Rotary kiln riding ring device with bearing bush oil film thickness real-time monitoring function

Abstract

Provided is a rotary kiln riding wheel device with a bearing bush oil film thickness real-time monitoring function, belonging to the technical field of rotary kiln equipment. The device comprises a riding wheel shaft, the riding wheel shaft is supported in a riding wheel shaft shell through a spherical seat, a spherical bush and a riding wheel bush, a riding wheel is fixed in the middle of the riding wheel shaft, a sealing flange is installed at the gap between the riding wheel shaft shell and the riding wheel shaft; the device further comprises at least two sets of oil film monitoring sensors, the oil film monitoring sensors are fixed on the outside of the sealing flange through a support in the axial direction, and the sensor probe is vertically close to the surface of the riding wheel shaft journal; the two sets of oil film monitoring sensors are separated by 90 DEG + 5 DEG in the same plane in the radial direction, and are symmetrically arranged on the two sides of the diameter through the contact point of the riding wheel and the rotary kiln. The device realizes dynamic monitoring of the oil film thickness by optimizing the sensor selection, installation position and system connection mode, and provides data support for fault early warning.

Description

Technical Field

[0001] This utility model belongs to the technical field of rotary kiln equipment, specifically relating to a rotary kiln support roller device with real-time monitoring function of bearing oil film thickness, which can monitor the oil film thickness between the support roller shaft and the bearing in real time. Background Technology

[0002] Rotary kilns are crucial equipment in industries such as building materials, metallurgy, and chemicals. The thickness of the oil film between the roller shaft and the bearing directly affects the operational stability and lifespan of the equipment. The roller bearing housing is internally oil-bearing, with limited operating space and numerous components, making it unsuitable for direct installation and adjustment of monitoring components. The lifting amount of the roller shaft equals the oil film thickness between the shaft and bearing; in a static state, the oil film thickness is close to 0mm; after rotation, oil is introduced, and the oil film thickness is affected by factors such as temperature, rotational speed, and load, gradually increasing and remaining in a dynamic state. Therefore, the oil film thickness range directly reflects the lubrication status of the shaft and bearing. Traditional methods for monitoring the roller shaft oil film thickness typically involve periodic shutdowns for inspection or indirect measurement. These methods cannot achieve real-time and accurate monitoring, leading to delayed fault warnings and potentially causing equipment damage or production interruptions. While eddy current sensors are used for vibration monitoring in existing technologies, they are not optimized for the specific operating conditions of the rotary kiln roller shaft and bearing oil film thickness. Therefore, a device capable of real-time and accurate monitoring of oil film thickness is urgently needed to improve equipment operational reliability. Utility Model Content

[0003] The technical problem solved by this utility model is to provide a rotary kiln support roller device with real-time monitoring function of bearing oil film thickness. This utility model aims to solve the problem that the oil film thickness cannot be monitored in real time in the prior art. By optimizing the selection of sensors, installation position and system connection method, dynamic monitoring of oil film thickness is realized, and data support is provided for fault early warning.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0005] A rotary kiln support roller device with real-time monitoring function of bearing oil film thickness includes a support roller shaft. The support roller shaft is supported in the support roller shaft housing by a spherical seat, a spherical bearing and a support roller bearing. The support roller is fixed in the middle of the support roller shaft. A sealing flange is installed in the gap between the support roller shaft housing and the support roller shaft.

[0006] It also includes at least two sets of oil film monitoring sensors, which are fixed to the outside of the sealing flange by a bracket, and the sensor probe is perpendicular to the journal surface of the support roller shaft; the two sets of oil film monitoring sensors are 90°±5° apart in the same plane in the radial direction, and are symmetrically arranged on both sides of the diameter through the contact point between the support roller and the rotary kiln.

[0007] Further defining the above scheme, the oil film monitoring sensor is connected to the transmitter via an extension cable, and the extension cable is connected to the oil film monitoring sensor and the transmitter via a high-frequency connector; the transmitter is connected to the monitoring instrument via a three-core shielded cable, thus forming a real-time monitoring system.

[0008] Further specifying the above scheme, the oil film monitoring sensor adopts an eddy current sensor with an ESP48mm probe, a measurement range of 0.5mm to 2.5mm, a measuring range of 2mm, and a power supply voltage of +24V.

[0009] Further limiting the above scheme, the shielding layer of the three-core shielded cable between the transmitter and the monitoring instrument is grounded at a single point, and the connection distance does not exceed 300m.

[0010] Further defining the above scheme, a thrust disc is installed on the roller shaft, with an oil spoon fixed to the end face of the roller shaft; an oil spray plate is installed on the upper housing of the roller shaft housing for uniform distribution of lubricating oil.

[0011] Advantages of this utility model compared to the prior art:

[0012] 1. Real-time monitoring in this solution: By installing an eddy current sensor on the roller shaft near the bearing, changes in oil film thickness can be dynamically captured, avoiding the drawbacks of traditional shutdown inspections;

[0013] 2. This solution offers high precision: it uses a sensor with a measurement range of 2mm, suitable for oil film thicknesses of 0-0.50mm, with an error of less than +1%.

[0014] 3. Anti-interference design of this solution: The dual sensor probes are symmetrically arranged at 90° and the shielded cable is grounded at a single point, which can effectively suppress signal noise;

[0015] 4. The structure of this solution is stable: the sensor is fixed to the sealing flange by a bracket, which can effectively avoid displacement deviation caused by vibration;

[0016] 5. This solution is easy to maintain: The modular design facilitates sensor replacement or system expansion. Attached Figure Description

[0017] Figure 1 This is a front view of the structure of this utility model;

[0018] Figure 2 This utility model Figure 1 Enlarged structural diagram of section A in the middle;

[0019] Figure 3 This is the left structural view of the present invention;

[0020] Figure 4This is a schematic diagram showing the radial installation angle of the two oil film monitoring sensors in this utility model;

[0021] Figure 5 This is a block diagram of the system circuit connection of this utility model;

[0022] Figure 6 This is the circuit diagram of this utility model. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present utility model.

