How to automatically control hammer mills? Remote monitoring in Industry 4.0

What are the challenges in controlling hammer mills?

The efficiency of hammer mills depends largely on precise control of the dosing process and the adjustment of operating parameters to a variety of raw materials. However, managing this process is not easy and involves a number of technical and operational challenges. Every production plant has different requirements for hammer mill control. Installations are designed individually, which means that there is no one-size-fits-all solution for all applications. The control system must take into account the type of raw material, the size of the mill, the drive power, and the safety and performance requirements. Each of these applications requires a different approach to control and automation, which means that standard solutions may not be sufficient.

Hammer mills are used to grind a wide range of materials, from grain and animal feed to wood and plant fibers to biowaste and biomass. Each of these materials behaves differently during processing – it has a different density, moisture content, and crushability. This means that the speed and capacity of the feeder must be constantly monitored and adjusted to the current conditions.

In addition, feeders used in hammer mills (e.g., screw, vibrating, drum feeders) are responsible for delivering a specific amount of material to the grinding chamber. Their speed must be strictly controlled to ensure optimal dosing.

How to ensure automatic control and monitoring in hammer mills? Our solution

To meet the challenges of precise control and automation of hammer mills in line with Industry 4.0, Tietjen Verfahrenstechnik GmbH was looking for a modern control component. The customer's goal was to implement precise speed control of feeders, remote maintenance, compliance with safety standards, and integration with production management systems. The device that met all requirements was the JUMO DICON touch – a multi-channel process controller and software that provides flexibility in various industrial applications.

Features tailored to demanding applications

JUMO DICON touch offers a range of features useful for controlling hammer mills:

• Precise drive speed control – the controller ensures accurate dosing of raw materials in accordance with application requirements.
  
• Time-dependent parameter block switching – enables automatic adjustment of settings depending on the process stage.
• Start-up ramp – ensures a smooth start-up of the system, which is crucial for installations requiring a stable start.
• Definition of limit values – allows the process to be automatically stopped in the event of overload or detection of anomalies.

How were hammer mills automated and adapted to Industry 4.0? Customer benefits

The implementation of the JUMO DICON touch controller in the hammer mills of Tietjen Verfahrenstechnik GmbH has brought measurable operational and financial benefits to customers. The greatest success of the solution is the precise dosing of raw materials, which eliminates the risk of mill overload, reduces material losses, and optimizes energy consumption. Thanks to remote diagnostics and monitoring of device operation, it is possible to detect and eliminate failures more quickly, which reduces downtime and service costs.

Integration with Industry 4.0 systems allows for continuous analysis of production data, enabling better process planning and increased overall plant efficiency. In addition, the modular design of the controller allows customers to easily adapt the configuration to their individual needs, making this solution versatile and future-proof.

Contact us for more information about applications dedicated to your industry! Let's take automation to the Industry 4.0 level together.