A method for quickly measuring the center line of a rotary kiln using only a common total station
By using a common total station and simple tools to establish a baseline on the rotary kiln, and combining the distance measurement principle of the total station with CAD software calculations, the high cost and difficulty in carrying equipment for rotary kiln centerline detection were solved, achieving low-cost and rapid centerline measurement and ensuring safe operation of the equipment.
Patent Information
- Application Number
- CN202610616535.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-05-07
- Publication Date
- 2026-08-04
AI Technical Summary
Existing technologies for measuring the centerline of rotary kilns suffer from high testing costs, difficulty in carrying or mailing the equipment, and the inability to perform rapid and convenient testing in hot environments, which affects the stable and safe operation of the equipment.
Using a common total station in combination with tools such as a tripod, target, leveling rod, bubble level, reflector, angle iron, and steel ruler, a baseline is established and the horizontal and vertical distances of the wheel tires are measured. The centerline of the rotary kiln cylinder is calculated using the distance measurement principle of the total station and CAD software.
It enables low-cost and rapid measurement of the rotary kiln centerline, suitable for remote or overseas projects, requiring no specialized institutions, avoiding equipment downtime and high testing costs, and ensuring safe equipment operation.
Smart Images
Figure CN122505202A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of rotary kiln centerline measurement. Specifically, this invention relates to a method for quickly measuring the centerline of a rotary kiln using only a common total station. Background Technology
[0002] Excessive deviation from the centerline of a rotary kiln can lead to malfunctions such as uneven load on the support rollers and refractory brick detachment. In severe cases, it can cause the kiln shell to crack, resulting in equipment shutdown. Hot-state monitoring of the centerline can provide early warnings and allow for timely adjustments to prevent major accidents. Regular inspections are crucial for ensuring stable, safe, and efficient equipment operation.
[0003] For rotary kiln users, the cost of a single centerline inspection is around 70,000 to 100,000 yuan, and regular inspections are required in the future, so continued investment is still needed.
[0004] For testing companies, some regions are so remote that it is difficult to carry a large amount of equipment; when testing rotary kilns abroad, there are issues such as customs clearance and providing various documents when mailing the testing equipment, and the arrival time is uncontrollable.
[0005] Patent CN103245306B, published on March 16, 2016, discloses a method for hot-state measurement of the centerline of a rotary kiln shell. This method is used for rotary kilns operating in a hot environment. Several cylindrical tires are installed around the periphery of the kiln shell to support it. Using two theodolites to accurately locate a point in space, the method measures and calculates the three-dimensional spatial coordinates of several points on the surface of the tires. Based on this, key parameters of the tire surface's spatial position and shape are calculated, and the center coordinates of the kiln shell at that tire are determined. By comparing the center positions of the kiln shell at each tire support point, the state of the kiln's centerline is obtained. However, this method for hot-state measurement of the centerline of a rotary kiln shell does not completely solve the aforementioned technical problems. Summary of the Invention
[0006] The purpose of this invention is to address the shortcomings of existing technologies by providing a method for quickly measuring the center line of a rotary kiln using only a common total station. This method is simple to implement, has low testing costs, and requires only a few tools, overcoming the problem of difficult-to-carry or mail testing equipment.
[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: This method for quickly measuring the centerline of a rotary kiln using only a common total station includes the following steps: S1, prepare tools; S2, establish a baseline; S3, use a total station to measure the horizontal distance from the baseline to the outermost edge of the tire; S4, calculate the horizontal deviation of the rotary kiln cylinder centerline; S5, locate the corresponding marker points for each tire position; S6, use a total station to measure the height difference between adjacent marker points; S7, use a total station to measure the height difference between each marker point and the lowest point of the corresponding tire; S8, measure the tire slippage of each tire position on-site and convert it into tire clearance under hot conditions; S9, calculate the vertical deviation of the rotary kiln cylinder centerline; S10, draw conclusions.
[0008] In step S2, four targets are attached to the cement walls on both sides of the rotary kiln to establish two baselines and measure their lengths; the distance between adjacent gear tires, the distance between the kiln head target and the first gear tire, and the distance between the kiln tail target and the third gear tire are measured.