[0024] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0025] Please see Figure 1-6 The embodiments of this utility model are described in detail below.

[0026] Example 1: See Figure 1-3 As shown, this embodiment provides a rotary kiln support roller device with real-time monitoring function of bearing oil film thickness, including a support roller shaft 2, which is supported in the support roller shaft housing 1 by a spherical seat 5, a spherical bearing 3, and a support roller bearing 4. A support roller 6 is fixed in the middle of the support roller shaft 2, and a sealing flange 7 is installed at the gap between the support roller shaft housing 1 and the support roller shaft 2. It also includes at least two sets of oil film monitoring sensors 8, which are axially fixed to the outside of the sealing flange 7 by a bracket 9, with the sensor probe perpendicularly close to the journal surface of the support roller shaft 2. (See reference...) Figure 4 As shown, the two sets of oil film monitoring sensors 8 are 90°±5° apart in the same plane in the radial direction, and are symmetrically arranged on both sides of the diameter of the contact point between the support roller 6 and the rotary kiln.

[0027] See Figure 5 , Figure 6As shown, the oil film monitoring sensor 8 is connected to the transmitter 10 via an extension cable, and the extension cable is connected to the oil film monitoring sensor 8 and the transmitter 10 via a high-frequency connector; the transmitter 10 is connected to the monitoring instrument via a three-core shielded cable, forming a real-time monitoring system.

[0028] Preferably, the oil film monitoring sensor 8 is an eddy current sensor with an ESP4 8mm probe, a measurement range of 0.5mm to 2.5mm, a range of 2mm, and a power supply voltage of +24V.

[0029] Preferably, the shielding layer of the three-core shielded cable between the transmitter 10 and the monitoring instrument is grounded at a single point, and the connection distance does not exceed 300m.

[0030] See Figure 1 As shown, a thrust disc 15 is mounted on the roller shaft 2; an oil scoop 17 is fixed to the end face of the roller shaft 2; and an oil spray plate 16 is mounted on the upper housing of the roller shaft housing 1. This structure is used for the uniform distribution of lubricating oil.

[0031] Working principle of this utility model:

[0032] The probe of eddy current sensor 8 is perpendicularly close to the journal surface of roller shaft 2. It detects changes in the gap between the journal and the bearing through a high-frequency electromagnetic field, converting the changes into an electrical signal that is transmitted to transmitter 10. Transmitter 10 processes the signal into a 4-20mA current signal, which is then displayed in real time by the distributed control system to measure the oil film thickness. The symmetrical installation of the two oil film monitoring sensors eliminates radial vibration interference, ensuring data accuracy.

[0033] Example 2: Taking a rotary kiln in a cement plant as an example, two sets of ESP4 8mm eddy current sensors were installed, with the probes 1mm from the journal surface. The alarm threshold of the monitoring instrument was set to oil film thickness <0.1mm or >0.45mm. Operational data showed that the system could provide real-time feedback on the oil film status and trigger an alarm when abnormalities occurred, effectively preventing equipment wear.

[0034] This invention achieves dynamic monitoring of oil film thickness through the coordinated operation of an eddy current sensor, transmitter, and monitoring instrument. Its optimized installation structure and anti-interference design significantly improve monitoring accuracy and reliability, making it suitable for various rotary kiln equipment.

[0035] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0036] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A rotary kiln support roller device with real-time monitoring function of bearing oil film thickness, comprising a support roller shaft (2), wherein the support roller shaft (2) is supported in the support roller shaft housing (1) by a spherical seat (5), a spherical bearing (3) and a support roller bearing (4), a support roller (6) is fixed in the middle of the support roller shaft (2), and a sealing flange (7) is installed at the gap between the support roller shaft housing (1) and the support roller shaft (2); characterized in that: It also includes at least two sets of oil film monitoring sensors (8), which are fixed to the outside of the sealing flange (7) by a bracket (9), and the sensor probe is perpendicular to the journal surface of the roller shaft (2); the two sets of oil film monitoring sensors (8) are 90°±5° apart in the same plane in the radial direction, and are symmetrically arranged on both sides of the diameter of the contact point between the roller (6) and the rotary kiln.

2. The rotary kiln support roller device with real-time monitoring function of bearing oil film thickness according to claim 1, characterized in that: The oil film monitoring sensor (8) is connected to the transmitter (10) via an extension cable. The extension cable is connected to the oil film monitoring sensor (8) and the transmitter (10) via a high-frequency connector. The transmitter (10) is connected to the monitoring instrument via a three-core shielded cable, forming a real-time monitoring system.

3. The rotary kiln support roller device with real-time monitoring function of bearing oil film thickness according to claim 1, characterized in that: The oil film monitoring sensor (8) is an eddy current sensor with an ESP4 8mm probe on it. The measurement range is 0.5mm to 2.5mm, the range is 2mm, and the power supply voltage is +24V.

4. The rotary kiln support roller device with real-time monitoring function of bearing oil film thickness according to claim 2, characterized in that: The shielding layer of the three-core shielded cable between the transmitter (10) and the monitoring instrument is grounded at a single point, and the connection distance does not exceed 300m.

5. The rotary kiln support roller device with real-time monitoring function of bearing oil film thickness according to claim 1, characterized in that: A thrust plate (15) is installed on the roller shaft (2), and an oil spoon (17) is fixed to the end face of the roller shaft (2); an oil spray plate (16) is installed on the upper shell of the roller shaft housing (1) for the uniform distribution of lubricating oil.

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