Inductive Distance Measurement (IDM) Tool Kit
Contents
1. Mild Steel 1 Stainless Steel approx 0 5 Aluminum approx 0 4 Copper approx 0 3 Display Within operating range yellow permanently lit Outside the operating range yellow flashing Non flush mountable Wiring Note IDM Controllers before 2011 use Pin 4 for input signal they can be re wired internally if required Page 7 Juli 4 2011 2 2 Features The power for the sensors is taken from the USB port of the PC and transformed to 24VDC The green light LED is indicating when these 24V are available on the four sensor plugs The sensors are also equipped with LEDs near their plugs which indicate the function of the sensor A constant light indicates that the sensor is working and is in normal range A blinking light shows that the sensor is out of range This means that the surface to measure is too far away or too close to the sensor 3 SOFTWARE 3 1 Installation There are two software components required to be able to run the IDM Tool on the computer Step 1 IDM Drivers Runtime Engine from National Instruments File name NIDAQ922f0Core Install first this software component from the CD or download it from www tomtom tools com or from the National Instruments website 160MB Step 2 TomTom Tools Measurement Studio The software which is used for the IDM Tool Kit and all the other TomTom Tools comes also along with the equipment on the CD Nevertheless it is recommended to install the soft2. Typically the manhole in the kiln shell is used as reference point Each time when this reference point is passing the direction of the measured roller push the button F9 to indicate the kiln rotation A yellow line in the graph will show the position of the reference point i 2011 01 15 Roller Shaft Bending 3 tms TomTom Tools Measurement Studio A Hide Unhide B x File Measurements Reports Window Help Curves i gt od Measured Signal fe 8 Events El Measurements Roller Shaft Bending Curve Heference Line when F9 was pushed Piers Roller shaft bending measurement starke Roller shaft bending measurement stopp Plant Name Kiln Number Measured by Date 15 01 2011 Tool ID Ho 20836 Remarks Kiln iz in normal operation 0 09mm Peak 167 14 Ton Channel 1 Scaling Sensor Physical Channel 12mm Drev al Am und Edi Roller Shaft Position Bending Value of Crank The green curve shows the measured values The blue curve is sinusoidal and shows the variation of roller shaft bending coming from a crank in the kiln shell The red curve indicates the roundness of the support roller and is the difference between the measured curve green and the shaft bending curve blue After about 3 kiln revolutions sufficient data are collected and the measurement can be stopped To stop the measurements push the Stop button or F6 e Page 19 J
3. Help Overview T IDh Tool Settings E Events 7 Connected to Deva USB 9201 Measurements E Bevery A _ Add Channel Channel M IDM Tool connected Sampling Bate 10 Hz change ETT TITTEN Lini xj Please enter a sampling rate in the range of 0 01 Hz 1000 Hz Sampling Rate Hz 10 00 OR Cancel Attention In case the sampling rate is tool low while measuring tooth wheels on the tooth tip the results will not be useful Adjust the sampling rate to min 5 times the gear mesh frequency e Page 13 Juli 4 2011 5 DISTANCE MEASUREMENT 5 1 Purpose The Distance Multi Channel application is general and multipurpose to measure distances with the inductive sensors which are included in the tool kit Any kind of other sensor with an output of 0 10V or 0 20mA with additional Signal Converter can be used and displayed as mentioned in Chapter 4 This application is typically used when measurements have to be taken where no specific application is available in the Measurement Studio The values are directly displayed in the screen where different zoom functions can be used For further analysis the data can also be exported to Excel 5 2 Starting the Software Application To start it click Measurements New IDM Distance Multi Channel 12011 06 04 Distance 1 tms TomTom Tools Measurement Studio Reports Window Help b Ovality Inclination 0M gt j A
