A method for online real-time monitoring of a center line of a rotary kiln

Abstract

The application discloses a kind of methods for monitoring rotary kiln center line in real time on line, comprising the following steps: S1, assemble laser ranging module;S2, erect fixed support;S3, adjust laser ranging module position;S4, measure the height difference and interval of adjacent laser ranging module;S5, set measurement period;S6, data processor handles, calculates center line horizontal deviation;S7, according to the amount of central control slip, calculates center line vertical deviation;S8, draw results, using the method for monitoring rotary kiln center line in real time on line of the application, real-time monitoring, without field measurement, reduce detection cost.

Description

Technical Field

[0001] This invention belongs to the field of rotary kiln centerline measurement. Specifically, this invention relates to a method for online real-time monitoring of the rotary kiln centerline. Background Technology

[0002] Rotary kilns are core equipment in industries such as building materials, metallurgy, and chemicals. Various thermal equipment on rotary kilns operate under heavy loads for extended periods in harsh environments, frequently experiencing wear, pitting, and spalling, which causes changes in equipment dimensions. The kiln temperature is closely related to kiln conditions and central control operations, and temperature changes also affect equipment dimensions. At the same time, on-site personnel may make significant adjustments based on the kiln's operating conditions.

[0003] Equipment wear, temperature changes, and human adjustments can affect the centerline of a rotary kiln. Therefore, the rotary kiln plant conducts centerline checks periodically and makes necessary adjustments based on the results. Currently, the rotary kiln centerline is measured under hot conditions, and the measured centerline value is a value at a certain moment or over a certain period of time. When large components are replaced on-site or the kiln has been in operation for more than two years, the centerline value needs to be remeasured. Changes in on-site operating conditions will also change the centerline value, making real-time online monitoring impossible.

[0004] Invention patent CN113008629A, published on June 33, 2021, discloses a flexible online detection device for rotary kilns, comprising a detection container, a kiln head discharge hopper, and a sample hopper, with a suction rod movably connected to one end of the detection container. However, this flexible online detection device for rotary kilns also fails to solve the aforementioned technical problems. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by providing a method for real-time online monitoring of the center line of a rotary kiln that eliminates the need for on-site measurement and reduces testing costs.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: The method for online real-time monitoring of the centerline of a rotary kiln includes the following steps: S1, assembling a laser ranging module; S2, setting up a fixed support; S3, adjusting the position of the laser ranging module; S4, measuring the height difference and spacing between adjacent laser ranging modules; S5, setting the measurement cycle; S6, data processing to calculate the horizontal deviation of the centerline; S7, calculating the vertical deviation of the centerline based on the central control slippage; S8, obtaining the result.

[0007] In step S1, the laser ranging modules are installed in parallel on a fixed bracket, and each laser ranging module is connected to the data processor via a data cable.

[0008] In step S2, the fixed bracket is welded to the steel base below each gear's tire, and the laser ranging module is placed horizontally and parallel to the tire to ensure that the laser irradiates the center of the bottom of the tire.

[0009] In step S3, each laser ranging module is kept parallel to the tire and moves horizontally by the same distance.

[0010] The fixed bracket includes a base and a crossbeam. The laser ranging modules are evenly distributed on the crossbeam. A support rod is connected to the middle of the base and the crossbeam. The data processor is located in the middle of the support rod. A reinforcing rod is connected to the end of the base and the crossbeam.

[0011] In step S6, a coordinate system is established, the position of the lowest point of each gear belt is determined on the coordinate system, and the horizontal deviation of the rotary kiln centerline is judged.

[0012] In step S4, a level or total station is used to measure the height difference and spacing between adjacent laser ranging modules.

[0013] The measurement period is 5s, 10s, 30s or 60s.

[0014] The laser ranging module has an accuracy of ±0.1mm, a temperature tolerance of 0-80℃, and a measurement range of 0-3.0m.

