CN101050955A - Dynamic measuring method for rotary kiln tubular axis and measuring and control system - Google Patents
Dynamic measuring method for rotary kiln tubular axis and measuring and control system Download PDFInfo
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- CN101050955A CN101050955A CN 200610039647 CN200610039647A CN101050955A CN 101050955 A CN101050955 A CN 101050955A CN 200610039647 CN200610039647 CN 200610039647 CN 200610039647 A CN200610039647 A CN 200610039647A CN 101050955 A CN101050955 A CN 101050955A
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Abstract
A method for measuring barrel dynamic axis of rotating kiln includes using connection line of riding wheel base center at kiln heat gear position to that at kiln tail as reference line, using theodolite to set up a vertical reference surface in parallel to said reference line as coordinate system of permanent reference surface at one side of kiln, measuring parameters of level and vertical displacement of outer circle on wheel belt and diameter of wheel belt as well as center height difference between wheel belt and barrel for confirming dynamic axis of barrel.
Description
Technical field
The present invention relates to the rotary kiln dynamic measurement method, particularly to the dynamic measurement method and the TT﹠C system of its tubular axis.
Background technology
Rotary kiln is the key equipment in metallurgy, chemical industry, cement, the fire resistive material production, is a kind of heavy duty, high pulling torque, many fulcrums, static indeterminacy (being generally the above situation of three fulcrums) operational system.The adjustment of rotary kiln running axis in the actual production is to carry out in conjunction with some empirical Calculation by the calm attitude of kiln is measured.And the kiln body is in operation owing to the reasons such as uneven wear of thermal deformation that each section of cylindrical shell difference variation causes, bearing bush of supporting roller, support roller, wheel band Internal and external cycle, will cause the variation of kiln operation axis, and it is a straight line that the operation axis of kiln reality is difficult to.The rotary kiln axis imbalance can cause regular kiln and the unnecessary loss of stopping, and regularly stops the bending that kiln can aggravate the kiln body again, makes the kiln axis deformation, and this is a vicious cycle process.Therefore, often need tubular axis be measured and centering, avoid causing bearing shell heating, the generation of faults such as cylindrical shell cracking because of the cylindrical shell bending according to the working order of kiln.
More representational to the measuring method of rotary kiln tubular axis at present is the scheme that Wuhan Polytechnical Univ proposes.Its measuring principle and method are:
As Fig. 1, outside kiln, set up rectangular coordinate system X, Y, Z, set up 2 parallel vertical plane L and R in the kiln both sides with 2 transits, under taking turns band, each sets up level reference H with spirit-leveling instrument, 3 displacement transducers are installed on measured wheel band level and straight vertical radial line, at 1 Hall element of the other fixed installation of cylindrical shell, measure wheel band mean place parameter L automatically by the system controlled by computer all the sensors
I2, R
I2, H
I2The guide rail chi of band slip target has been installed on 2 horizontal displacement sensors, has been cooperated with the transit of frame on L, R face the slip target is moved on to L, R face, write down its reading L on the guide rail chi
I2, R
I2Height H between perpendicular displacement sensor and the reference field H
I1Be to measure with spirit-leveling instrument.The horizontal coordinate X of wheel band place cylindrical shell central point
iBe calculated as follows: X
i=1/2 (D+L
i+ R
i) i is wheel band sequence number, L in the formula
i, R
iBe respectively and take turns the mean distance that takes L, R face to, D is the distance between L, the R face.
L
i＝L
i1+L
i2，R
i＝R
i1+R
i2
Wheel band mean radius r=1/2 (D-L
i-R
i)
The vertical coordinate Z of wheel band place cylindrical shell central point
i=H
I1+ H
I2+ (r
i-
i) cosa
iBe the difference in height of cylindrical shell with wheel band center, a is a kiln body mounting inclination angle.The problem that above-mentioned method exists is:
(1) measurement coordinate system is not an absolute coordinate system, is unfavorable for the comparison of each time measured value;
(2) its measurement result is a series of data, measurement result is not further handled, and is unfavorable for the analysis to the tubular axis dynamic change;
(3) measurement result can not be directly used in the operation to rotary kiln, control;
(4) systemic-function is single, is unfavorable for function expansion;
(5) stability is poor, and precision is low, and instrument costs an arm and a leg, complicated operation.
Summary of the invention
The purpose of this invention is to provide a kind of rotary kiln tubular axis dynamic measurement method and TT﹠C system.It is fast to have measuring speed, measuring accuracy height, the advantage that cost is low.
