Smart Transformation of Industries and Mining

Transforming industrial equipment and processes into intelligent systems for monitoring, analysis, and decision-making

Project Title

Intelligent Ball Mill Monitoring System

Project Description​​​​​​​

This project focuses on developing an integrated approach based on multi-sensor monitoring and artificial intelligence to enhance the monitoring, control, and optimization of ball mill performance. In this approach, data from vibration, acoustic, and thermal analyses, along with strain-gauge measurements, are analyzed in an integrated manner to monitor and assess the structural health and performance of the mill without relying on periodic shutdowns.

The proposed solution incorporates a Digital Twin and a closed-loop intelligent control system to enable the prediction of key parameters, real-time response to feed variations, and automated process control. The ultimate goal is to move from operator experience-based monitoring and adjustments toward intelligent, data-driven control, with a focus on increasing production capacity, improving efficiency, and reducing energy consumption.

●  Online monitoring of the mill’s structural health and performance
●  Detection and prediction of shell cracks and damage
●  Integration of multi-sensor data and development of an intelligent monitoring system
●  Development of a Digital Twin of the mill
●  Prediction of key process parameters
●  Real-time autonomous control of mill performance
●  Optimization of production capacity and energy consumption
●  Implementation of a predictive maintenance approach
●  Reduction of forced downtime and maintenance costs

Project Outcomes