4. Signal Radial Gear Runout Polar Diagramm lt Title gt Plant Nama Radial Measurement Kiln Mumber Eecentricity 288mm Mas at 571 Haundness Deviation 4 25mm eee a a Scaling Sensor a30mm Physical Channel arl Meas Value mm lj Roundness Flt aN Axial Measurement of Gear Eccentricity 423mm Max at 292 Houndness Deviation 5 2mm B sl ami 0 Channel 2 Axial Run Out 2 g3 mm Physical Channel ai Meas value m Straightness Edit z gt Wobbling of Front Face e Page 24 Juli 4 2011 The green graph shows the measured values from the radial sensor Jw The green curve is the calculated sinus from the radial readings The blue graph shows the measured values from the axial sensor SS The blue curve is the calculated sinus from the axial readings After about 3 kiln revolutions sufficient data are collected and the measurement can be stopped To stop the measurements push the Stop button or F6 7 5 Results The Results are shown as graphs in the graph window and as numbers below The radial run out can also be seen as polar graph click Radial Gear Run Out Polar Diagram Note TomTom Tools Ltd does not provide guide lines about acceptable run out limits It has to be according to the equipment manual or discussed with the suppliers how much run out and roundness error can be allowed Out of experience the following table can be taken as an example for kiln girth g
5. surface type In case of measuring the run out on tooth tips click on the left button this activates the measurement filter which will hide automatically the not useful measurement points between the teeth For evaluation this filter function can also after measuring be activated and deactivated See the green bar which indicates the Sensor Distance gap between measured surface and sensor It should be approximately in the middle of the sensor range at least never go to one of the extreme positions unless between teeth where the distance is out of range Attention For measuring tooth wheels on the tooth tip adjust the sampling rate to min 5 times the gear mesh frequency See also chapter 4 4 2011 06 04 Gear Runout 1 tms TomTom Tools Measurement Studio DE Ox File Measurements Reports Window Help p o Overview l Messages u Measured Signal H Measurements E eee eee ree ere eee teeter ree etree etree etree etree tre tty i Devices Switch to Polar View Radial Sensor Distance Radial Gear Runout Polar Diagramm oF 00m 4 00 n Surface Type Switch radial Measured Signal Remark EME EIA Fields Radial Measurement Eccentricity mm Max at Houndness Deviation mm eis IDM Tool Meas Settings a e no virtual channel set Scaling Physical Channel Meas Value Edit Plant M ame Kil Number Measu
6. Extras X IDM Tool connected The computer screen will show the graph window with the empty sensor window below Software for Distance Measurement 2011 01 02 Roller Shaft Bending 1 tms TomTom Tools Measurement Studio File Measurements Reports Window Help E m V Ovewew R E Measurements B Devices Graph Window Remark Fields IDM Tool Meas Settings Lo FA Plant Name Kiln Number Measured by Date 02 01 2011 se Tool ID No Remarks Tool Si li a 5 P al C Umm caling Sensor hysical Channel r el2mm Dev3 ail Meas Value 1 4 mm Edit 4 a k Sensor Input Sensor Type Cannel Distance Edit Add Channels e Page 14 Juli 4 2011 To add a sensor channel click the button Add Channel see picture above Select an existing scaling or create a new one as described in chapter 4 3 See the green bar which indicates the Sensor Distance gap between roller surface and sensor 5 3 Take Measurements To start the measurements push the Start button or F5 Js 7011 01 02 Roller Shaft Bending 1 tms File Measurements Reports Window F LuRRSsRARRRRRRRRESESERSERESESRRREERERISESERESERSERRERERESEEESEREEREREERESEREERSEESERERRERERENSESSENSE B Devices 2 IDM Tool connected After starting the measurement the values will appear on the computer screen Eac
7. TomTom Tools GmbH Phone 1 41 79 774 06 42 Wiesenstrasse 15 Phone 2 41 79 774 06 44 5400 Baden Info tomtom tools com Switzerland www tomtom tools com User Manual Draft Version Inductive Distance Measurement IDM Tool Kit 1 INTRODUCTION The Inductive Distance Measurement IDM Tool Kit is a multi purpose measurement tool Typically it is used to check the condition of rotating parts during operation e g on Rotary Kilns Dryers Ball Mills It measures variation of distances of moving metal surfaces without contact typically steel Surfaces with high accuracy and high speed up to 1000 measurements per second It can be considered as a contactless dial gauge Typical applications e Run out measurement of girth gears on rotary kilns rotary dryers and ball mills e Run out measurement of kiln tires e Roller shaft bending measurement of support rollers on rotary kilns e Shaft movements in gear boxes and drives e Roundness and run out check of trunnions on ball mills More applications The control box in the tool kit can be used for any kind of sensor with an output of 0 10V Signal Converters are available which allow also to measure signals with 0 20mA included in kit from July 2011 Hence there are much more applications possible E g e High speed hydraulic pressure measurement on vertical roller mills and roller presses e Shell deformation measurement on rotary kilns or ball mills with laser distance sens