Technical scheme of the present invention is as follows: a kind of rotary kiln tubular axis dynamic measurement method, earlier coordinate system is set up in the rotary kiln locus, determine the coordinate position of measurement point, each grade wheel band is divided into the M five equilibrium, and the parameter of measurement comprises taking turns is with level and perpendicular displacement, tyre diameter, wheel band and the cylindrical shell centre-height difference of cylindrical can determine the dynamic axis of cylindrical shell; Concrete grammar is as follows:
(1) determining of measurement coordinate system: at first the support roller base line of centres with kiln hood and kiln tail gear is a datum line, side at kiln is set up a vertical reference face (1) that parallels with datum line with transit, minimum point place surface level with kiln hood gear wheel band is horizontal basic side, crosses the minimum point of kiln hood gear wheel band and the vertical reference face (2) vertical with the support roller base line of centres;
(2) measurement of straight vertical dimension: measure the difference in height of each grade wheel band minimum point and the diameter of each grade wheel band and calculate the straight vertical dimension; Concrete grammar is: at first use spirit-leveling instrument to set up a level reference and read under each gear wheel band minimum point with respect to the height h of level reference by scale
kAnd then measure the diameter D of each grade wheel band
kAnd wheel band center O
kWith the cylindrical shell center O
kDifference in height Δ h
k' obtain the height H of each gear cylindrical shell axle center with respect to reference field
kComputing formula is as follows:
H
k＝h
k+D
k/2-Δh
k′ (1)
Δh
k＝H
k-H
1-(S
1+S
2+……S
k-1)×(H
n-H
1)/S (K＝2、3……n) (2)
Cylindrical shell operation axis with respect to the height tolerance δ hk of design axis suc as formula (3)
δh
k＝H
k-H
1-(S
1+S
2+……+S
k-1)×Sina (K＝2、3……、n) (3)
S is two distances between the adjacent wheels band in the formula;
A is the design gradient;
(3) the straight horizontal dimension is measured: measure cylindrical shell at the horizontal radial displacement L of n gear place wheel belt surface with respect to reference field
k(j) and the diameter D of wheel band
k, calculate the horizontal level X that each gear is taken turns the tape spool heart
k(j), computing formula is as follows:
X
k(j)＝L
k(j)+D
k/2 +?(j＝1、2……m；K＝1、2……n)
ΔX
k(j)＝X
k(j)-X
1(j)-[X
n(j)-X
1(j)]×(S
1+S
2+……S
k-1)/S
Each grade horizontal departure mean value Δ X
k=[Δ X
k(1)+Δ X
k(2)+... X
k(m)]/m
In the formula: X
k(j) be the horizontal departure at cylindrical shell center, j calibration place of K shelves;
Δ X
kBe each grade horizontal departure mean value;
(4) measurement of tyre diameter: the girth by the measuring wheel band calculates tyre diameter;
(5) on-line measurement of slippage calculates cylindrical shell and the difference in height of taking turns the band center by measuring cylindrical shell with gap, top of taking turns the band center or slippage; Computing formula is:
D-d＝(T
D/T
d)d
In the formula: d is that cylindrical shell adds diameter behind the backing plate, and D is wheel band internal diameter, T
dBe cylindrical shell rotation period, T
DBe wheel band rotation period.
A kind of rotary kiln tubular axis dynamic measuring control system that is applied to described method, it is characterized in that it comprises the sensor of gathering displacement signal, the sensor of collection position signal, the disposal system of signal condition unit, the data collecting card that power module, bleeder circuit and filtering circuit are formed and the computing machine composition that stores process of measurement; Sensor, signal condition unit, data collecting card, computing machine electrically connect successively; Described sensor adopts inductance fm formula displacement transducer.
Owing to adopted such scheme, the present invention to have following advantage:
1, the coordinate of choosing is an absolute coordinate system, can guarantee the each benchmark unanimity of measuring of rotary kiln, is convenient to analysis and research.
2, only need a displacement transducer in the measuring system, have simple and reliable, the on-the-spot preliminary work of measuring operation and auxiliary to implement less, save man power and material, measuring speed fast etc.
When 3, measuring, Hall element is installed on cylindrical shell, can be guaranteed that each grade measurement data has unified phase information as the switching signal of measuring each file data.
4, the whole test system configuration is reasonable, and function is good, has good open performance and extensibility.Measurement data is linked computing machine (host computer) by data collecting card, can analyze, handle, show measurement data by virtual instrument technique easily.
5, can extrapolate each grade of rotary kiln force-bearing situation by measurement data, and can be by computing machine with various graph directs of employing such as tubular axis situation of change, each grade stressing conditions, dynamically show.In case misalignment of axe is excessive or support roller is stressed excessive, can be by operation, the control of computer-implemented rotary kiln.
