Siemens has extended the Simine portfolio for high-pressure grinding mills (HPGR) to include a new controller. Plug-and-play functionality makes the load share controller available for immediate use. The web-server based operator interface allows the process engineer at any time (on-line and off-line) to adapt the controller parameters and thus optimise the torque distribution. The controller it is already being successfully used by one customer, where tests done before and after optimisation have demonstrated significant benefits for the mill.
The new controller follows an established scheme. During startup of the HPGR, it is inactive, but once a certain torque level has been reached, the controller takes over the load share regulation. If the controller is not ready for use, for example in the event of disruption, the drives do not start. However, operation without load sharing is available and in this case the drives take the speed reference from the mill automation.
Variable load distribution
The load distribution between the rollers in an HPGM is generally 50:50. The master follows the speed command and the slave follows the torque of the master. If an alternative load distribution is required, it is possible to change the load distribution between the drives using the load distribution factor. The reference torque on the slave drive is then decreased or increased compared to the reference torque of the master drive. At the same time, the load share controller maintains the speed difference between the rolls within given limits. Via the web-server based operator interface, the process engineer can adjust the load share factor and limitation for speed difference at any time – even during grinding operation.
The plug-and-play system is supplied fully tested and ready for use. The webserver functionality allows the process and production engineers quick and easy access to the parameters of the controller. Programming skills or special equipment knowledge is not required.
KHD Humboldt Wedag, an OEM in the cement and mining industry, is already using the load share controller in its Conakry project. Before and after tests show the benefits of using this controller: amongst other things, changes in the roll gap and roll pressure could be kept in a substantially smaller range.
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