Monitoring grinding parameters by signal measurements for an industrial ball mill

Abstract Mechanical grinding emits a high-intensity vibration signal that contains information on the mill operating state. Vibration signals from the mill are presented in the form of both mechanical vibration and acoustic pressure. To apply these source signals to monitoring of grinding parameters, industrial scale grinding tests were performed with an iron ore at LKAB, Malmberget. Three operating parameters were considered: the feed rate, the mill feed size and the pulp density of mill discharge. The measured response parameters were the ground product size, the power draw and the pulp temperature. The source signals of the time-domain waveforms were simultaneously sensed by accelerometer and microphone so as to obtain a “stereograph” of grinding. The signals were first stored on a DAT recorder and then converted into digital format by an oscilloscope. The digitised waveforms were transformed into frequency-domain spectra by power spectral estimation. The variations on the power spectra can be described by a few “latent” variables derived by principal component analysis. Finally, close relations were established between key grinding parameters and “latent” variables by multiple regression. Using signal measurements, an automatic and efficient strategy can be developed to monitor operating parameters for the control system in a ball grinding circuit.