VEGA measurement technology for the optimization of stone crushers

Manual intervention in the process is usually difficult, so to continuously monitor the individual process steps, the main goal becomes reducing the load on the machine components. MA-ESTRO's system automatically controls the entire process by connecting all the machines in the system. The sensors installed in the critical areas make it possible to constantly adjust the load in the individual parts of the system. For example, loading is controlled, material flow is adjusted, and any clogging scenario is avoided. This protects the equipment, saves energy, and leads to higher product quality.

In Ma-estro’s world, sensor technology plays a major role. For about a year already, measurement technology from VEGA has been involved in the monitoring and optimization of the crushing machines. A total of 50 instruments are being used for this, including VEGASON 61, 62, 63, VEGAPULS 69 and VEGABAR 82. Most of them are level sensors. VEGA radar technology is used to measure material in crushers and mills, but it also warns of screen clogging and measures the level of water used for washing the material. Other examples are the VEGA sensors located at the opening of the press to control the level in the machine, on the conveyor belts to measure the load and in the storage containers to measure the quantity of the end product.
Ma-estro had previously used sensors from other manufacturers for these tasks. However, these had to be integrated, at great expense, into the existing automation systems. Dust, residual material and moisture cause a lot of interfering reflections. It was a set of circumstances that caused considerable problems for the previously used sensors and thus led to inaccurate measurement.

MA-ESTRO hardly knew anything about VEGA previously. They were convinced to give some new sensors a try, so they installed a few for testing. It wasn't long before MA-ESTRO was convinced. The new technology and the sensors have since found their permanent place in the crushing systems. The measurement engineering team was especially impressed by the simple configuration of the instruments. Thanks to the plics® concept, the standardized user interface independent of measuring principle, the team didn’t have to re-familiarize themselves with the different sensor types over and over again.

VEGAPULS 69, in particular, delivered extremely reliable and accurate measured values – an important prerequisite for starting an optimization of the crushing process. The level sensor operates with 80 GHz and has an antenna diameter of approximately 75 mm. This allows the 80-GHz beam to bypass anything that could otherwise get in the way, such as internal fixtures or buildup on the vessel wall. Plus, it easily penetrates dense clouds of dust. All these factors makes measurements more reliable, especially in the harsh environments found in crushing machines.

On additional feature delighted the Italian company - the option to use wireless communication via Bluetooth. This is especially useful for hard-to-reach areas, harsh industrial environments, and Ex hazardous zones. VEGA sensors can be configured and parameterized from a safe distance with a smartphone or tablet. A fast, easy-to-use display, and diagnostic functions are also available. VEGA technology fit perfectly into MA-ESTRO's optimization environment.