Application Scenario
In modern cement manufacturing, optimizing the load of the vertical raw mill is crucial for energy efficiency, equipment longevity, and process stability. This application focuses on automating the feed control of a vertical raw mill using real-time monitoring and intelligent feedback to maintain optimal grinding load.
System Configuration
ARMxy Controller – Core logic execution platform running OpenPLC
Y-AI Analog Input Module – For capturing real-time motor and vibration signals
X-DO Digital Output Module – To control the variable-frequency drive (VFD) of the feed belt
Implementation Details
Signal Acquisition via AI Module:
Main Motor Current Monitoring: Through a 500A/5A current transformer (CT) for real-time load feedback
Gearbox Vibration Detection: Using a 4–20mA industrial accelerometer for early fault identification
Control Logic:
OpenPLC calculates load deviation and dynamically adjusts feed rate through DO outputs to the VFD
A load-based PID algorithm ensures stable operation even under fluctuating raw material conditions
Communication:
Seamless integration with the plant’s DCS system via Modbus TCP, enabling real-time data sharing and monitoring
Remote Capabilities:
Engineers can set and adjust load thresholds remotely
Quick deployment and updates of PLC logic through BLRAT and OpenPLC interface
Key Advantages
Energy Optimization: Automatically matches feed rate with actual grinding demand, reducing power consumption
Predictive Maintenance: Vibration monitoring helps detect mechanical issues early, preventing costly breakdowns
Remote Management: Engineers can remotely fine-tune load control parameters and upload new control programs
Hardware Capability: Y-series AI modules can directly interface with CTs, eliminating the need for external signal converters
