Research On Operation State Analysis System Of Cement Rotary Kiln Reducer Based On Feature

Cement industry is a typical process industry with large, complicated andintegrated equipments. If any of the equipment’s malfunctions occurs, it will lead toserious economic loss. As the core and the most critical part, rotary kiln must alwaysbe continuously running except when there is a component failure. Reducer is thekey component of cement rotary kiln as it provides energy. Because of the kilnsystem working at high temperature, high humidity, dusty and overloadedenvironment, the equipment fails easily. Therefore, we need to master the speedreducer operational condition accurately and in time to makes sure rotary kilnoperates in continuous, stable and efficient state.Under the background of the research project “Monitoring and fault diagnosingtechnique for the key components in NSP cement production line”, the paperchooses the rotary kiln main reducer as the research object, and carries out thefollowing researches.First of all, the thesis summaries the equipment condition monitoring method,fault diagnosis technique and the maintenance management system. After masteringthe issues occur in monitoring the state of cement production industry andequipment maintenance condition, the paper analyzes the necessity and theimportant of establishing rotary reducer operation state diagnostic system.Secondly, this thesis analyzes the requirements of establishing the reduceroperation state diagnostic system according to the situation of equipmentmaintenance, condition monitoring and fault diagnosis level. Based on the result ofanalysis, system structure and function structure are confirmed. Combined therequirements and features of cement rotary kiln speed reducer, the thesis researchesits composition structure, operation state, state conduction, state feature, repair andmaintenance and so on. On this basis, the equipment operation state model isestablishes.Thirdly, in accordance to the state definition, repair and maintenance methodand failure mechanism of the cement rotary kiln speed reducer, the thesis researchesits equipment operation state analysis and troubleshooting skills. On the basis, thetime domain analysis, frequency domain analysis and the wavelet packet analysismethod are conformed.Then, the project studies the characteristics performance of the reducer stateand fault, characteristics analysis method and way of characteristics extraction. Italso analyzes state trend prediction method, and builds the state trend analysis method based on grey theory.Finally, based on the completion of system overall design and the basis oftheory research, the project selects LabVIEW as the system development platform,takes SQL Server as data storage and management tools, and uses MATLAB tomixed programmed. The operation state analysis system of cement rotary kilnreducer is developed.Through the analysis, judgment, forecast and state overrun alarm; we canmaster the cement rotary kiln reducer state and provide strong support to equipmentfault diagnosis and preliminary diagnosis. In other words, the production linerunning continuously, consistency, high efficiency, safety, and environmentalfriendly is guaranteed.