[0015] The technical advantages of this invention are as follows: The method for online real-time monitoring of the rotary kiln centerline utilizes parallel laser ranging modules to form a ranging module. This module is fixed to a steel base below the tire, positioned horizontally and parallel to the tire to ensure the laser beam illuminates the center of the tire's running section. Ranging modules are installed on all three kiln supports. After installation, vertical and horizontal reference data are measured and entered into the system. The laser debugging system is activated, and the system's working cycle is set. The three laser ranging modules simultaneously measure data, which is transmitted to the data processor and central control unit. Based on the principle that multiple points can determine the center of a circle, computer software calculates the tire diameter. Combined with the central control unit's slippage, the deviation of the rotary kiln's centerline in the horizontal and vertical directions is determined and directly displayed on the central control screen. This method eliminates the need for professional personnel to inspect the kiln centerline, enabling real-time online monitoring and providing reliable data to the manufacturer, thus providing a basis for diagnosing and resolving kiln operation problems. Attached Figure Description

[0016] This manual includes the following figures, which illustrate the following: Figure 1 This is a schematic diagram of the laser ranging module of the present invention. Figure 2 This is a schematic diagram of the fixed support structure of the present invention; Figure 3 This is a schematic diagram of the height difference between adjacent laser ranging modules in an embodiment of the present invention; Figure 4 This is a schematic diagram of the spacing between adjacent laser ranging modules in an embodiment of the present invention; Figure 5 This is a schematic diagram of the lowest point position of the tire in an embodiment of the present invention. Figure 6 This is a schematic diagram of the horizontal skew of the center line in an embodiment of the present invention. Figure 7 This is a schematic diagram of the center point of the cylinder in an embodiment of the present invention. Figure 8 This is a schematic diagram of the vertical skew of the center line in an embodiment of the present invention. Figure 9 yes Figure 8 An enlarged schematic diagram of the second gear tire area.

[0017] The following are marked in the diagram: 1. Fixed bracket; 11. Base; 12. Crossbeam; 13. Support rod; 14. Reinforcing rod; 2. Laser ranging module; 21. Laser ranging module; 3. Data processor; 4. Data cable; 5. Tire; 6. Tire pad; 7. Cylinder body; 8. Support roller. Detailed Implementation

[0018] 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.

[0019] The method for online real-time monitoring of the centerline of a rotary kiln includes the following steps: S1, assembling the laser ranging module 2; S2, setting up the fixed support 1; S3, adjusting the position of the laser ranging module 2; S4, measuring the height difference and spacing between adjacent laser ranging modules 2; S5, setting the measurement cycle; S6, processing the data with the data processor 3 and calculating the horizontal deviation of the centerline; S7, calculating the vertical deviation of the centerline based on the central control slippage; S8, obtaining the result.

[0020] When a significant deviation occurs in the centerline of the rotary kiln, the alternating load on the cylinder 7 increases, leading to metal fatigue and ultimately cracking. Current methods involve professional inspection teams measuring the centerline at a specific moment on-site and adjusting the kiln accordingly. This new method allows for real-time measurement of the rotary kiln's centerline, eliminating the need for on-site measurement by a professional team and reducing inspection costs. The laser ranging module 21 combines the measurement data with computer software and, based on other on-site data, calculates the horizontal and vertical centerlines of the rotary kiln under hot conditions. The real-time centerline measurement results are displayed on the central control screen, providing reliable data for the manufacturer to adjust the rotary kiln. It also allows for the analysis and assessment of the impact of process factors and other changes on the rotary kiln. After installation, the centerline can be monitored in real-time at the central control station, eliminating the need for multiple measurements by a professional team.

[0021] like Figure 2 As shown in Figure S1, laser ranging modules 21 are installed in parallel on the fixed bracket 1, and each laser ranging module 21 is connected to the data processor 3 via data cable 4. Installing multiple laser ranging modules 21 in parallel allows for the simultaneous acquisition of distance data from multiple measuring points on the bottom of the tire 5, improving measurement redundancy and reliability. The equal spacing of the multiple laser ranging modules 21 facilitates the construction of a coordinate system, identifying the lowest position of the tire 5, and thus obtaining the offset of the centerline. The data cable 4 is centrally connected to the data processor 3, enabling synchronous acquisition and processing of multi-channel data, avoiding the tediousness and errors of manual point-by-point measurement.

[0022] like Figure 3 As shown in step S2, the fixed bracket 1 is welded to the steel base below the tire 5 at each gear position. The laser ranging module 2 is placed horizontally and parallel to the tire 5, ensuring that the laser irradiates the center of the bottom of the tire 5. The fixed bracket 1 is welded to the steel base, ensuring long-term stability and preventing displacement, thus guaranteeing the consistency of the measurement reference. Irradiating the center of the bottom of the tire 5 with the laser irradiating facilitates the acquisition of parameters at the lowest point of the tire 5. The laser ranging module 2 can also be placed below the thick cylinder 7 near the tire 5, with the laser irradiating the thick cylinder 7. This eliminates the need to input slippage data, and the centerline can be measured using the same method, making it suitable for rotary kilns with different structures.

