The Ovality Sensor is a measurement tool for rotary kilns, which measures the changes of the roundness / curvature in the kiln shell during operation. This elastic deformation is called Ovality and is primarily present in the area of a kiln tire. The measurement gives accurate information about the degree of mechanical loads in the refractory / kiln shell and allows defining the countermeasures in advance to increase the lifetime of the kiln components. The Ovality Sensor is small, easy to use and comes along with a tough transport case.
The Ovality Sensor consists of a Deflection Plate, which will be attached with heat resistant magnets to the kiln shell close to a tire. Due to the strong magnetic connection, the deflection in the Deflection Plate follows the deflection of the kiln shell below. Strain gauges are measuring the deflection in the Deflection Plate. The electronic converter is amplifying and conditioning the signals from the strain gauges and sending them together with the values of the angle position sensor via Bluetooth connection to a laptop. The software TomTom-Tools Measurement Studio (for Windows), which comes together with the measurement tool is made to receive, store and process the values from the Ovality Sensor. During the measurement, the values are displayed and calculated directly in real time. There are different display, zoom and report printing options available.
The Measuring Wheel is a measurement tool, which measures the diameter of slow rotating cylinders during operation; for example on support rollers or tires on rotary kilns or dryers. These components are typically subject to a certain amount of wear and have to be re-machined or replaced after some time of operation. In order keep the kiln or drier axis aligned; it is essential to know the changes of the diameters and to compensate them by adjusting the roller positions. By measuring the diameter at various positions along the width of a support roller or tire, its cylindricity gets known, which helps to define the corrective action in case of deviations. The Measuring Wheel can be considered as a caliper to measure diameters of huge rotating cylinders.
The Measuring Wheel kit consists of three main components, the wheel itself with the integrated rotation encoder, the heat resistant light barrier sensor to indicate the rotation of the item to be measured and the controller which calculates and displays the diameter. The wheel with the diameter of 176mm is running without slippage on the surface to be measured (e.g. support roller). During each wheel revolution 1760 electrical impulse are sent to the Wheel Controller which is counting them. With the help of a magnetic switch flag attached to the side face of the support roller or tire, the light barrier sensor provides each revolution an electrical impulse to the Wheel Controller. This revolution impulse starts the counting of the impulses coming from the wheel encoder. After one revolution of the support roller or tire, a new impulse from the barrier sensor is stopping the counting, the diameter value is displayed and immediately the next measuring cycle is started. With each revolution the diameter value is refreshed whereupon the last reading appears at the lowest of the three rows in the display. The second and the third row show the previous readings.
IDM Tool Kit
The inductive distance measurement tool is a device, which measures the distance or change of any distances contact less on any running equipment. It measures distances in vertical direction to any metal surface with a high accuracy, which replaces basically the traditional dial indicator and allows to measure on not cleaned surfaces during operation.
Inductive sensors use the physical effect of the change of quality of a resonance circuit, which is caused by eddy current losses in leading materials. A LC-resonant circuit produces a high frequency alternating field. This field withdraws at the active surface of the sensor. If an electrically conductive material arrives into the field, then eddy currents occur according the induction law which extract energy from the resonant circuit. The peak-to-peak swing becomes smaller. This change is converted into a switching signal. From the operational principle it follows that all metals are seized – independently of whether they move or not.
Kiln Shell Laser
The Kiln Shell Laser is a measurement tool, which measures the deformations in rotary kilns or dryers or other slow rotating cylinders during operation. The tool can be used to measure just one cross section, a specific area containing a few cross sections of interest or the whole kiln to get the full picture. The steel shell of rotary kilns is exposed to high temperature. In case of excessive heat the shell might deform. In areas with deformations the refractory installation becomes typically difficult, which has a negative impact on its lifetime.
To measure the shape (roundness and eccentricity) of the shell, the Kiln Shell Laser is placed along the rotating kiln and measures continuously the distance to the shell surface. Deformations result in changes of the distance and will be recorded by the laptop PC, which is connected via Bluetooth with the laser. From each measured position a graph with the cross-section of the kiln is generated. Several measurements along the kiln can be combined in the software to a full 3d graph. The 3d graph shows the severity of the deformations in different colors. It is a great help to identify the areas where special attention to the refractory is required. In case of reduced refractory life time, due to shell deformation, the software helps to decide, which shell sections need to be replaced.
The Rotary Inclinometer measures the axle inclinations of slow rotating parts during operation on Rotary Kilns, Dryers, or Ball Mill. Its extremely high accuracy makes rotary alignments on units work much easier.
Kiln Axis Alignment System
The Kiln Axis Alignment system is used to determine any axis deviation on a kiln or dryer or any other slowly rotating, large cylinder. The system can be used whether the equipment is in operation or shut down. The shell of a rotary kiln is exposed to elevated mechanical stresses which can cause misalignment. In the case of excessive deviations, the shell might suffer from circumferential cracks and in extreme cases, kiln collapse.
Mechanical Monitoring System (MKM-System)
The MKM-System is an on-line measuring unit used to detect abnormalities during kiln operation which can lead to mechanical failures on any rotary kiln system (with more than 2 Stations). The main objective is to detect such abnormalities (thermal or permanent kiln cranks, lack of tire play) at an early stage.