8. away from the pinion to avoid items get caught between Axial Sensor K y Radial Sensor on tooth tip e Page 21 Juli 4 2011 Sensor Size In this application it is also recommended to use the smallest possible sensor to have the highest accuracy Unfortunately often is the sensor range not sufficient hence a bigger sensor with more range has be used especially on kilns Note The surface which gets measured has to be bigger than the sensor diameter in order to get the correct distance value see picture below On small surface use small sensor otherwise the error has to be evaluated case by case and corrected in the sensor scaling Correct induction field E Too big induction field Girth Gear I Kiln 2 Girth Gear y Kiln fil amm Sensor E T e Page 22 Juli 4 2011 7 3 Start The Software Application The Measurement Studio includes a specific application to measure and calculate the run out of gears It can also be used for measuring the axial run out of kiln tires To start it click Measurements New IDM Gear Runout 2011 06 04 Distance 1 tms TomTom Tools Measurement Studio Reports Window Help ality Inclination Roller Shaft Bending Bes lags E En is pm S Distance Multi Channel The computer screen will show the graph window with the value window below Both types of measurements radial and axial are equipped with two buttons to select the
9. d a new scaling can be created by selecting lt New gt If a pressure sensor flow meter or temperature probe is connected just replace the unit mm to bar or C or any kind of unit AAA Name Enter scaling name Scaling Parameters 12r Inclination y Olfset 104 Se Senet A Xam 1 00 0 00 c E Equation E y 2 1 00 x 0 00 Unit Unecaled Scaled ler il re i o 4A e d i a i 2 s d eo S B S o1 vult Malt mm OK Cancel e Page 12 Juli 4 201 1 4 4 Sampling Rate Frequency Adjustment The sampling rate is the numbers of measurements which are taken within one second hence the unit is Hz Hertz It is important to adjust the sampling rate to the measurement application In case of fast changing signals e g run out measurement of a kiln girth gear under full speed the frequency has to be high to catch each tooth tip e g 100Hz In case of slow changing signals e g kiln support roller shaft bending the frequency can be low e g 10Hz because the interesting value varies only once over one complete kiln revolution Of coarse slow applications could also be measured with a high sampling rate but then unnecessary big data files would be created Some guidelines about the adequate sampling rates are also given later in the chapters of the different measurement applications ll TomTom Tools Measurement Studia x File Measurements Reports Window
10. e position hence the peak angle will stay more or less same within 309 at least in the same quadrant of the kiln In case of indication for a permanent crank it is recommended to perform the roller shaft bending measurement also in cold kiln condition 2 revolutions with auxiliary drive to be sure no thermal effect is taking place e Page 20 Juli 4 2011 7 GEAR RUN OUT 7 1 Measurement Principle Most rotary kilns and many ball mills are driven by open gear drives pinion and girth gear Due to difficulties during the installation or later during the operation the girth gears might do not run concentrically nor straight The so called axial and radial run out can be measured both in the same time with the IDM Tool Kit during normal operation e Radial Run Out Results in a change of centre distance and affects the tooth engagement it is measured on the tip of the teeth e Axial Run Out Affects the load distribution over the tooth width and is measured on a machined side face of the girth gear or on the side face of the teeth 7 2 Place the Sensor To measure the axial and radial run out two inductive sensors typically 218mm are placed somewhere on an inspection window in the girth gear cover where is access to the tooth tip and to a machined side face of the girth gear See pictures below Safety first see page 3 Never place sensors where the teeth are engaging place them always on the out running side or far
