitoring of high pressure grinding rolls, in accordance with an embodiment of the present subject matter.
[0010] Figure 2 illustrates an architecture of the system for online wear monitoring of high pressure grinding rolls, in accordance with an embodiment of the present subject matter.
[0011] Figure 3A and 3B illustrates implementation of one or more sensors for online wear monitoring of high pressure grinding rolls, in accordance with an embodiment of the present subject matter.
[0012] Figure 4 illustrates a method for online wear monitoring of high pressure grinding rolls, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION
[0013] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any system and methods for online wear monitoring of high pressure grinding rolls similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, system and methods are now described. The disclosed embodiments for online wear monitoring of high pressure grinding rolls are merely examples of the disclosure, which may be embodied in various forms.
[0014] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure for online wear monitoring of high pressure grinding rolls is not intended to be limited to the embodiments described, but is to be accorded the widest scope consistent with the principles and features described herein.
[0015] In Cement Industry, Roll Presses are used for grinding Limestone, Clinker and Blast Furnace Slag. The roller press machinery is used to crush and grind limestone and other materials to produce cement. The input material is force fed into the unit by creating a bed of material over the machine. The material is drawn in by two counter rotating rollers (one fixed and one movable) that crushes the material under high pressure. The required commination pressure is transmitted by hydraulic system via the movable roll. The pressure can get built up to 250MPa. The machinery is typically in operation for up to 22 hrs a day, 600 hrs a month. The approximate operational lifetime of roller presses is approximately 24k hours. The MTBF (mean time between failures) is typically 10k-13k hours, which is extended by subsequent reconditioning to provide an additional 8k hours, then 6k hours, then 4k hours of usage.
[0016] Currently the rollers are maintained, only when they breakdown and need repair. Unscheduled maintenance stops disrupt production at the plant thereby reducing output and efficiency. The breakdown hurts the most when an unplanned stoppage occurs during the period of maximum demand resulting in lost revenue. A second issue exists where metal enters the roller press through the input stock.
[0017] In one embodiment, of the present subject matter, the objective is to create a system with which the roller press equipment can be monitored remotely. It is envisaged that this remote monitoring will provide: Real-time status of the rollers, including: Wear, Surface damage, Fracture damage, Lifetime prediction, Presence of metallic parts in the input stock which may cause damage to the rollers. With this information in hand, it will then be possible to design an algorithm that can predict any failures which may lead to breakdowns.
[0018] In one embodiment, of the present subject matter, the IOT has the capability to measure/record: Wear, Surface damage, Under-surface fractures. The system should provide remote monitoring capabilities. The system should provide information regarding the health of the machine to the customer that can be used to take contingent actions. The system should be able to analyze wear, surface damage and under-surface fractures. The data collection should allow the development of algorithm to predict time to next failure. Optimum period for carrying out repair.
[0019] The present subject matter proposes to undertake a fast overview of potentially suitable sensing technologies and identify most the most suitable. From this we propose to outline a high-level Scope of Work, to develop and test a prototype product. To test the product with using the field and take further inputs from the customer to design the final equipment. To final develop the final sellable product in the market.
[0020] Now, referring now to Figure 1, a network implementation 100 of a system 102 for online wear monitoring of high pressure gringing rolls is disclosed. Although the present subject matter is explained considering that the system 102 is implemented through a server, it may be understood that the system 102 may also be implemented through a variety of computing systems, such as a laptop computer, a desktop computer, a notebook, a workstation, a mainframe computer, a server, a network server, and the like. In one implementation, the system 102 may be implemented through a cloud network. Further, it will be understood that the system 102 may be accessed by multiple users through one or more user devices 104-1, 104-2…..104-N, collectively referred to as user device 104 hereinafter, or applications residing on the user device 104. Examples of the user device 104 may include, but are not limited to, a portable computer, a personal digital assistant, a handheld device, and a workstation. The user device 104 may be communicatively coupled to the system 102 through a network 106.
[0021] In one implementation, the network 106 may be a wireless network, a wired network or a combination thereof. The network 106 may be implemented as one of the different types of networks, such as intranet, local area network (LAN), wide area network (WAN), the internet, and the like. The network 106 may either be a dedicated network or a shared network. The shared network represents an association of the different types of networks that use a variety of protocols, for example, Hypertext Transfer Protocol (HTTP), and the like, to communicate with one another. Further, the network 106 may include a variety of network devices, including routers, bridges, servers, computing devices, storage devices and the like.
[0022] In one embodiment, the system 102 may receive one or more operating parameters of the roller press machine devices connected through a communication network 106.
[0023] In one embodiment, the present subject matter is explained with reference now to figure 2 and 3A and 3B.
[0024] Referring to Figure 2, the system 102 for online wear monitoring of high pressure grinding rolls is illustrated in accordance with an embodiment of the present subject matter. In one embodiment, the system 102 may include at least one processor 202, an input/output (I/O) interface 204, and a memory 206. The at least one processor 202 may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, state machine logic circuitries, and/or any device that manipulate signals based on operational instructions. Among other capabilities, at least one processor 202 may be configured to fetch and execute computer-readable instructions stored in the memory 206.