[0023] like Figure 4 As shown, in S3, each laser ranging module 2 is kept parallel to the tire 5 and moved horizontally by the same distance. After the fixed bracket 1 is fixed, its top crossbeam 12 has slots for installing modules. By moving each gear module horizontally by the same distance, all measuring points are ensured to be located in the same relative coordinate system. This facilitates the elimination of installation position differences when calculating the horizontal deviation of the center line, and improves the comparability and accuracy of the measurement data.

[0024] like Figure 2As shown, the fixed bracket 1 includes a base 11 and a crossbeam 12. Laser ranging modules 21 are evenly distributed on the crossbeam 12. A support rod 13 is connected between the base 11 and the crossbeam 12. A data processor 3 is located in the middle of the support rod 13. Reinforcing rods 14 are connected to the ends of the base 11 and the crossbeam 12. The evenly distributed laser ranging modules 21 on the crossbeam 12 can cover a certain width of the bottom of the tire 5, avoiding misjudgments caused by local defects on the surface of the tire 5 in single-point measurements. The triangular stable structure formed by the support rod 13 and the reinforcing rod 14 ensures that the bracket does not deform during long-term use, ensuring a constant positional relationship between the measuring beam and the tire 5.

[0025] In S6, a coordinate system is established, and the position of the lowest point of the wheel 5 at each gear is determined on the coordinate system to judge the horizontal deviation of the rotary kiln centerline. Data processor 3 establishes a coordinate system and calculates the coordinates of the lowest point of the wheel 5 at each gear. By comparing the positional relationship between the line connecting gears one and three and the point at gear two, the horizontal deviation is quickly quantified.

[0026] In S4, a level or total station is used to measure the height difference and spacing between adjacent laser ranging modules 2. During initial installation of the fixed bracket 1, a level or total station is used to accurately calibrate the relative height difference and horizontal spacing between each module, serving as the system's fixed reference parameters. This one-time calibration allows for long-term use, eliminating systematic errors caused by inconsistent references in subsequent dynamic measurements.

[0027] The measurement cycle is 5s, 10s, 30s, or 60s. Users can flexibly set the sampling frequency according to the operating conditions of the rotary kiln and monitoring needs, which ensures timely capture of changes in key parameters, avoids data redundancy, and balances real-time monitoring with data processing efficiency.

[0028] The laser ranging module 21 has an accuracy of ±0.1mm, a temperature tolerance of 0-80℃, and a measurement range of 0-3.0m. Using these parameters, the laser ranging module 21 improves measurement accuracy, adapts to the thermal radiation environment at the bottom of the rotary kiln, ensures long-term stable operation, and meets the installation requirements of most industrial kilns. Example

[0029] a) Assemble the laser ranging module 2: Install 100 laser ranging modules 21 in parallel on the fixed bracket 1. The fixed bracket 1 is 1.5m long. Assemble as follows: Figure 2 .

[0030] b) Connect data cable 4: Connect each laser ranging module 21 through data cable 4, and finally connect it to the data processor 3.

[0031] c) Erecting fixed support 1: According to the actual site conditions, weld fixed support 1 to the steel base. The welding position of fixed support 1 should be as low as possible below the lowest point of tire 5 and close to the center of tire 5 when the kiln is running.

[0032] d) Adjust the position of laser ranging module 2: The module should be installed parallel to the tire 5. For positions one and three, extend the center position of the module outwards by the same distance. Then adjust position two to achieve the same distance. Figure 4 Medium distance M.

[0033] e) Measurement data between modules: Use a level or total station to measure the elevation difference H1 between the first and second levels, and the elevation difference H2 between the second and third levels, such as... Figure 3 ;Measure the horizontal distances L1 and L2 between the modules, such as Figure 4 .

[0034] f) Set the measurement cycle: The data update cycle can be set according to actual needs, such as setting it to measure once every 30 seconds in this embodiment.

