SOUND 2 PREMIUM : Digital electronic ear for ball mills
- HASLER Group
- DOSING
- SOUND 2 PREMIUM : Digital electronic ear for ball mills
SOUND 2 PREMIUM : Next-generation electronic ear, digital listening for industrial dosing processes
SOUND 2 PREMIUM is a next-generation digital electronic ear. This unique electro-acoustic transducer incorporating significant technological advances can measure the noise level of a ball mill with unparalleled accuracy. The SOUND 2 PREMIUM digital listening solution includes an ultra-precise measurement system, and its algorithms are much more effective than the devices currently available on the market.
Designed with an LCD screen for supervising the data in real time, this digital listening equipment is the ideal solution to optimise your productivity. This unique electronic ear for continuous processes was entirely designed and created by HASLER Group.
An entry-level version of this latest-generation electronic ear is also available. Discover the SOUND 2 ADVANCED.
Technical sheet
ADVANTAGES OF THE SOUND 2 PREMIUM ELECTRONIC EAR
LATEST-GENERATION TECHNOLOGY
This unique digital electronic ear maximises the effectiveness of your ball mill for unrivalled improvements to the performance of cement processes.
PREMIUM DIGITAL ACCURACY
The signal from the microphone is processed in real time to ensure greater accuracy in data measurement and analysis.
BUILT-IN PREDICTABILITY
The digital signal processors (DSPs) simplify filters by providing predictable, highly reproducible results, which are characteristic of digital circuits in comparison to analogue circuits.
INTEGRATED CROSSTALK COMPENSATION
SOUND2 PREMIUM incorporates a crosstalk compensation system to eliminate noise interference from adjacent mills (see image above).
VERSATILE COMMUNICATION PROTOCOLS
This digital electronic ear offers flexible configuration thanks to its compatibility with multiple communication protocols, facilitating the transfer of measurement data (Modbus TCP, Modbus RTU and Profibus DP) or the provision of analogue data output (0/4 … 20 mA)
REAL-TIME VIEW
Display of personalised information, such as fill level, in real time on a digital screen, providing greater visibility and accuracy.
PLUG & PLAY INSTALLATION
The system incorporates an auto-calibration function to simplify commissioning. This enables faster, more efficient commissioning and backup of the configuration to an SD card for quick product replacement.
ENERGY OPTIMISATION
Opting for the SOUND 2 PREMIUM electronic ear significantly reduces power consumption per ton of product processed
LONG LIFE
HASLER Group’s digital ear for ball mills is specially designed to withstand dusty environments and meet the needs of applications in harsh environments.
PROVEN RELIABILITY
Thanks to the expertise of HASLER Group, which has been designing and installing electronic ears to ensure the performance of the biggest cement players for more than 35 years.
APPLICATIONS OF THE SOUND 2 PREMIUM ELECTRONIC EAR
The SOUND 2 PREMIUM digital electronic ear is a device that measures sound to indicate the fill level in ball mills, which are widely used in:
CEMENT INDUSTRY
Cement, building materials…
MINING & MINERAL CHEMISTRY
Minerals, ceramics, ores…
FERTILIZER INDUSTRY
Phosphates, fertilisers…
FINE CHEMICALS
Varnishes, colours…
DESCRIPTION OF THE SOUND 2 PREMIUM ELECTRONIC EAR
The SOUND 2 PREMIUM digital ear for ball mills consists of a microphone and a front screen incorporating software with advanced control algorithms. This robust solution is specially designed to fulfil the rigorous requirements of cement applications in several ways:
/ The microphone head is positioned 4–5 cm from your mill and is protected by a fine mesh covered with a thin plastic film over the foam layer.
/ The microphone is insulated from background noise in the factory, ensuring accurate data acquisition.
/ The front screen has a waterproof cover, preventing dust from getting in and guaranteeing a faithful response from the electronic ear regardless of any disturbance.
Key features:
/ Acquisition and processing of the digital sound signal
/ LCD display (HMI)
/ Automatic calibration
/ Host reading and communication (remote control)
/ Adapts to the material to be ground
/ Compatible with the previous Sound 1 electronic ears
/ IP65 metal body
/ Multilingual interface
Controller:
The system incorporates an auto-calibration function to simplify commissioning. The digital outputs are flexible and user-configurable. In addition, the fill level can be viewed directly on the LCD screen. This solution offers the possibility of accurately filtering the sound signals emitted by the ball mill, enabling a high level of accuracy to be achieved in the measurements made.
Easy configuration and maintenance:
/ Maintenance can be performed by the web server
/ The calibration parameters can be stored on an SD card
/ Settings can be restored from an SD card
Crosstalk compensation:
/ The Sound 2 PREMIUM electronic ear compensates for interference noise from adjacent mills.
/ The crosstalk compensation is adjustable between 0 and 17%.
/ A 0–6 V signal (independent of the monitor configuration) is used to correct the information from the other ear. This signal is called CT OUT, an abbreviation for “CrossTalk OUTput”.
Installation:
The SOUND 2 PREMIUM microphone is designed for plug & play installation on the ball mill.
The mill control system consists of a very sensitive microphone installed near the outlet from chamber 1 of the mill, at the point of impact of the grinding balls and as close as possible to the housing of the mill. The foam on the digital electronic ear should almost touch the housing of the mill.
Technical specifications
/ Setting level : 0dB to 45dB
/ Operating frequency range : From 300 Hz to 4500 Hz
/ Customer voltage output : 0 … 10 V, minimum load of 1 kΩ
/ Customer current output : 0/4 … 20 mA, maximum load of 600 Ω
/ Humidity : Complies with DIN40040 class F 95% at 25 °C with no condensation
/ EMI tolerance : ±2 kV for signals, ±4 kV for the 220 V AC power supply
/ Case dimensions : Width 256 mm, height 270 mm, depth 118 mm
/ Ingress protection : IP65
/ Weight : 2900 g
/ Power:
88 V AC up to 264 V AC.
Frequency: 47 Hz to 63 Hz
/ Temperature:
In operation: -10°C to + 50°C
Storage: -30°C to +70°C
/ Relay contacts:
Switched max. current: 2 A, AC
Switched max. voltage: 24 V DC, 250 V AC
Switched max. power: 125 VA (48 VA)
/ Certification:
General electrical emissions: EN50081-2
General electrical immunity: EN50082-2
Electrical safety: EN61010-1
An entry-level version of this latest-generation electronic ear is also available. Discover the SOUND 2 ADVANCED.
HASLER Group global support services for dosing solutions
In order to improve the efficiency and availability of your industrial dosing systems, our specialists offer you a full range of services, including:
/ Technical audits, industrial process audits and laboratory tests.
/ On-site services, such as assembly, commissioning, servicing and preventive or corrective maintenance, with or without remote assistance.
/ Supplies of material tests, simulations and dosing precision tests.
/ Revamping, retrofit or upgrade services aiming to:
- Increase the reliability of your dosing equipment and manage the obsolescence of SCM/RMS automation.
- Improve your processes by adapting them to new flow or material constraints or production defects (clogging, fusing, precision) and by adapting their operating range (speed 1–100%).
- Optimise your mechanical equipment, especially in terms of abrasion resistance (belt).
/ Training modules on your solutions to strengthen the skills of your maintenance and production teams.
/ Comprehensive support to advise you and provide you with spare parts including:
Controllers
Electronic cards (I/O, communication, etc.)
Display and programming consoles
Weight sensors (digital and analogue)
Mechanical components (rollers, drums, extrusion screws, etc.)
Rubber belts
Metal weighing elements
Speed measuring devices (encoders, measuring wheels).