Key elements of the virtual sensor:
The IsaMill Disc Wear Virtual Sensor 2.0 (Constant wear/kWh) offers significant additional monitoring and assists in determining the optimal time for disc replacement or refurbishment. This is crucial because replacing discs too early can result in unnecessary maintenance costs, while replacing them too late can lead to excessive wear and reduced grinding efficiency.
A list of benefits to the user
Extended Disc Lifespan: By identifying the ideal time for maintenance, the virtual sensor helps maximize the lifespan of the grinding discs, reducing the frequency of replacements and lowering maintenance costs.
Reduced Downtime: Proactive maintenance planning and monitoring of disc wear help reduce unplanned downtime, which can be costly and disruptive to operations.
Process Stability: Consistent and well-maintained grinding discs enhance process stability, resulting in more reliable and consistent grinding performance.
To access the Virtual Sensor, follow the steps below:
Step 1: Login to the brains.app site.
Step 2: Click on the dashboard icon to access the list of dashboard available on the site. Select the disc wear dashboard.
Step 3: After selecting the disc wear dashboard, you will find a time graph showing IsaMill Disc Thickness virtual sensors.
The Virtual Sensors report IsaMill disc thickness predictions in real time. This is for mill with 7x1720mm disc configuration with initial disc thickness of 138mm. Reduction in disc thickness is a function of mill power. The highest point of the time graph, at disc thickness of 138mm indicates the point when a new disc was added and the lowest point of the time time graph, at disc thickness of 85mm is the point a disc needed a replacement.