[0035] g) Processor data processing: Based on the measurement data, calculate the lowest point position of the three gear pulleys on belt 5, such as... Figure 5 and Figure 6 The fact that the lowest point of the second gear is not on the line connecting the lowest points of the first and third gears indicates a horizontal deviation of the centerline. Based on the coordinate system constructed using the module spacing, the height difference between adjacent modules, and the spacing, the horizontal skewness and offset of the centerline can be calculated. The distance from the lowest point of tire 5 to the module, and the radius of tire 5, are also relevant. Figure 7 .

[0036] h) Based on the control slippage amount, the vertical centerline of the rotary kiln cylinder 7 can be calculated using the slippage amount. The principle is as follows: Figure 9 The data processed by the data processor 3 is transmitted to the central control computer to obtain the horizontal and vertical deviations of the centerline.

[0037] i) Display results: Display the results at a specific location in the central control unit.

[0038] The implementation of this method eliminates the need for multiple measurements by a professional team in the later stages. It enables real-time online monitoring of the centerline of the rotary kiln and allows observation of the impact of changes in the rotary kiln's operating conditions on the centerline.

[0039] This method for real-time online monitoring of the rotary kiln centerline utilizes a laser ranging module 21 connected in parallel to form a laser ranging module 2. The laser ranging module 2 is fixed to a steel base below the tire 5, positioned horizontally and parallel to the tire 5, ensuring the laser beam illuminates the center of the tire 5's running section. Laser ranging modules 2 are installed on all three kiln piers. After installation, vertical and horizontal reference data are measured and entered into the system. The laser debugging system is activated, and the system's working cycle is set. The three laser ranging modules 2 simultaneously measure data, which is transmitted to the data processor 3 and the central control unit. Based on the principle that multiple points can determine the center of a circle, the diameter of the tire 5 is calculated using computer software. Combined with the central control unit's slippage measurement, the deviation of the rotary kiln cylinder 7's centerline in the horizontal and vertical directions is obtained and directly displayed on the central control screen. This method eliminates the need for professional personnel to inspect the kiln centerline, enabling real-time online monitoring and providing reliable data to the manufacturer, thus providing a basis for diagnosing and resolving kiln operation problems.

[0040] 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 online real-time monitoring of the centerline of a rotary kiln, characterized in that, Includes the following steps: S1. Assemble the laser ranging module; S2. Erect a fixed support frame; S3. Adjust the position of the laser ranging module; S4. Measure the height difference and spacing between adjacent laser ranging modules; S5. Set the measurement cycle; S6. Data processor processes and calculates the horizontal deviation of the centerline; S7. Calculate the vertical deviation of the centerline based on the central control slip amount; S8. Obtain the result.

2. The method for online real-time monitoring of the center line of a rotary kiln according to claim 1, characterized in that: In step S1, the laser ranging modules are installed in parallel on a fixed bracket, and each laser ranging module is connected to the data processor via a data cable.

3. The method for online real-time monitoring of the center line of a rotary kiln according to claim 1, characterized in that: In step S2, the fixed bracket is welded to the steel base below each gear's tire, and the laser ranging module is placed horizontally and parallel to the tire to ensure that the laser irradiates the center of the bottom of the tire.

4. The method for online real-time monitoring of the center line of a rotary kiln according to claim 1, characterized in that: In step S3, each laser ranging module is kept parallel to the tire and moves horizontally by the same distance.

5. The method for online real-time monitoring of the center line of a rotary kiln according to claim 2, characterized in that: The fixed bracket includes a base and a crossbeam. The laser ranging modules are evenly distributed on the crossbeam. A support rod is connected to the middle of the base and the crossbeam. The data processor is located in the middle of the support rod. A reinforcing rod is connected to the end of the base and the crossbeam.

6. The method for online real-time monitoring of the center line of a rotary kiln according to claim 1, characterized in that: In step S6, a coordinate system is established, the position of the lowest point of each gear belt is determined on the coordinate system, and the horizontal deviation of the rotary kiln centerline is judged.

7. The method for online real-time monitoring of the center line of a rotary kiln according to claim 1, characterized in that: In step S4, a level or total station is used to measure the height difference and spacing between adjacent laser ranging modules.

8. The method for online real-time monitoring of the center line of a rotary kiln according to claim 1, characterized in that: The measurement period is 5s, 10s, 30s or 60s.

9. The method for online real-time monitoring of the center line of a rotary kiln according to claim 2, characterized in that: The laser ranging module has an accuracy of ±0.1mm, a temperature tolerance of 0-80℃, and a measurement range of 0-3.0m.

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