ovality sensor i manual - tomtom-tools · rimarily pres e degree of easures in lity sensor safety:...

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Juli 14, 2016

TABLE OF CONTENT 1. Introduction: .................................................................................................................................. 1

1.1 Safety: .................................................................................................................................... 1

1.2 Measuring Principle: .............................................................................................................. 4

1.3 Tool Kit includes: ................................................................................................................... 5

2. Ovality Sensor ............................................................................................................................... 6 2.1 Components: ......................................................................................................................... 6

2.2 Features: ................................................................................................................................ 6

3. Software: ........................................................................................................................................ 7 3.1 Bluetooth Adapter .................................................................................................................. 7

3.2 Software Installation: ............................................................................................................. 7

4. Start the Tool: ................................................................................................................................ 8 4.1 Connect Ovality Sensor with Laptop .................................................................................... 8

4.2 Signal from the Deflection Plate ............................................................................................ 9

4.3 Calibration of Integrated Orientation Sensor ........................................................................ 9

5. Measurements ............................................................................................................................ 10 5.1 Set Up the Measurement Window ..................................................................................... 10

5.2 Marking the Kiln Shell ......................................................................................................... 11

5.3 Place Tool on Kiln............................................................................................................... 11

5.4 Temperature Resistance .................................................................................................... 13

6. Report .......................................................................................................................................... 13 6.1 Export to Excel ................................................................................................................... 13

6.2 Create a report ................................................................................................................... 13

7. Annex ........................................................................................................................................... 14 7.1 Typical Graphs ................................................................................................................... 14

7.2 Results ................................................................................................................................ 15

7.3 Typical Ovality Value Limits ............................................................................................... 15

7.4 Ovality Report ..................................................................................................................... 16

7.5 Drawing ............................................................................................................................... 16

Juli 14, 2016

Caution:

Falling: The tool might fall off the attached surface, if it is not properly attached. Dust, dirt, corrosion, roughness or high surface temperature (>330°C) increase the risk. Do not stand in the area and keep it clear, where the tool might fall down Helmet: Wear a proper helmet while using the measurement tool. Hot Surface: After the measurement, the magnets might be very hot. Use the T-handles for holding and do not touch the downside of the tool, especially not the magnets. Let the tool cool down before stowage. Otherwise the box may get damaged. Gloves: Wear proper gloves, which prevent burning the hands. Especially for attaching, removing and handling the tool, when it is hot. Magnetic Fields: Be aware of the strong magnet field on the magnet surface. 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. Radio Waves: Be aware of the radio waves (Bluetooth) which are emitted from the tool as well from the Bluetooth adapter on the computer. Do not keep the tool unnecessary in operation; switch it off, after usage.

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Juli 14, 2

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Juli 14, 2016

3. SOFTWARE: 3.1 Bluetooth Adapter

To ensure, the data connection between the Ovality Sensor and the PC is reliable, even in the difficult environment around a rotary kiln, it is recommended to use the Bluetooth adapter (Parani UD100), which comes along with the Sensor. Note:

• The TomTom-Tools are designed to communicate only with Windows Bluetooth Stack. If there is another Bluetooth software installed (e.g. Toshiba, Widcomm), deactivate it or uninstall it.

• Then plug the Bluetooth adapter UD100. Windows will recognize the new hardware and automatically install the suitable Windows driver (Windows generic Bluetooth)

3.2 Software Installation:

The software (TomTom-Tools Measurement Studio), which is used for the Ovality Sensor, comes along with the equipment on a USB Memory Stick. Nevertheless it is recommended to install the software 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.

Click to download the Software

Click to install the Software

Juli 14, 2016

4. START THE TOOL: 4.1 Connect Ovality Sensor with Laptop

When the software installation is completed, it starts automatically. To connect a tool for the first time it has to be paired with the computer. To do so, follow this sequence:

• Switch on the Ovality Sensor (green LED).

• Click on “Tools / Bluetooth Devices / Add a device”

• Wait until the tool got found Note: Depending on the search speed of the computer, it might take up to one minute.

• Select the device, which has to be connected; (here the Ovality Sensor) and click “OK”

Fig. 4.1.1 (Add Device) Fig. 4.1.2 (Connect Device)

• The Ovality Sensor gets added to the Device List

• To connect the Ovality Sensor, click on the “Connect” Button

Fig. 4.1.3 (Device Window)

To connect click here

Device can be connected, when displayed here (in black letters)

“Set Zero” Button To set the deflection

plate to “0” (not required, is done automatically later)

Battery Status

To calibrate the Orientation Sensor

Shows 0° if Sensor lays horizontal after calibration

Elongation Value shows the deformation in the flexing plate

The size of the buttons can be changed here

Juli 14, 2016

4.2 Signal from the Deflection Plate

The main Sensors in the Ovalily Sensor are the strain gauges, which are attached to the Deflection Plate (see Fig. 2.1.1). When the Deflection Plate gets deformed, it is shown as changes in the elongation of its surface (see in Fig. 4.1.1). Out of this elongation value, the ovality will be calculated. Note: With a simple test, it can be verified, if the flexing measurement is working correctly:

• Hold the Ovality Sensor on the electronic box horizontally that the magnets look downwards (do not touch the magnets nor the handles) then click the “Set Zero” Button.