Description of drawings
The present invention is described in more detail below in conjunction with drawings and Examples.
Fig. 1 is prior art wheel band place's cylindrical shell position measurement synoptic diagram;
Fig. 2 is rotary kiln axis straight vertical dimension measuring principle figure of the present invention;
Fig. 3 is rotary kiln axis straight horizontal dimension measuring principle figure of the present invention;
Fig. 4 is a tubular axis horizontal survey sectional view;
Fig. 5 is the output synoptic diagram of Hall element and speed pickup;
Fig. 6 is the TT﹠C system theory diagram;
Fig. 7 is the TT﹠C system program flow diagram.
Among the figure: 1, wheel band, 2, cylindrical shell, 3, support roller, 4, base, 5, Hall element, 6, magnetic links, 7, the vertical reference face, 8, vertical basic side, 9, speed pickup, 10, displacement transducer, 11, measuring instrument.
Embodiment
As shown in Figure 2, the contour structures of rotary kiln is generally multi-point support, has two support rollers 3 to be with 1 the kiln body supported by wheel at each gear place, and there are certain gradient α in tubular axis and surface level.Each supporting gear is by a base 4, two support rollers 3 and be enclosed within wheel on the cylindrical shell 2 and be with parts such as 1 to constitute.
For making things convenient for in-site measurement, need set up space coordinates to the rotary kiln locus, suppose that simultaneously certain rotary kiln has the n shelves, the main measuring element of whole measuring system is a transit, spirit-leveling instrument, displacement transducer 10, speed pickup 9, a Hall element 5 (as switching signal, being convenient to the management of each grade measurement data).When measuring each grade, will take turns band and be divided into m five equilibrium (m can change arbitrarily, is convenient to obtain required precision).Then the parameter that need measure comprise the wheel can determine the dynamic axis of cylindrical shell with level and perpendicular displacement, tyre diameter, wheel band and the cylindrical shell centre-height difference etc. of 1 cylindrical.Concrete measuring method is as follows:
1, measurement coordinate system determines
As shown in Figure 3, at first the support roller base line of centres with kiln hood and kiln tail gear is a datum line, side at kiln is set up a vertical reference face 8 that parallels with datum line with transit, minimum point place surface level with kiln hood gear wheel band is a level reference, crosses the minimum point of kiln hood gear wheel band and the vertical reference face 7 vertical with the support roller base line of centres.
2, the measurement of straight vertical dimension
At first, by measuring the difference in height between each gear cylindrical shell centre of gyration, distinguish the straight vertical dimension of cylindrical shell operation axis.Because the diameter of each grade wheel band is also inequality, so the difference in height that the difference in height between the axle center of each gear cylindrical shell need be by measuring each grade wheel band minimum point simultaneously and the diameter of each grade wheel band are tried to achieve measuring principle such as Fig. 2, shown in Figure 3.At first use DS
3The type spirit-leveling instrument is set up a level reference, and reads under each gear wheel band minimum point with respect to the height h of level reference by scale
k(k=1～n), and then by measuring the diameter D of each grade wheel band
kAnd wheel band center O
k' and the cylindrical shell center O
kDiscrepancy in elevation Δ h
k' obtain the height H of each gear cylindrical shell axle center with respect to reference field
k(ignoring the influence at a inclination angle during calculating).Then have:
H
k＝h
k+D
k/2-Δh
k’ (1)
(L) cylindrical shell operation axis is with respect to 1 grade of height tolerance with the n shelves cylindrical shell line of centres
Δh
k＝H
k-H
1-(S
1+S
2+…+S
k-1)×(H
n-H
1)/S (k＝2，3，…，n) (2)
S=S in the formula
1+ S
2+ ... + S
N-1(S
1, S
2)
(2) cylindrical shell operation axis is with respect to the height tolerance (a is the design gradient) of design axis
δh
k＝H
k-H
1-(S
1+S
2+…+S
k-1)×sina (k＝2，3，…，n) (3)
3, the measurement of straight horizontal dimension
Realize that by the diameter and the surperficial horizontal radial displacement thereof of measuring each gear wheel band its principle as shown in Figure 3 and Figure 4.By measuring cylindrical shell at the horizontal radial displacement L of n gear place wheel belt surface with respect to reference field
k(j) and the diameter D of wheel band
k, can obtain the horizontal level X that each gear is taken turns the band place
k(j).Because the wheel band rotates in the process in a week, its radial level displacement is not quite similar, thereby when actual measurement, and we measure (j=1～m) with rotary kiln along circumferentially uniformly-spaced being divided into m phase place, so that when accurately understanding cylindrical shell and forwarding out of phase to, the horizontal departure situation of axis.Can get by Fig. 3:
X
k(j)＝L
k(j)+D
k/2 (j＝1，2…，m；k＝1，2，…n) (4)
Wherein, L
k(j)=S
k(j)+l
k
In the formula: S
k(j)-the sensor displacement; l
k-Di k shelves sensor scale label.