11. ears but might need to be adjusted to the specific case Rada _ ROOBBMo o75m ha jROUISD 025 0000975D 025 M Module mm D Gear Diameter mm 8 REPO RT i s 2010 07 28 Test Ems TomTom Tools Measurement Studio Measurements Reports Window Help Open 8 1 Export to Excel Save Save AS Export to Excel Exit All data can easily be exported to excel Fig 8 1 1 8 2 Create a report The measurements can be extracted into a report All additional information from Setting Window is included in the report as well h 2010 07 28 Test tms TomTom Tools Measurement Studio File Measurements Reports Window Help Fig 8 2 1 pre El Measurements Create a report For the currently selected measurement a i Devices TomTom Tools Ltd Switzerland www tomtom tools com info tomtom tools com
12. h channel has its own curve with its own color The lines can be hided or displayed by clicking to the tick mark To stop the measurements push the Stop button or F6 To extract the data in to Excel click File Export to Excel 2011 06 04 Distance 1 tms T Reports Measurements Open Save Save AS Export to Excel he Close Exit e Page 15 Juli 4 2011 6 ROLLER SHAFT BENDING 6 1 Measurement Principle On a kiln support roller the variation of the deflection of the roller shafts show possible cranks in the kiln shell Cranks are straightness errors in the kiln shell which are affecting the loads on the roller stations with each kiln revolution There are two types of cranks e Permanent Mechanical Crank Caused by plastic deformations in the kiln shell or errors during the kiln construction e Thermal Crank Caused by uneven temperature distribution thermal expansion around the kiln shell circumference most severe close to the middle tire The load changes caused by cranks can be very strong and overload the tires and rollers which results in cracks in tires rollers and roller shafts The crank pushes the roller down hence the distance between the sensor and the roller surface is reduced Half a kiln revolution later the crank turns up and the load gets reduced on this station hence the distance to the sensor is getting bigger 6 2 Place the Sensor To meas
13. mpaigns and might need to be adapted to the local safety requiremenis Caution Pinching Points Do not put your hands nor any items close or into pinching points e g girth gear pinion kiln tires support rollers Keep safe distance to avoid getting caught by moving parts For gear run out measurements never place sensors on the side where the teeth are engaging place them always on the out running side to avoid the items get caught between Magnet Fields Be aware of the strong magnet field of the magnet stands Keep the tool away from people with pace makers or any other sensitive item as credit cards or magnetic data carrier Clamping Do not put fingers between the magnets and magnetic surface There is the risk for clamping or pinching due to the strong magnetic force Gloves Wear proper gloves to protect your hands from hot and rough surfaces and sharp edges Page 4 Juli 4 2011 1 2 Measuring Principle The Too Kit is equipped with different inductive distance sensors This sensors use the physical effect of the change of a resonance circuit which is caused by eddy current losses in conductive materials A resonant circuit produces a high frequency alternating field This field withdraws at the active surface of the sensor if an electrically conductive material enters the field The eddy currents occur according the induction law which extract energy from the resonant circuit This energy value
14. n devices for TomTom Tools If a TomTom Tool is detected it will be displayed in the Overview Window under devices Fig 4 1 1 Device Window Bi TomTom Tools Measurement File Measurements Reports IDM Controller is connected when TN Measurements displayed here E Devices 4 2 Adding a Channel When the software is opened the input channels have to be added in the software in order to get the physical signal from the IDM controller input to the software This can be done on the tool page see picture below or also later when a specific measurement application is opened ii TomTom Tools Measurement Studio HE El xj File Measurements Reports Window Help ere Everts eee Events A pe pa Connected ta Dev3 USB S201 B Deiter eatin eM tool connected Sampling Rate 10Hz To add a channel To change the sampling frequency e Page 9 Juli 4 2011 4 3 Adding a Sensor Scaling The four inputs of the IDM Controller measure 0 10V which correspond to the measurement range of the sensors Hence each type of sensor needs its scaling which describes the relation between sensor distance and voltage output The scalings of the sensors which are included in the IDM Tool Kit are already defined in the software and can be selected as nowy in 1 the picture below E TomTom Tools Measurement pr NE E i E x File Measurements Reports Window Help lt Basi