[0009] Step S3 includes the following steps: Set up the total station at the intersection of the extension line of the tire center and the baseline; align the total station with the center of the target; rotate the total station after the angle is zeroed; and lock the horizontal brake after the total station interface displays the rotation setting value; turn on the total station laser, select the continuous distance measurement horizontal distance mode, rotate the telescope up and down, and select the minimum reading value after multiple rotations.
[0010] In step S1, the tools include a tripod, a target, a leveling bubble, a reflector, AB glue, an angle iron, and a steel ruler; the target is vertically glued to the bottom of the angle iron with AB glue, and the reflector is glued to the angle iron; the steel ruler is glued and fixed into a T-shaped assembly with AB glue, and the reflector is glued to it.
[0011] In step S6, the angle steel is placed on the marked point, and the leveling rod is used to assist in straightening it. The total station is set up on the ground, and the total station is aimed at the reflector on the angle steel to measure the height difference between adjacent marked points.
[0012] In step S7, the steel ruler assembly is placed at the bottom of the tire and leveled using a leveling rod with a bubble level. The total station is then used to first align with the reflector on the angle steel, select the vertical distance measurement mode, and then align with the reflector on the steel ruler assembly to measure the height difference between the two reflectors.
[0013] In steps S4 and S9, the center position of the tire is calculated using CAD software or other software, the center points of the first and third gear tires are connected, and the center position of the second gear tire is determined.
[0014] The marked points include anchor bolts.
[0015] The total station has a prism-free continuous measurement function.
[0016] The technical advantages of this invention are as follows: The method for rapidly measuring the centerline of a rotary kiln using only a common total station involves first establishing horizontal and vertical benchmarks on the kiln, then using the distance measurement principle of the total station to measure the required data, and finally using CAD software to calculate the centerline of the kiln body. This method has low measurement costs, saving significant funds, and uses simple tools and is easy to operate. The method is performed directly while the rotary kiln is running, without requiring shutdown for cooling, thus not affecting normal production and enabling online monitoring, which helps avoid major equipment accidents. Measurement also does not require specialized institutions; only a common total station and a few accessories are needed for centerline detection. No special customs clearance or mailing is required, and subsequent testing costs are almost zero. This overcomes the shortcomings of high testing costs and difficulties in mailing equipment in some cases, making it suitable for overseas projects or remote areas. Attached Figure Description
[0017] This manual includes the following figures, which illustrate the following: Figure 1 This is a flowchart illustrating the process of the method for rapidly measuring the center line of a rotary kiln using only a conventional total station, as described in this invention. Figure 2 This is a schematic diagram of establishing a baseline in an embodiment of the present invention; Figure 3 This is a schematic diagram showing the position of the total station set up on the baseline in an embodiment of the present invention; Figure 4 This is a schematic diagram illustrating the horizontal distance from the baseline to the outermost edge of the tire measured by the total station in an embodiment of the present invention. Figure 5 This is a schematic diagram of the horizontal distance measurement results from the baseline to the outermost edge of the tire in an embodiment of the present invention; Figure 6 This is a schematic diagram showing the distance from the center of the tire to the baseline in an embodiment of the present invention; Figure 7 This is a schematic diagram of the horizontal deviation of the centerline in an embodiment of the present invention; Figure 8 This is a schematic diagram of the elevation difference between adjacent marker points in an embodiment of the present invention; Figure 9 This is a schematic diagram of the height difference between adjacent marker points measured in an embodiment of the present invention; Figure 10 This is a schematic diagram illustrating the height difference between each gear marking point and the lowest point of the corresponding tire in an embodiment of the present invention; Figure 11 This is a numerical diagram of the lowest point height of the tire in an embodiment of the present invention; Figure 12 This is a numerical diagram of the tire center height in an embodiment of the present invention; Figure 13 This is a schematic diagram of the tire center and cylinder center in an embodiment of the present invention; Figure 14 This is a schematic diagram of the vertical deviation of the centerline in an embodiment of the present invention; Figure 15 yes Figure 14 A schematic diagram of the vertical deviation of the second gear pulley.
