Research On Cylinder Mechanical Fault Monitoring Method And System Of Rotary Kiln

Rotary kiln is widely used in building materials,metallurgy and other production industries,which mainly comprises the cylinder,rollers and tires,transmission components,wherein the cylinder is the calcination place of materials.The long-term operation of the kiln in high temperature,heavy load,dusty and harsh conditions,often lead to potential faults of bending deformation and offset center point of the cylinder,if unchecked,do not take timely measures,will lead to the faults extent until production disruptions,causing significant economic losses.At present,the technical means for the faults of the cylinder still remain in the stage of after-service maintenance and regular inspection,and it can not get the information of the cylinder’s running status in real time,and discover the early potential faults of the cylinder in time.For this reason,a cylinder fault measurement method is proposed,and its validity is verified.Based on that,a set of on-line monitoring system is designed.The main study contents are as follows:(1)Through the qualitative analysis of the stress of the supporting roller,the influence of the bending deformation and the center point deviation on the deflection of the supporting shaft is studied.It is pointed out that the signal of deflection roller shaft contains the waveforms of the cylinder and roller frequency,these two waves amplitude can reflect two kinds of faults of the cylinder,and a measurement method of the cylinder fault is presented by collecting the deflection signal of the supporting roller.(2)In view of the above measurement methods,a set of measuring system of deflection signal of supporting shaft is designed.Field measurement is carried out on a rotary kiln,during which time and frequency domain data are analyzed,and the characteristic parameters of the signal are extracted,then the fault condition of the cylinder is obtained finally.The results are compared with the results measured by the other two methods,and the correctness of the original measurement method and the validity of the time frequency analysis method are verified.(3)Based on the above theory,combined with the actual needs of the project,a PC based monitoring system management software based on LabVIEW is developed to monitor the running status of the rotary kiln in real time.The overall framework of the software and the implementation of the functional modules are briefly introduced,and the system tests are carried out to verify the reliability of the monitoring software.In order to achieve distributed data collection and reduce the cost of installation and maintenance,a monitoring platform based on wireless sensor network is designed.The hardware and software design of WSN node are introduced in detail,and the connection with monitoring software is achieved.