15. ors e Verification of values of any installed sensor output signal directly on site 4 July 2011 e Page 2 Juli 4 2011 TABLE OF CONTENT 1 INTOdUCHON e Deme 1 1 1 sog uev A P R 3 1 2 WIGASUEING Principle saian acacia ia 4 1 3 TOOrKITINCUJO Sin I t I E 5 2 TING Sensors pee 5 2 1 OMPOMCINS m e a aid 5 2 2 ESOS upload did 7 3 nn A 7 3 1 o A ee ee eee 7 4 Start the TOO A 8 4 1 Connect IDM Controller with PC ccccccccsssccsssseccssseeeessseeeeseeeessaeeeessseeeesseeeeeseeeessseeeesees 8 4 2 Adang habiles iunc aca istos Soles canit as 8 4 3 Adding a Sensor Scaling esos topo Deo at ERE RO G 9 4 4 Sampling Rate Frequency Adjustment cooococcnocccnnococcnooooncnnoonnnnononnnononnnnnnnnnoncnanoncnns 12 5 Distance Measurement di 13 5 1 PUNMDOS 6 pati ta 13 5 2 Starting the Software AppliCatiON ccooccccnnoccncononcnoooonnnnonononcnnnnnnononnncnnnnnnncnnnnncnnnnnnnns 13 5 3 Take Measurements ccccscesssssseceeeeeeeecessesseeeeeeceeeecessesseeaeeeseeeeeeessesssesssseeeeeeeessssssssaaes 14 6 Roller Shaft Benne p E 15 6 1 Measurement Principle cccccccsssssssceeesssseeceeeeecsssenseceesesseneeseecesessenseeeesesssssnseeeeeesseess 15 6 2 Place Me SCMSOM MN ND EI T TU E PR 15 6 3 start The Software ADDIICAtOItus ues ita outer as to eut 16 6 4 Take Measurements cccescesssss
16. red by Axial Measurement Date 04 06 2011 Eccentricity mm Max at 7 Haundness Deviation mm E H Surface Type Tool ID No E E Switch axial Remarks no virtual channel zet Scaling Physical Channel Meas Value Took El ff Sensor Input Axial Sensor Edit Sensor Type Cannel Distance Settings Edit e Page 23 Juli 4 2011 7 4 Take Measurements To start the measurements push the Start button or F5 j 2011 06 04 Gear Runout 1 Em File Measurements Reports After starting the measurement the values will appear on the computer screen green curve Note To be able to calculate the run out value and its position the software needs a reference signal when the reference point is passing the sensors position Typically the manhole in the kiln or mill shell is used as reference point Each time when this reference point is passing the position of the sensors push the button F9 to indicate the rotation A yellow line in the graph will show the position of the reference point 1 2011 05 18 BE Gear Runout 4 tms TomTom Tools Measurement Studio E Nic File Measurements Reports Window Help Hide Unhide U curves C m NEUEM uu eee udi Axial Sensor Signal blue E e en du JE d em cj uu uunupnges 4osuas elxg ce nr a Mi n ur m a m na 1 1 1 E M HL Radial Sensor Signal green Switch to A Polar Graph Measured
17. s S Reg CCE EA p Measurements Devices Connected to Dev3 058 9201 Add Channel Channel 5 DM Tool connected Sampling Rate 10 Hz J NiDAQmz Channel Channel Name Channel 1 Physical Channel GE Channel 1 ail Scaling No ala New a Sensor 40 40rmm Sensor al mim ancel Senso al 8mm Sensor a3lmm I Scaling Sensor 012mm Range 0 4 4mm M ame Sensor al mr Scaling Parameters Inclination v Liffset lo 3b o 40 E Equation E y 0 36 x 0 40 Unit Unscaled Wolt mm OF Cancel e Page 10 Juli 4 2011 Scaling Sensor 018mm Range 0 8 8mm Scaling ni xi Mame Sensor al mm Scaling Parameters 10 Inclination y Olfset 8r 0 72 0 80 Equation y 0 72 x 0 80 Unit Volt Volt mm Scaling Sensor 030mm Range 1 15mm Scaling nix Mame Sensor galmm Scaling Parameters 207 Inclination y Olfset Equation y2140 2 1 00 Unit a rz 4 5 E 7 E d 1n Unsealed Scaled Walt Volt mm e Page 11 Juli 4 2011 Scaling Sensor 40x40mm Range 1 25mm Mame Sensor 4mm Scaling Parameters Inclination y Offset 240 1 00 Equation yz2407841 00 IE Unit 5 E 55 E E E 10 Unscaled Scaled Vult Wolt mm OK Cancel Create a new Scaling If an other sensor with output 0 10V has to be connecte