[0025] The I/O interface 204 may include a variety of software and hardware interfaces, for example, a web interface, a graphical user interface, and the like. The I/O interface 204 may allow the system 102 to interact with the user directly or through the user device 104. Further, the I/O interface 204 may enable the system 102 to communication with other computing devices, such as web servers and external data servers (not shown). The I/O interface204 may facilitate multiple communication within a wide variety of networks and protocol types, including wired networks, for example, LAN, cable, etc, and wireless networks, such as WLAN, cellular, or satellite. The I/O interface 204 may include one or more ports for connecting a number of devices to one another or to another server.
[0026] In one implementation, a user may access the system 102 via the I/O interface. The user may be registered using the I/O interface in order to use the system 102. In one aspect, the user may access the I/O interface of the system 102 for obtaining information, providing input information or configuring the system 102.
[0027] The memory 206 may include any computer-readable medium known in the art including, for example, volatile memory, such as static random access memory (SRAM) and dynamic random access memory (DRAM), and/or non-volatile memory, such as read only memory (ROM), erasable programmable ROM, flash memories, hard disks, optical disks, and magnetic tapes. The memory 206 may include data.
[0028] The processor 202 is connected to a plurality of sensors 208. The system 102 comprises plurality of sensors as surface profiling sensor (210), metal piece detection sensor (212), under surface crack detection sensor (214) and side plate distance detection sensor (216).
[0029] The data 210, amongst other things, serve as a database for storing data process, received, and generated by one or more of the sensors 208. The 210 may also include a database 218, and other data 220. In one embodiment, the other data 220 may include data generated as a result of the execution of one or more sensors in the other sensors.
[0030] In one embodiment, the one or more sensors may be communicatively coupled to the processor. Further, the one or more sensors may be connected to the roller press machine for measuring one or more operating parameters of the roller press machine. The one or more operating parameters comprises at least one of surface profile of the roller press machine. The sensor measuring surface profile 210 details of the roller press is configured to map the surface of one or more rolls.
[0031] In one embodiment one or more operating parameter may further include metal piece details and under surface crack details. The sensor measuring metal piece 212 may be configured to detect the metal piece and calculate size of the metal and the crack detection sensor 214 may be configured to detect under surface cracks. The crack detection sensors may further be placed away from a centre of rolls (306a and b). Further, in an embodiment the one or more operating parameters measured may comprise side plate distance details. The sensor measuring side plate distance 214 may be configured to measure distance between fixed set of points and the one or more rolls. The side plates may avoid slipping of griding materials.
[0032] In an embodiment the one or more operating parameters may be sensed by using radar technology. Further, the sensors using the radar technology may use radar frequency for measuring a distance between a fixed set of points and the roller press machine for measuring the surface profile.
[0033] In an embodiment, the one or more parameters are received and processed by the processor for generating a working status of the roller press machine in real-time.
[0034] Referring to figure 3A, shows position of one or more sensors positioned on the high pressure grinding rolls, the sensor measuring metal piece 302, the sensor measuring surface profile 304a and 304b, the sensor measuring crack 306a and 306b. As observed the sensor measuring crack are positioned away from the centre of the rolls. Further, figure 3B shows the position of the sensor measuring side plate distance 216 a and b
[0035] Referring now to figure 4, a method 400 for online wear monitoring of high pressure grinding rolls, is disclosed in accordance with an embodiment of the present subject matter.
[0036] The order in which the method 400 is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method 400 or alternate methods. Additionally, individual blocks may be deleted from the method 400 without departing from the spirit and scope of the subject matter described herein. Furthermore, the method 400 can be implemented in any suitable hardware, software, firmware, or combination thereof. However, for ease of explanation, in the embodiments described below the method 400 may be considered to be implemented in the above described system 102.
[0037] At block 402, one or more operating parameters of the roller machine may be measured using one or more sensor. The one or more parameters may comprise at least one of surface profile of the roller press machine, metal piece details, under surface crack details, side plate distance details. The one or more parameters may be sensed by using radar technology.
[0038] At block 404, the one or more parameter of the roller machine may be received and further the oner or more parameters may be processed by the processor to generate a working status of the roller press machine in real-time.
[0039] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, the advantages may include those provided by the following features.
[0040] Some embodiment of the system and method may enable real-time detection of tear and wear of roller machine.
,CLAIMS:
1. A system for monitoring a roller press machine, the system comprising:
a processor (202);
a memory coupled to the processor, wherein the memory stores a set of instructions to be executed by the processor; and
one or more sensors communicatively coupled to the processor (202), wherein the one or more sensors are connected to the roller press machine for measuring one or more operating parameters of the roller press machine, wherein the one or more operating parameters comprise at least one of surface profile of the roller press machine, metal piece details, undersurface crack details, side plate distance details, wherein the one or more operating parameters are sensed by using radar technology;
wherein the one or more parameters are received and processed by the processor for generating a working status of the roller press machine in real-time.