[0018] The markings in the diagram are: 1. Total station; 2. Tire; 3. Baseline; 4. Target; 5. Reflector; 6. Angle iron; 7. Steel ruler; 8. Cement wall; 9. Anchor bolt. Detailed Implementation
[0019] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of the present invention, and to facilitate its implementation.
[0020] like Figure 1 As shown, this method for quickly measuring the centerline of a rotary kiln using only a common total station includes the following steps: S1, preparing tools; S2, establishing a baseline 3; S3, using a total station 1 to measure the horizontal distance from the baseline 3 to the outermost edge of the tire 2; S4, calculating the horizontal deviation of the rotary kiln's centerline; S5, finding the corresponding marker points for each tire 2 position; S6, using a total station 1 to measure the height difference between adjacent marker points; S7, using a total station 1 to measure the height difference between each marker point and the lowest point of the corresponding tire 2; S8, measuring the slippage of each tire 2 position on-site and converting it into tire 2 clearance under hot conditions; S9, calculating the vertical deviation of the rotary kiln's centerline; S10, drawing conclusions.
[0021] like Figure 2 As shown, in step S2, four targets 4 are attached to the cement walls 8 on both sides of the rotary kiln to establish two baselines 3 and measure their lengths. The distance between adjacent gear tires 2, the distance between the kiln head target 4 and the first-gear tire, and the distance between the kiln tail target 4 and the third-gear tire are measured. By attaching targets 4 to the cement walls 8 on both sides of the rotary kiln to establish two parallel baselines 3, a stable measurement reference system is provided for the total station 1. Measuring the distance between each gear tire 2 and the distance between the kiln head / tail and the targets 4 ensures the accuracy of subsequent horizontal distance measurements and eliminates the influence of thermal expansion or deformation of the kiln body on the baseline.
[0022] like Figure 4As shown, step S3 includes the following steps: Set up the total station 1 at the intersection of the extended line of the tire 2 and the baseline 3; align the total station 1 with the center of the target 4; after zeroing the angle, rotate the total station 1; once the rotation setting value is displayed on the total station 1 interface, lock the horizontal brake; turn on the laser of the total station 1, select the continuous distance measurement mode (horizontal distance), and rotate the telescope up and down repeatedly to select the minimum reading. This method of zeroing the angle and then rotating to fix the angle ensures that the measurement direction of the total station 1 forms a precise angle with the baseline 3, facilitating subsequent geometric calculations. Rotating the telescope up and down in continuous distance measurement mode and selecting the minimum value accurately locates the outermost edge of the tire 2, improving the accuracy of horizontal distance measurement.
[0023] like Figure 10 As shown, in step S1, the tools include a tripod, target 4, leveling bubble level, reflector 5, AB glue, angle iron 6, and steel ruler 7. The target 4 is vertically glued to the bottom of the angle iron 6 using AB glue, and the reflector 5 is glued to the angle iron 6. The steel ruler 7 is then glued and fixed into a T-shaped assembly using AB glue, and the reflector 5 is attached to it. These tools are ordinary hardware or measuring consumables, low in cost, and easy to carry. The target 4, angle iron 6, and steel ruler 7 can be easily processed into specialized measuring accessories, eliminating the need for specialized equipment and making them suitable for use in remote areas or overseas projects.
[0024] like Figure 8 As shown, in step S6, angle steel 6 is placed on the marked point and aligned with the leveling rod using a bubble level. The total station 1 is set up on the ground and aligned with the reflector 5 on the angle steel 6 to measure the height difference between adjacent marked points. The angle steel 6, in conjunction with the reflector 5 and the leveling rod's bubble level, quickly establishes a vertical measurement target on the marked point, ensuring the accuracy of the total station 1's measurement. The leveling rod's bubble level ensures the verticality of the angle steel 6, thereby obtaining accurate elevation data for the marked point and providing a reliable benchmark for calculating vertical deviation.