18. s are transformed internally into the 0 10V industrial standard analog output signal The signals of maximal four sensors are measured by the IDM Controller which converts them into a digital signal and sends it via USB port to a PC 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 IDM Controller There are already 3 types of applications available in the software e Raw Data Acquisition In this mode the data are one to one displayed in real time on the computer screen e Roller Shaft Bending Measurement This application is used on rotary kilns with 3 or more stations It calculates automatically the variation of shaft deflections which are caused by a crank in the kiln shell e Run Out Measurement The application is calculating automatically the radial and axial run out eccentricity and roundness of rotating parts typically girth gears kiln tires and mill trunnions Measurement of Roller Shaft Bending Y 1 7 Re Measurement of Girth Gear Run Out Measurement of Girth Gear Run Out e Page 5 Juli 4 2011 1 3 Tool Kit includes The IDM Tool is coming as a tool kit in a strong and tight transport case which includes the following items 1 IDM Controller With four input channels 0 10V and an integrated 24VDC power supply for the sensors fed via USB 2 Inductive Sensors 2 Sensors 212mm 2 Sen
19. seceeeeeeeesessesscseeeeeceeeesesseseceaeeeceeeeesesseseseseasseeeeeeesesssssseaes 17 6 5 Interpretatio OF nestle 19 T Gear RUN OUN sioria a 20 7 1 Measurement PARC unir n 20 7 2 Place SO vrs 20 7 3 Start The Software Application cooococonocccncoocccnnooononononcnonnnnnnnnonnnncnnnnnnnnnnnncnnnnnncnnnnnnnns 22 7 4 Fake Me ase m iS T M 23 7 5 e Un 24 8 PROPS OM e 24 8 1 FIO TO CS aceasta ech ia 24 8 2 Create a repor odes dash A A M 24 e Page 3 Juli 4 2011 1 1 Safety Rotary kilns dryers and mills where this tool typically is used are huge rotating equipments with many pinch points they can cause serious injuries Therefore only specialized and trained personnel shall work close to these machines To use the tool follow strictly the local safety rules given by the respective plant factory local authorities and discuss the application with the safety engineer in charge The tools provided by TomTom Tools GmbH have proven their functionality in various applications nevertheless TomTom Tools GmbH does not take any responsibility for the application on site regarding safety The plant is responsible for the safety according to the local law in a way that nobody can be hurt or injured The application and safety instructions below are guidelines and not exhausted which include the experience from previous measurement ca
20. sors 218mm 2 Sensors WM30mm 1 Sensor 4x40mm 3 Sensor Cables with 2 and 5m length 4 Magnet Stands Including connectors extension rods and sensor holders 5 Dial Gauge for reference measurements 6 Magnetic switch flag with heat resistant magnet up to 300 C and extension rods 7 Transport Case with foam cushioning extra tough water and dust seal suitable for air cargo 8 Manual and Software for Windows in lid TomTom Tools Measurement Studio 9 Signal Converter transfers 0 20mA signals CD into 0 10V 2 pcs included from July 201 1 2 THE SENSORS Magnet Stand 2 1 Components Magnetic Inductive Sensor Suck Flag AAA S Cotroller Magnet Stand De Saw 2 Inductive Dial Gauge Sensors USB Plug to connect to PC IDM Controller with 4 input channels e Page 6 Juli 4 2011 Inductive Sensors Any sensor with 0 10V output on Pin 2 can be connected to the IDM controller maximal power consumption of all connected sensors together 100 mA 24VDC IFM Sensor D12 IFM Sensor D18 IFM Sensor D30 IFM Sensor 40x40 0 4 4mm 0 8 8mm 1 15mm 1 25mm Diameter 12mm_ 18MM 30MM 40x40mm 70 66 i intercept L 04 08 4 IO 4 Temp Coefficient 10 of UA max 5 of UA max 5 of UA max 10 of UA max 25 70 C 25 70 C 10 of UA max 70 80 C Temperature 0 10VDC analog 15 30VDC 20 mA yes IP 67 Correction Factors
21. the green bar which indicates the Sensor Distance gap between roller surface and sensor It should be approximately in the middle of the sensor range at least never go to one of the extreme positions e Page 17 Juli 4 2011 Software for Roller Shaft Bending Measurement 2011 01 02 Roller Shaft Bending 1 tms TomTom Tools Measurement Studio File Measurements Reports Window Help lp ma V Overview 1 v Measured Signal 0 v 8 j E Montonen O d p IDM Tool connected Select the roller to measure Remark t Fields ES gt a Right Click to IDM Tool Meas Setings v7 add more piers Plant Name Kiln Number I Measured by Date 02 01 2011 v Tool ID No Remarks Tool Channel 1 Scaling Sensor Sensor Input Type Cannel Distance Edit Sensor Settings 6 4 Take Measurements To start the measurement select the roller on the computer screen and push the Start button or F5 pib 2011 01 02 Roller Shaft Bending 1 tms File Measurements Reports Window a Devices amp IDM Tool connected After starting the measurement the values will appear on the computer screen green curve e Page 18 Juli 4 2011 Note To be able to calculate the roller shaft bending value and its position around the kiln the software needs a reference signal when the reference point is passing the roller which is measured