The horizontal departure Δ X at cylindrical shell center, j calibration place of k shelves then
k(j) be:
ΔX
k(j)＝X
k(j)-X
1(j)-[X
n(j)-X
1(j)]×(S
1+S
2+…+S
k-1)/s
Each grade horizontal departure can represent with mean value, that is:
ΔX
k＝[ΔX
k(1)+ΔX
k(2)+…+ΔX
k(m)]/m (5)
4, the measurement of tyre diameter
The diameter of wheel band determines that by measuring its girth measuring principle as shown in Figure 4.With standard rolling bearing manufacturing speed sensor 9, make between itself and the support roller 3 and do nonslipping rolling, thereby the linear velocity of bearing surface and the linear velocity of taking turns belt surface are consistent, and the number of turns that turns over all process centre bearers in rotation by the measuring wheel band can record the diameter that wheel is with.Testing the speed is equipped with the Hall element and the magnetic sheet of the usefulness that tests the speed on the pinch roller, and the pinch roller revolution is crossed a circle, and Hall element will be exported a pulse signal, thereby obtains the speed of wheel band.Meanwhile, adopt another one Hall element 5 to measure the rotation period of cylindrical shell, magnetic sheet 6 on cylindrical shell is by directly over the Hall element 5 time, Hall element will be exported a pulse signal, the time interval T of pulse represents its rotation period, and in the process of wheel with the moving circle of 1 revolution, the Hall element on the pinch roller that tests the speed also can produce series of pulses, suppose that it is N that cylindrical shell rotates the whole pulse number that speed pickup is exported between one-period, the fifth wheel diameter is d
c, t
1And t
2Speed is during this time used two the most close recurrence interval T respectively
1And T
NConvert, can take turns the diameter D of band thus, computing formula is:
D＝(N+t
1/T
1+t
2c/T
N)×d
c (6)
5, the on-line measurement of slippage
D-d＝(1-T
d/T
D)×D (7)
6, tubular axis TT﹠C system
The testing hardware of total system is as shown in Figure 5:
1) Sensor section comprises:
Speed pickup: the surface line displacement that is used to measure cylinder of rotary kiln.
Hall element: be used to measure the cylinder of rotary kiln rotation period.
Displacement transducer: the horizontal shift that is used to measure rotary kiln tyre.
The inductive displacement transducer that system adopts, highly sensitive, linear, good reproducibility, hysteresis are little.Range 50mm, nonlinearity erron (%)≤0.2, operating voltage is 5VDC, output current 4～20mA allows environment temperature-30～+ 120 ℃.
Speed pickup is a Hall element, and the used Hall element of native system is a HBB series, and operating voltage 3～28VDC detects apart from 10mm repetitive positioning accuracy≤0.02mm, response frequency 5000Hz, operating ambient temperature :-30～+ 80 ℃.
2) signal process box.Comprise the usb data capture card, power module, circuit such as division module.
Data collecting card usb bus form provides power supply and communication by the USB mouth, need not external power supply.8 connection terminals are used for the analog quantity input, can be independently 8 the tunnel single-ended, 4 tunnel difference, or the mixing between them, and there is 12 resolution on every road, and the highest picking rate is 8kHz.Single-ended input measurement scope+/-5V.One 32 digit counter is arranged, and count frequency is 1MHz, has 4 road digital quantity input and output to be connected power supply with+5 in addition.Capture card is connected to by cable on the USB mouth of notebook, connects the back card and goes up LED indication flicker and close expression for 4 times and connect normal.
It is 10V that high level is carried out in Hall switch output, so will carry out dividing potential drop, signal is output as in the direct current 5V after conditioning, can directly receive data collecting card.
Power module mainly is to the sensor power supply, and two parts circuit is arranged, and can be Alternating Current Power Supply, also can be made as direct current supply.Alternating Current Power Supply is partly imported AC220V, through output behind the rectifying and voltage-stabilizing+/-12V and+/-the 5V power supply.Direct current supply input can be 4 joint 1.5V batteries, output after transformation+/ 12V and+/-the 5V power supply, its power satisfies the working sensor needs fully.
3) computing machine (host computer)
Running software requires to support the above version of WINDOWS2000, more than the internal memory 128M, more than the hard disk remaining space 400M.