[0025] like Figure 10 As shown, in step S7, the steel ruler 7 assembly is placed at the bottom of the tire 2, and the leveling bubble of the leveling rod is used to assist in leveling it. The total station 1 is first aligned with the reflector 5 on the angle steel 6, and the vertical distance measurement mode is selected. Then, it is aligned with the reflector 5 on the steel ruler 7 assembly to measure the height difference between the two reflectors 5. The top bonding point of the T-shaped steel ruler 7 contacts the lowest point of the tire, thereby corresponding to and measuring the height difference between the lowest point of the tire and the marked point. The T-shaped steel ruler 7, in conjunction with the leveling bubble of the leveling rod, ensures that the reflector 5 is in a horizontal position, which makes it easy for the total station 1 to directly read the height difference between the two reflectors 5 through the vertical distance measurement mode without complicated calculations, thus facilitating the subsequent calculation to obtain the height data of the tire 2 at each gear.
[0026] like Figure 7 and Figure 14As shown, in steps S4 and S9, the center position of tire 2 is calculated using CAD software or other software, the center points of the first and third gear tires are connected, and the center position of the second gear tire is determined. Using the graphical function of CAD software, the measurement data is directly input and points and lines are drawn, which can intuitively display the relative positions of the centers of the first, second, and third gear tires, and quickly determine the offset direction and amount of the second gear center relative to the line connecting the first and third gears.
[0027] The marking points include anchor bolts 9. Utilizing existing anchor bolts 9 as marking points eliminates the need for additional permanent markers, saving time and material costs. Anchor bolts 9 are typically firmly embedded and not easily displaced, enabling them to serve as long-term measurement benchmarks and ensuring consistency of data from multiple tests.
[0028] The total station 1 has a prism-free continuous measurement function. Example
[0029] a) Prepare and make tools: ① One total station: Select a total station with prism-free and continuous measurement functions. The model of the total station used in this embodiment is Topcon OS-103. ② One tripod. You can use your existing tripod directly. If you can choose to buy one, try to choose a good quality wooden tripod, which costs around 300 yuan. ③ Five targets, which are made using thin steel sheets, one level bubble level on a measuring rod, and a reflector: estimated cost 30 yuan; ④ Two boxes of AB glue and one 1.5-3 meter angle steel: Attach a target 4 to the bottom of the angle steel 6 with AB glue, keeping the angle steel 6 perpendicular to the target 4, and attach a reflective sheet 5 to the surface of the angle steel 6; ⑤ Two steel rulers: Use AB glue to glue and fix the steel rulers 7 to form a T-shaped ruler, and glue on the reflective sheet 5.
[0030] b) Attach targets 4 to both sides of the rotary kiln: Based on the actual site conditions, attach four targets 4 to the cement walls 8 on both sides of the rotary kiln using AB glue, establishing two baselines 3. Baseline 3 should be as parallel as possible to the kiln axis, and the distances between the kiln head and kiln tail should be as consistent as possible. Measure the distances of baseline 3: Lkiln head = 10883mm, Lkiln tail = 10878mm. Use a total station 1 to measure the distance H1 between the first and second gear tires (H1 = 28.30m), and the distance H1 between the second and third gear tires (H1 = 37.10m). Measure the distance Hkiln head from the kiln head target 4 to the middle of the first gear tire (Hkiln head = 5.91m), and the distance Hkiln tail from the kiln tail target 4 to the middle of the third gear tire (Hkiln tail = 8.08m). Figure 2 .
[0031] c) Measure the distance from baseline 3 to the outermost edge of tire 2 using total station 1: Set up total station 1 on the extended line of the middle of tire 2 and on baseline 3, as shown in the figure. Figure 3Align total station 1 with the center of target 4, and zero the angle. Then rotate total station 1 until the interface displays 100° rotation (this model of total station uses Japanese angle units, one revolution is 400°, while a typical total station is 360°). Lock the horizontal brake. Turn on the laser on total station 1 and activate the continuous distance measurement mode (since this model of total station has multiple distance measurement modes, select the horizontal distance mode from total station 1 to a specific point). Rotate the telescope up and down as follows... Figure 4 The distance reading on the total station will continuously change. Rotate the instrument multiple times to select the minimum reading, repeating this operation at other positions and recording the data. Simultaneously, using CAD or manual calculation, the diameters of the first, second, and third gear tires can be determined: D1=7370.9mm, D2=7429.8mm, D3=7407.1mm. Figure 5 ; d) Calculate the horizontal deviation of the rotary kiln shell centerline using CAD or other software: The center position of tire 2 (shell) can be found using CAD or manual calculation, such as... Figure 10 Connecting the centers of the first and third gear tires (cylinder body), it was found that the center of the second gear tire (cylinder body) was to the left of the line connecting the first and third gears (viewing from the kiln head to the kiln tail); The conclusion is that the horizontal centerline is offset to the left by 1.4mm. Figure 7 .