2. The system as claimed in claim 1, wherein the sensor uses the radar technology used radar frequency for measuring a distance between a fixed set of points and the roller press machine for measuring the surface profile.

3. The system as claimed in claim 1, wherein the sensor measuring metal piece (302) details is configured to detect the metal piece and calculate size of the metal.

4. The system as claimed in claim 1, wherein the sensor measuring surface profile (304) is configured to map the surface of one or more rolls.

5. The system as claimed in claim 1, wherein the sensor measuring crack (306) is configured to detect under surface cracks and wherein the one or more crack detection sensors are placed away from a centre of rolls.

6. The system as claimed in claim1, wherein sensor measuring side plate distance (308) is configured to measure distance between fixed set of points and the one or more rolls.

7. The system as claimed in claim 1, the sensor for measuring crack details comprises an ultra-sonic sensor.
8. A method for monitoring a roller press machine, the method comprising:
measuring, by one or more sensors, one or more operating parameters of the roller machine, wherein the one or more operating parameters comprise at least one of surface profile of the roller press machine, metal piece details, undersurface crack details, side plate distance details, wherein the one or more operating parameters are sensed by using radar technology;
receiving one or more parameters and processing by the processor for generating a working status of the roller press machine in real-time.

9. The method as claimed in claim 8, wherein the sensor uses the radar technology used radar frequency for measuring a distance between a fixed set of points and the roller press machine for measuring the surface profile.

10. The method as claimed in claim 8, wherein the sensor measuring metal piece (302) details is configured to detect the metal piece and calculate size of the metal.

11. The method as claimed in claim 8, wherein the sensor measuring surface profile (304) is configured to map the surface of one or more rolls.

12. The method as claimed in claim 8, wherein the sensor measuring crack (306) is configured to detect under surface cracks and wherein the one or more crack detection sensors are placed away from a centre of rolls.

13. The method as claimed in claim 8, wherein sensor measuring side plate distance (308) is configured to measure distance between fixed set of points and the one or more rolls.

14. The method as claimed in claim 8, the sensor for measuring crack details comprises an ultra-sonic sensor.