22. uli 4 2011 6 5 Interpretation of Results To detect a crank on a 3 Station Kiln measuring the roller shaft bending on the middle station is normally sufficient And both rollers of a station should deflect in the same way Nevertheless it is recommended to measure both rollers on the middle station to double check the result Note TomTom Tools Ltd does not provide guide lines about roller shaft limits It has to be according to the equipment manual or discussed with the suppliers how much roller shaft bending can be allowed Nevertheless based on the experience of different kiln supplier the following guide values were established It has also been seen that the values are valid for small and for big kilns because the ratio between the load on the rollers and the dimensions is for all kilns similar Roller Shaft Bending Value gt z0 2m m gt 10 15mm 0 2mm Warning 0 0 15mm The position of the crank peak is indicated by the angle in deg relatively to the reference point on the kiln shell e g manhole For example the value 167 means that the peak of the crank is located 167 after the manhole consider the sense of kiln rotation Note The angle value of the crank peak is not important to judge the severity of a crank but it helps to find out if it is a permanent or a thermal crank Thermal cranks occur randomly hence the peak angle will change Permanent mechanical cranks stay on the sam
23. ure the effect of a crank an inductive sensor typically 212mm is placed under the support roller in the line of force That means on the opposite side of the contact to the kiln tire See pictures below Due to the high stiffness of the roller shafts these movements are very small within tenths of millimeter therefore it is recommended to use the smallest sensor of the IDM Tool Kit 212mm to have the highest accuracy By j La wy P A Lt 3 we t eam 3 a E Low Load Low Load High Load Low Load High Load A i i 4 i E 1 A 1 iV 1 1l i i f A i T Fi fae a if i FE I A I Pa ILL iF I s D T ma c bs e a gil Roller Low Not Loaded Inductive Sensor Inductive Sensor gap reduced gap increased e Page 16 Juli 4 2011 EN i Inductive Sensor 6 3 Start The Software Application The Measurement Studio includes a specific application to measure and calculate the variation of the roller shaft bending To start it click Measurements New IDM Roller Shaft Bending hil TomTom Tools Measurement Studio Window Help Oyvality Inclination DM Roller Shaft Bending 1 Add Channel Extras Distance Multi Channel 10 Hz Change The computer screen will show a kiln tire with two rollers top view To add more tires click right mouse button and select Add Pier see picture below See
24. ware from www tomtom tools com where always the latest version is available During any start of the Measurement Studio it is checking for updates if the computer is connected to the internet In case of available upgrades the user gets asked if they should be downloaded and installed wr d ib Downloads dd Home Downloads M Click to download lomlom lools Lt Manuals the Software easurement Studio Wiesenstrasse 15 CH 5400 Baden infoctomtom tools com Tomilom Tl SASS s Issisuranang Siudio Impressum Contacts m Name TomTom Tools Measurement Studio Login Version 2 6 3 186 Partners SOTA Publisher TomTom Tools s Downloads The following prerequisites are required Manual Downloads e Windows Installer 3 1 e NET Framework 3 5 Click to install Measurement Studo the Software If these components areAfready installed you can launch the application now Otherwise click the peftton below to install the prerequisites and run the application sl Done I LI 08 internet 100955 7 DM Drivers http Ju bambomtnals comi Measurement studio publish htm e Page 8 Juli 4 2011 4 START THE TOOL 4 1 Connect IDM Controller with PC After the software installation is completed connect the controller to the USB port of your laptop PC Note Do not use USB hubs or USB extension wires Whenever the Measurement Studio is started it will search for know
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