[0032] e) Find a marker point in each gear: Find a solid and stable marker point in each of the first, second and third gears, such as anchor bolt 9.
[0033] f) Use total station 1 to measure the elevation difference of each marker point: Place the angle steel 6 assembly on the marker point, use a leveling rod with a bubble level to help it be aligned, set up total station 1 on the ground, and align total station 1 with the reflector 5 attached to the angle steel 6, such as... Figure 13 The measured elevation difference V1 between the first and second level markers was 847 mm, and the elevation difference V1 between the first and third level markers was 2405 mm. Figure 9 .
[0034] g) Use a total station 1 to measure the height difference between each marked point and the lowest point of the tire 2: Place the steel ruler 7 assembly in the middle of the tire 2, and try to place it at the lowest point of the tire 2. Use a leveling rod with a bubble level to help level the tire. Figure 10Using total station 1, first align the reflector 5 on angle steel 6 (angle steel 6 is placed on the marked point and leveled with a leveling rod bubble), select vertical distance measurement mode, and then align the reflector 5 on the steel ruler assembly 7; the height differences between the first, second, and third gear reference points and each marked point can be measured, which are d1=1211mm, d2=1462mm, and d3=1397mm respectively; it can be assumed that the lowest point height of the first gear tire is 1211mm, then the lowest point height of the second gear tire is d2+V1=1462+847=2309mm, and the lowest point height of the third gear tire is d3+V2=1397+2405=3802mm; if Figure 11 Then, based on the measured diameter of the tire 2, such as... Figure 12 It can be calculated that: The height of the center of the first gear belt, O1', is calculated as follows: O1' = 1211 + 7370.9 / 2 = 4896.5 mm. The height of the second gear pulley center, O2', is calculated as follows: O2' = 2309 + 7429.8 / 2 = 6023.9 mm. The height of the center of the third gear belt, O3', is 3802 + 7407.1 / 2 = 7505.6 mm; h) Measure the slippage at each level on-site and convert it into tire 2 clearance under hot conditions: The center of the cylinder and the center of tire 2 are affected by the slippage, such as... Figure 13 By directly querying the central control slip distance: first gear is 17.6mm, second gear is 22.0mm, and third gear is 15.4mm; to convert to tire clearance, divide by π: first gear tire clearance is 5.6mm, second gear tire clearance is 7.0mm, and third gear tire clearance is 4.9mm; The following can be calculated: The height of the center of the first-stage cylinder, O1, is calculated as O1' - 5.6 / 2 = 4893.7 mm. The height of the center of the second-stage cylinder, O2, is calculated as O2' - 7.0 / 2 = 6020.4 mm. The height of the center of the third gear belt is O3 = O3' - 4.9 / 2 = 7503.2mm; i) Calculate the vertical deviation of the rotary kiln cylinder centerline using CAD or other software: The vertical position of the cylinder center can be found using CAD or manual calculation; connecting the centers of the first and third gears, it is found that the center of the second gear is below the line connecting the first and third gears; it is determined that the vertical centerline is deviated by 2.4mm. Figure 14 .
[0035] k) Conclusion: The centerline of the rotary kiln is 1.4 mm to the left in the horizontal direction and 2.4 mm lower in the vertical direction; since the centerline deviation is very small and within a reasonable range, no adjustment is required.
[0036] The above measurement method allows for the quick and easy determination of the rotary kiln centerline using only a standard total station, saving significant funds and making it suitable for inspection projects where carrying a large number of tools is inconvenient. While a professional centerline measurement company charges 70,000-100,000 RMB per measurement, the cost of all tools and equipment for this method can be kept under 50,000 RMB, and multiple measurements can be performed subsequently.
