Research On The Real Time Monitoring Method And System For Rotary Kiln

Rotary kiln is the key equipment in the productions of corresponding enterprises of building materials,metallurgy,chemical industry,mineral processing and environmental protection and so on.Once shutdown of kiln will bring interruption to the whole production line,and make great productivity losses.Currently,when domestic rotary kilns appear faults,workmen still maintain these kilns by traditional afterward-maintenance method most of the time.For the large-scale rotary kiln,the method is inefficient and expensive,and it needs to stop the kiln during large-scale maintenance,so,the maintenance method will affect production of enterprise and can't favor the health movement of all equipments.By building rotary kiln real-time monitoring system,which monitors some important parameters,it can prevent some faults from emerging in time,and improve the running rate of rotary kiln and the quality of product.Building the real time monitoring system of rotary kiln includes four parts, which are selecting required measuring parameters,choosing the measuring method of real-time monitoring system,building its database and developing its application.Firstly,by the analysis of structure and common faults of rotary kiln,the monitoring parameters of real time monitoring system of rotary kiln are determined, that are the axes of rotary kiln's shell,the diameter of tyre and supporting roller,the pitching of shell and big gear,and the gap during the pad outside shell and tyre.Secondly,through the analysis and comparison of the advantage and disadvantage of some domestic and foreign rotary center' detecting method of rotary kiln' shell,and meanwhile taking into account of the analyzing result of the rotary kiln supporting part by the finite element analysis,the rotary center method of measuring rotary kiln' axes is proposed.How to choose three mean positions for three measuring points is the emphasis of this method.All three are located at the same section of shell,which is 50～100mm away from tyre side.The included angle is 40°between the line,which consist of first measuring point and theoretic center,and perpendicular of shell section,the second one like the first,and the third one's included angle is 50°.Besides,the probe of sensor is vertical to the surface of shell. Other parameters are measured by existing methods.Thirdly,the database of rotary kiln real-time monitoring system(called "Monitor DB") is constructed in Microsoft SQL Server 2000 according to the principle of software engineering.The DB can effectively manage the information of user and staff,the information of equipments and sensors,the collecting data,the calculate data after feature extraction,the alarm during appearing fault and the guide way of adjusting rotary kiln.Finally,the application of rotary kiln real-time monitoring system was developed by the tool of labVIEW.It can select,insert,update and delete the data of the database of "Monitor DB",and extracts the characteristic data,from the originally collecting data,which are consist of axes of rotary kiln's shell,diameter of tyre and supporting roller,pitching of shell and big gear,and gap during the pad outside shell and tyre and so on.In order to make the users observe the result of testing obviously,the application of the rotary kiln real-time monitoring system demonstrates the result by the real-time curve and the historical curve.Besides,the application can also backup and restore the database of Monitor DB.