the design of ball grinding mill automatic controlling system based on configuration software

7/27/2019 The Design of Ball Grinding Mill Automatic Controlling System Based on Configuration Software

1/4978-1-4673-0024-7/10/$26.00 2012 IEEE 2418

2012 9th International Conference on Fuzzy Systems and Knowledge Discovery (FSKD 2012)

The Design of Ball Grinding Mill Automatic

Controlling System Based on Configuration Software

REN Jia-fuWU Shou-yong

Chengdu University of TechnologyChengdu,China

AbstractA new method to design ball grinding mill automatic

controlling system based on the MCGS configuration software

was introduced,and the structure and the working principle of

the whole system were studied.In the design of this system, the

computer with MCGS configuration software was used as a host

computer,and the monitoring functions,such as data collection,

processing,display,alarm,report output,etc.,were realized.

Hypogynous machine (PLC)was used as regulator ,so the process

controlling was realized.The system can be completed on the

mills work situation of real-time remote monitoring and

overload alarm.And the real-time adjustment of the input of

mineral and water can be done according to the changes of the

output of pulp granularity,pulp density and motor current.Automatic controlling of the ball grinding mill system would be

finally completed.

Keywords-configuration software; MCGS; ball grinding mill;

automatic controlling; PLC

I. INTRODUCTIONThe ball mill is a very common form of grinding tool in the

industrial production process,and mainly used in mineralprocessing, ceramics, chemicals, cement, glass, refractoriesand other industries.The main study here is to research itsautomatic controlling system when used in the grinding inmineral processing plant.Industrial controlling system in thepast, be automated,relied on specific software programming

for the hardware system,this method worked lowerefficiency,higher error rate,and poor software universal.Withthe continuous development of the industrial sector,specificallyindustrial controlling configuration software came intobeing,which is a software tool for user to quickly buildindustrial automatic controlling system with monitoringcapability,under a software platform of the automaticcontrolling system for monitoring and developmentenvironment,to provide with the advantages of low cost,easy todevelop,rich resources,strong scalability and versatility[1].With the help of the platform combined MCGS configurationsoftware with computer, the motor current,the feeding volumeof mineral,the volume of water and the pulp granularity anddensity of the output of ball mill in real-time monitoring whenthe mill running can be better achieved. And the achieved

datas by monitoring would be counted,analyzed,compared toright,and finally the control instructions could be issued.

The PLC(Programmable Logic Controller)as a controllingcommunication "bridge" between the configuration system andthe lower machine,after receiving the instructions, PLC

module output a corresponding analog controlling signal tocontrol the amount of mineral and the volume of the water,thusthe entire system maintains in a state of automatic.

II. THEDESIGNOFMONITORINGANDCONTROLLINGSYSTEMBASEDONMCGS

A. Introduction to MCGS configuration softwareMCGS(Monitor and Control Generated System) is a

windows-based platform for rapid construct and generatemonitoring system configuration software,it can be run on a

variety of 32-bit Microsoft Windows operating system. MCGSconfiguration software with functions of animation show,processing and device controlling, data acquisition and reportoutput,has some prominent features such as easy operation,nice visibility,and strong maintainability.So it is very practicalin the field of industrial process controlling and real-timemonitoring[2].

B. The real-time database settings of MCGS configurationenvironment

Analyzing the engineering project constitution and thespecification of the ball mill automatic controlling system,monitoring objects and their characteristics can be acquired,as

is shown in Table. Defining the corresponding data variable

in the MCGS real-time database, assigning their names, types,starting values and the value scopes, then determine the relatedparameters of these variables,such as saving cycle, savingrange, and shelf life ,and so on.

C. The design of the engineering static pictureWith the analysis, the need to create three user windows

can be named as "automatic controlling system of ball mill","parameters setting" and "graph datas". Configurate on themseparately.

a) The configuration of "automatic controlling system ofball mill" static screen. In accordance with the kind ofworkflow, select a combination hardware icons, and add theappropriate material flow module and text notes, etc.. In orderto make it easier to observe the entire system controlling, thereal-time display of pulp density, pulp granularity, feedingvolume, water volume, and motor current are set in the samewindow with the controlling system,which is shown in Fig.1.

b) The configuration of "graph datas" static screen. Usingthe MCGS equipment toolbox, the real-time and historical


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Figure 2 Alarm information display.

Figure 3 The statistics of the system.

Figure 4 The real-time curve of the system.

C. Data display and report outputa) The display of alarm datas.In MCGS real-time database,

alarm bounds should be set for data variables, such as motorcurrent, pulp granularity and density. Append these threevariables as alarm groups object members. Then add anappropriate user policy and set its new pull-down menu. Whilethe system running, the exact moment can be shown when anyvariables over the limits.

b) The display of the graphs. Graph processing is animportant part of industrial controlling system. Analyzing thetrend of graphs can be helpful to find out the data variation andbenefit to system optimization. In order to display the datagraphs normally when the system running, related propertiesshould be set for the real-time and historical graph which wereestablished before.

c) The display of system work.This function is mainly usedfor recording and displaying the feeding volume,the watervolume,the pulp granularity and density. This information canbe automatically recorded and displayed at a certain cycle. Inthe MCGS real-time database, establish new object and set thefeeding volume, water volume, pulp granularity, pulp densityas its members. Creating relative user strategy, with its strategybehaviour named Inventory data browsebeing added,set its

display property.