4) slave computer
Receipt source is in the relevant controlling signal of host computer, and goes to report to the police or control the operation of rotary system equipment by slave computer.
Claims (2)
1, a kind of rotary kiln tubular axis dynamic measurement method, earlier coordinate system is set up in the rotary kiln locus, determine the coordinate position of measurement point, the parameter of measurement comprises taking turns is with level and perpendicular displacement, tyre diameter, wheel band and the cylindrical shell centre-height difference of cylindrical can determine the dynamic axis of cylindrical shell; It is characterized in that:
(1) determining of measurement coordinate system: at first the support roller base line of centres with kiln hood and kiln tail gear is a datum line, side at kiln is set up a vertical reference face (7) that parallels with datum line with transit, this reference field is as permanent benchmark, be convenient to measure from now on, minimum point place surface level with kiln hood gear wheel band is horizontal basic side, crosses the minimum point of kiln hood gear wheel band and the vertical reference face (8) vertical with the support roller base line of centres;
(2) measurement of straight vertical dimension: measure the difference in height of each grade wheel band minimum point and the diameter of each grade wheel band and calculate the straight vertical dimension; Concrete grammar is: at first use spirit-leveling instrument to set up a level reference and read under each gear wheel band minimum point with respect to the height h of level reference by scale
kAnd then measure the diameter D of each grade wheel band
kAnd wheel band center O
kWith the cylindrical shell center O
kDifference in height Δ h
k' obtain the height H of each gear cylindrical shell axle center with respect to reference field
kComputing formula is as follows:
H
k＝h
k+D
k/2-Δh
k′ (1)
Δh
k＝H
k-H
1-(S
1+S
2+……S
k-1)×(H
n-H
1)/S (K＝2、3……n) (2)
Cylindrical shell operation axis with respect to the height tolerance δ hk of design axis suc as formula (3)
δ
hk＝H
k-H
1-(S
1+S
2+……+S
k-1)×Sina (K＝2、3……、n) (3)
S is two distances between the adjacent wheels band in the formula;
A is the design gradient;
(3) the straight horizontal dimension is measured: measure cylindrical shell at the horizontal radial displacement L of n gear place wheel belt surface with respect to reference field
k(j) and the diameter D of wheel band
k, calculate the horizontal level X that each gear is taken turns the tape spool heart
k(j), will take turns band and be divided into adjustable some five equilibriums, each grade measurement data is come the unified management data by near the position transducer that is fixed on the cylindrical shell; Computing formula is as follows:
X
k(j)＝L
k(j)+D
k/2 (j＝1、2……m；K＝1、2……n)
ΔX
k(j)＝X
k(j)-X
1(j)-[X
n(j)-X
1(j)]×(S
1+S
2+……S
k-1)/S
Each grade horizontal departure mean value Δ X
k=[Δ X
k(1)+Δ X
k(2)+... X
k(m)]/m
In the formula: X
k(j) be the horizontal departure at cylindrical shell center, j calibration place of K shelves;
Δ X
kBe each grade horizontal departure mean value;
(4) measurement of tyre diameter: the girth by the measuring wheel band calculates tyre diameter;
(5) on-line measurement of slippage calculates cylindrical shell and the difference in height of taking turns the band center by measuring cylindrical shell with gap, top of taking turns the band center or slippage; Computing formula is:
D-d＝(T
D/T
d)d
In the formula: d is that cylindrical shell adds diameter behind the backing plate, and D is wheel band internal diameter, T
dBe cylindrical shell rotation period, T
DBe wheel band rotation period.
2, a kind of rotary kiln tubular axis dynamic measuring control system that is used for the described method of claim 1, it is characterized in that it comprises the sensor of gathering displacement signal, the sensor of collection position signal, the disposal system of signal condition unit, the data collecting card that power module, bleeder circuit and filtering circuit are formed and the computing machine composition that stores process of measurement; Sensor, signal condition unit, data collecting card, computing machine electrically connect successively; Described sensor adopts inductance fm formula displacement transducer.
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|---|---|---|---|
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| CN102359773B (en) * | 2011-06-27 | 2013-07-17 | 武汉理工大学 | Device and method for measuring operating axis of barrel of rotary kiln |
| CN102359773A (en) * | 2011-06-27 | 2012-02-22 | 武汉理工大学 | Device and method for measuring operating axis of barrel of rotary kiln |
| CN102654396B (en) * | 2012-05-21 | 2014-12-03 | 武汉理工大学 | Detecting and monitoring method and measuring system for dynamic axis and bending of rotary kiln tube |
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