[0037] This method for quickly measuring the centerline of a rotary kiln using only a standard total station involves first establishing horizontal and vertical benchmarks on the kiln, then using the total station's distance measurement principle to obtain the necessary data, and finally using CAD software to calculate the centerline of the kiln body. This method is low-cost, saving significant funds, and uses simple tools and is easy to operate. It can be performed directly while the rotary kiln is running, without requiring shutdown for cooling, thus not affecting normal production and enabling online monitoring, which helps prevent major equipment accidents. The measurement also does not require a specialized institution; only a standard total station and a few accessories are needed for centerline detection. No special customs clearance or mailing is required, and subsequent testing costs are virtually zero. This overcomes the shortcomings of high testing costs and difficulties in mailing equipment in some cases, making it suitable for overseas projects or remote areas.
[0038] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution; or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.
Claims
1. A method for quickly measuring the center line of a rotary kiln using only a common total station, characterized in that, Includes the following steps: S1. Prepare tools; S2. Establish a baseline; S3. Use a total station to measure the horizontal distance from the baseline to the outermost edge of the tire. S4. Calculate the horizontal deviation of the centerline of the rotary kiln shell; S5. Locate the corresponding markers for each gear position on the pulley; S6. Use a total station to measure the elevation difference between adjacent marked points; S7. Use a total station to measure the height difference between each marked point and the lowest point of the corresponding tire; S8. Measure the slippage of each tire on site and convert it into tire clearance under hot conditions; S9. Calculate the vertical deviation of the centerline of the rotary kiln shell; S10. Conclusion.
2. The method for quickly measuring the center line of a rotary kiln using only a common total station according to claim 1, characterized in that: In step S2, four targets are attached to the cement walls on both sides of the rotary kiln to establish two baselines and measure their lengths; the distance between adjacent gear tires, the distance between the kiln head target and the first gear tire, and the distance between the kiln tail target and the third gear tire are measured.
3. The method for quickly measuring the center line of a rotary kiln using only a common total station according to claim 1, characterized in that, Step S3 includes the following steps: Set up the total station at the intersection of the extension line of the tire center and the baseline; align the total station with the center of the target; rotate the total station after the angle is zeroed; and lock the horizontal brake after the total station interface displays the rotation setting value; turn on the total station laser, select the continuous distance measurement horizontal distance mode, rotate the telescope up and down, and select the minimum reading value after multiple rotations.
4. The method for quickly measuring the center line of a rotary kiln using only a common total station according to claim 1, characterized in that: In step S1, the tools include a tripod, a target, a leveling bubble, a reflector, AB glue, an angle iron, and a steel ruler; the target is vertically glued to the bottom of the angle iron with AB glue, and the reflector is glued to the angle iron; the steel ruler is glued and fixed into a T-shaped assembly with AB glue, and the reflector is glued to it.
5. The method for quickly measuring the center line of a rotary kiln using only a common total station according to claim 4, characterized in that: In step S6, the angle steel is placed on the marked point, and the leveling rod is used to assist in straightening it. The total station is set up on the ground, and the total station is aimed at the reflector on the angle steel to measure the height difference between adjacent marked points.
6. The method for quickly measuring the center line of a rotary kiln using only a common total station according to claim 5, characterized in that: In step S7, the steel ruler assembly is placed at the bottom of the tire and leveled using a leveling rod with a bubble level. The total station is then used to first align with the reflector on the angle steel, select the vertical distance measurement mode, and then align with the reflector on the steel ruler assembly to measure the height difference between the two reflectors.
7. The method for quickly measuring the center line of a rotary kiln using only a common total station according to claim 1, characterized in that: In steps S4 and S9, the center position of the tire is calculated using CAD software or other software, the center points of the first and third gear tires are connected, and the center position of the second gear tire is determined.
8. The method for quickly measuring the center line of a rotary kiln using only a common total station according to claim 1, characterized in that: The marked points include anchor bolts.
9. The method for quickly measuring the center line of a rotary kiln using only a common total station according to claim 1, characterized in that: The total station has a prism-free continuous measurement function.