MillScan G4

MillScan G4 is a unique tool for instant and accurate measurement of the fill level of ball mills.

Developed by Digital Control Lab (technology partner of Texas Instruments since 1990), uses the latest technology in Digital Signal Processing (DSP - Digital Signal Processing) to obtain measurements in real time.

The MillScan G4 is an excellent tool to automatically control the mill due to the high signal reliability and real time response of any small change in the mill.


  • Precise mill fill level measurement that can be used to increase the ROI of your existing mill.
  • Zero crosstalk from adjacent (nearby) mills.
  • All digital system, no component drift, not affected by temperature, dust or dirt as is the case in typical mic based systems.
  • 4-20mA output for traditional automated loop control in the production control room.
  • 3X resolution when compared to microphone based systems.
  • Fast and easy installation that typically can be performed in less than two hours and does not require mill shutdown.
  • A quick calibration procedure that can be perfomred in less than 5 minutes when the mill is operating under normal conditions. i.e. The mill is filled to a level that is used in normal 'day to day' production.
  • Signal sensitivity changes can be made very quickly without re-calibrating the unit.

All the counters can have interface with the PLC, which can be a

  • Digital signal – Detected a known consumption of energy (eg. 1KW);
  • Analog signal – Normally providing flows or instantaneous consumption (eg. compress air flow);
  • Fieldbus communication – Providing consumption informations and others (eg. quality parameters).

The price of the overall solution must take all these informations from the client.

System Components

The G4 consists of a main unit and a custom vibration sensor. The vibration sensor is magnetically mounted on the side of the bearing housing closest to the chamber desired for monitoring. The vibration sensor cable is 10 meters (~30 ft.) long and is shielded.

The main unit requires AC power (100-220 VAC, 50/60 Hz) and has a 4-20mA output that corresponds to the mill fill level. An optional USB cable and PC can be attached to view vibration spectrums but is not required for system calibration.