• Turn the Ovality Sensor 180° that the magnets look upwards Due to the own weight of the magnets, the Deflection Plate gets slightly deformed and an Elongation of about 25…28 um should be displayed

4.3 Calibration of Integrated Orientation Sensor

When the Ovality Sensor is connected, it constantly transfers its orientation values and the deflection values from the deflection plate to the computer, which can be seen in the moving numbers in the Device Window. Note: First the orientation sensor has to be calibrated. Push the button “calibrate” and the following sketch indicates to place the sensor on a horizontal surface (e.g. table, floor). Fig. 4.2.1 Push “next” and hold the sensor onto a vertical surface (e.g. wall), as shown in the next sketch. Note: There is no high accuracy of the surfaces required. An error of 2° will not influence the accuracy of the sensor. Fig. 4.2.1 This calibration will be saved and remain in the registry of the computer. Hence the calibration has not to be done before each measurement. Nevertheless it is recommended to re-calibrate the sensor after a long period not in use. A re-calibration is required when the tool is placed onto a horizontal surface and the angle value does not show values close to 0°, resp. hold onto a vertical surface and the value is not close to 90° or 270° (see Fig. 4.1.1)

Juli 14, 2016

5. MEASUREMENTS 5.1 Set Up the Measurement Window

a. To start a new measurement, click on “Measurement / New / Ovality” as shown in Fig. 5.1.1

b. The first pier will be displayed per default. c. More piers can be added by mouse right click to “Add Pier” d. Put some additional useful information about the measurement into the “Settings Window”

Fig. 5.1.2

Enter Additional Information

Type the inner Kiln Diameter

Enter the Temperature of

Kiln Shell and Tire

Enter the Relative Tire Movement

Klick mouse right button to change the Flow Direction

Klick mouse right button to add more piers

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Juli 14, 2

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Juli 14, 2016

Fig. 5.3.2 (Measurement Window)

g. The measurement will be taken, after the tool reaches the top point. The measured points are displayed continuously until the tool reaches the second time the top point.

h. Remove the tool, when the measurement is taken. Do not let the instrument unnecessary attached to the hot kiln, it might overheat after a while

Start Button / F5

Select the position to be measured

Important Messages

To reset the window layout

Switch from Radar to Linear Chart

Mouse right click to change from line to point graph

Juli 14, 2016

5.4 Temperature Resistance

The Ovality Sensor is made for hot applications; nevertheless it has to be kept as cool as possible to prevent damages. The magnets are heat resistant up to 330°C. The electronic board in the sensor is temperature resistant up to 65°C, therefore it is protected by the heat shield and by insulators. If the internal temperature reaches 60°C or the magnet temperature reaches 300°C, a warning will be given by the LED2 (yellow blinking) (see chapter 2.2). Also a pop up window in the Measurement Studio will indicate the increased temperature. The measurement still can be finished. If the temperatures reach 65° in the electronic board or 330°C at the magnet, the tool will alarm you (LED2 red flashing and pop up window). In this case, the Ovality Sensor has to be removed from the kiln and cooled down as fast as possible. To cool down the tool, let it cool on the fresh air or by a ventilator (e.g. kiln shell cooling fan), never use water. The temperature of one of the magnets and the battery status are measured and displayed in the right lower corner of the Measurement Studio

Fig 5.5.1

6. REPORT

6.1 Export to Excel

All data can easily be exported to excel.

Fig.6.1.1

6.2 Create a report

The measurements can be extracted into a report. All additional information from “Setting Window” is included in the report as well.

Fig. 6.2.1 TomTom-Tools GmhH Switzerland www.tomtom-tools.com [email protected]

Magnet Temperature

Juli 14, 2016

7. ANNEX

7.1 Typical Graphs

a. Low ovality: Normal flattening on top Moderate and symmetrical deflection at contact with support rollers b. High ovality: Strong flattening on top

└►Indication for high relative movement └►Tire shimming seems to be required

High, symmetrical deflection at contact with support rollers b1.)In case A,B,C have similar shapes

└►indication for possible overload due to vertical misalignment of kiln axis

B2.)In case A,B,C have very different ovality and roller contact

└►indication for cyclic overload due to crank in kiln shell └►need verification by roller shaft bending measurement with IDM Tool Kit

c. Asymmetric roller load:

└►Kiln axis is not aligned in horizontal direction d. Tilted top area:

└►particles and scuffing between tire inner diameter and the tire plates

e. Inconsistent readings :

└►In the blue reading, one of the middle magnets lost the contact to the kiln shell.

└►clean the magnets and repeat measurement

Note: Jumps in the graph might also be indications for insufficient hold of the magnets. Make sure, the magnets are clean and there is not eccessive dust or corrosion on the kiln shell

Juli 14, 2016

3 4 5 6 70.0

0.2

0.4

0.6

0.8

7.2 Results

The Ovality Values are good and simple indicators, to see whether other investigations or measurements are required. But the corrective actions on the kiln should never be based only on the results of the Ovality measurement. Ovality measurement does NOT replace creep measurement nor measurement of the kiln axis! TomTom-Tools Ltd. does not provide guide lines about acceptable ovality values or limits. It has to be discussed with the refractory suppliers, how much ovality can be allowed. Out of experience the following table can be taken as an example but might need to be adjusted to the specific case:

7.3 Typical Ovality Value Limits

Fig.7.3.1

Risk for Refractory Failures

Risk for Shell Constriction

Ova

lity

[%]

Kiln Diameter [m]

High Ovality: Search the root cause (e.g. excessive wear of tire pads) Tire Shimming Required

Elevated Ovality: Should be monitored

Normal Ovality: No action required

Low Ovality: Excellent for the refractory, but closely monitor the relative movement of the tire

Very Low Ovality: Search the root cause e.g. wrong tire shimming, high shell temperature, upset kiln condition)

4

7.5

16

Ovality R

Drawing

Report

g

Juli 14, 22016

ovality sensor i manual - tomtom-tools · rimarily pres e degree of easures in lity sensor safety:...

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