IV. ANALYSISANDDEBUGGINGOFTHEAUTOMATICCONTROLLINGSYSTEM

After the design of the system completed,then may inputthe simulated signals to carry on the synthesis. Start the currentproject in the configuration environment,enter in themovement environment, the " Ball Grinding Mill AutomaticControlling System " begins. Operating the switch on theinterface,the system begins to run. According to the designrequests, there are several functions need be tested.

a) The controlling function of the system switch,tomanually turn on the system or manually forced to shut downthe system. According to the lab test,when the system switch

was turned on, also turned on the material switch and the waterswitch,the pulp density,etc.,displayed normally;while thesystem switch was shut down,the whole system stopped.

b) Alarm and alarm datas display. According to the lab test,when the motor current was less than 6.5 units ,there would bea lower alarm, while the motor current is greater than 8.5 unitscaused a upper limit alarm; when the pulp granularity was

greater than 85 units,there would be a upper limit alarm,whilethe pulp granularity was less than 65 units caused a lower limitalarm; when the pulp density was less than 65 units,there was alower limit alarm, while the pulp density was greater than 85units caused a upper limit alarm; motor current more than 9units caused overload alarm, meanwhile the system stopped.Alarm data is shown in Fig.2.

c) The records for the system show the sample values of thefeeding volume, the water volume,the pulp granularity,and thepulp density within a certain period of time, and the statisticsof the total and average. According to the lab test, the samplingtook place every 6 seconds, finally counted the total andaverage of each, as is shown in Fig.3.

d) Automatic controlling functions, that is, within a certainrange, the water volume changes with the changes in output ofpulp density;the feeding volume changes with the changes ofthe motor current and the output of pulp granularity.According to the lab test, when the motor current increased inthe normal working range of 6.5-8.5 units,there was acorresponding increase of the feeding volume;when the motorcurrent reduced, the feeding volume showed a correspondingreduction. When the pulp granularity increased within thenormal range , there was a corresponding reduction in thefeeding volume; when the pulp granularity decreased, the

feeding volume increased. When the pulp density increasedbetween the normal working range of 65-85 units, acorresponding increase in the amount of water volume, pulpdensity decreased, giving a corresponding reduction in watervolume.


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Figure 5 The historical curve of the system.

e) Data graph shows, which display the real-time and thehistorical graphs of the system. According to the lab test, real-time graph is shown in Fig.4, historical graph is shown inFig.5. With the analyzing of the graphs, it might discoverthat,for the whole system,there is a inverse relationshipbetween the feeding volume and the pulp granularity, as well

the motor current;while a positive correlation between thewater volume and the pulp density,what conforms to thedesign requirements of the system basically.

V. THECONCLUSIONSThis article is based on the industrial control configuration

software MCGS, combined with hardware equipments, such asPLC, inverter, sensor,and so on, and an automatic controllingsystem of ball mill was designed. And with the input ofsimulated signals, its automatic controlling functions weretested, its recorded real-time and historical graphs wereanalyzed, then come to the following conclusions.

a) Compared with the traditional instrumentation hardwarecontrol, this paper developed an automatic control system

based on the configuration software MCGS, capable ofautomatic control the feeding volume and the water volume,which depend on the changes of output of the pulpgranularity, the pulp density,and the motor current. And obtainfunctions of alarm and overload automatic breaking. Thesystem has a better interactive interface, scalability andversatility.

b) Through the configuration of real-time graph,historicalgraph,etc.,which provided by MCGS, it is possible to keep abreast on the running status of the system,and to count theinterested objects, just in the central control room,that wouldmake it easier to optimize and improve the system in the longrun.

c) By the configuration of parameters interface, user can

adjust the normal working ranges of the parameters accordingto the actual need when the quality of ore changed.So torealize the automatic controlling.

d) Because the records and the output report of the systemare completed by the way of gap sampling, there are certain

errors in data statistics and the average value analysis of eachobject.So,it need to be further optimized.

e) Because of the automatic controlling system could notbe really used in the factory,the stability of the system need tobe further tested ,and lots of detail technical issues may beencountered in practical applications.

[1] Cao Hui, Ma Dong-ping, Wang Xuanet al. Configuration SoftwareTechnology and Application. BEIJING:Publishing House of ElectronicsIndustry, 2009,p.1.

,, . [M]. :, 2009,1.

[2] Zhang Wen-ming, Liu zhi-jun.Configuration Software Technologies.Beijing: Qing Hua University Press, 2006

,. [M]. :,2006

[3] Beijing Kunlun State Automation Software Technology co., Ltd. MCGSReference Manual. Beijing: Beijing Kunlun-State automation softwaretechnology limited, 2004.

.MCGS [M].:, 2004.

[4] Li Dan. MCGS Monitoring Configuration Software in Densely OreDressing Plant Crushing Plant Application. Kunming: KunmingUniversity of Science and Technology, 2004, pp.35-36

. MCGS [D]. :, 2004,35-36.

the design of ball grinding mill automatic controlling system based on configuration software

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