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User Manual:
I
D
nductive
istance
1.
INTRODUCTION:
The Inductive Distance Measurement (IDM) Tool Kit is a multi-purpose measurement tool. Typically
it is used to check the condition of rotating parts during operation (e.g. on Rotary Kilns, Dryers, Ball
Mills). It measures variation of distances of moving metal surfaces without contact (typically steel
surfaces) with high accuracy and high speed (up to 1000 measurements per second).
It can be considered as a contactless dial gauge.
Typical applications:
•
Run-out measurement of girth gears on rotary kilns, rotary dryers and ball mills
•
Run-out measurement of kiln tires
•
Roller shaft bending measurement of support rollers on rotary kilns
•
Shaft movements in gear boxes and drives
•
Roundness and run out check of trunnions on ball mills
More applications:
The IDM II Controller can be used for any kind of sensor with an output of 0...10V or 0...20mA
(supplied from January 2020)
Hence there are much more applications possible. E.g.:
•
High speed hydraulic pressure measurement on vertical roller mills and roller presses
•
Shell deformation measurement on rotary kilns or ball mills with laser distance sensors
•
Verification of values of any installed sensor output signal directly on site
•
........
TomTom-Tools GmbH
Zelgli 20
8905 Arni
Switzerland
M
easurement (IDM) Tool Kit II
4 April 2022
Phone: +41 79 774 06 44
Info@tomtom-tools.com
www.tomtom-tools.com
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Table of Contents
Summary of Contents for TomTom Inductive Distance Measurement Tool Kit II
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Page 1: Introduction
TomTom-Tools GmbH Phone: +41 79 774 06 44 Zelgli 20 Info@tomtom-tools.com 8905 Arni Switzerland www.tomtom-tools.com User Manual: nductive istance easurement (IDM) Tool Kit II INTRODUCTION: The Inductive Distance Measurement (IDM) Tool Kit is a multi-purpose measurement tool. Typically it is used to check the condition of rotating parts during operation (e.g. on Rotary Kilns, Dryers, Ball Mills). -
Page 2: Table Of Contents
Page 2 April 4, 2022 TABLE OF CONTENT Introduction: .......................... 1 Safety: ..........................3 Measuring Principle: ......................4 Tool Kit includes: ......................... 5 Components:........................5 The Sensors .......................... 6 Features: ..........................7 IDM2 Controller: ........................7 Software: ..........................8 Bluetooth Adapter ....................... -
Page 3: Safety
/ factory / local authorities and discuss the application with the safety engineer in charge. The tools provided by TomTom-Tools GmbH have proven their functionality in various applications; nevertheless TomTom-Tools GmbH does not take any responsibility for the application on site regarding safety. -
Page 4: Measuring Principle
The signals of maximal six sensors can be measured by the IDM2 Controller, which converts them into numeric values and sends them via Bluetooth to a PC. The software TomTom-Tools Measurement Studio (for Windows), which comes together with the measurement tool is made to receive, store and process the values from the IDM Controller. -
Page 5: Tool Kit Includes
7. Transport Case with foam cushioning extra tough, water and dust seal (suitable for air cargo) 8. Manual and Software for Windows on USB memory TomTom-Tools Measurement Studio 9. Bluetooth adapter to connect the controller with the PC Magnetic Switch Flag... -
Page 6: The Sensors
Page 6 April 4, 2022 THE SENSORS Any sensor with 0…10V or 0…20mA output can be connected to the IDM controller (maximal power consumption of all connected sensors together: 400 mA @ 24VDC) Sensor Name: IFM D12 IFM D18 IFM D30 IFM 40x40 Turck 30x14... -
Page 7: Features
Page 7 April 4, 2022 Features: The IDM II controller is equipped with a Li-Ion Battery pack and a power convertor to supply the sensors with 24VDC. The battery gets charged by the charger, which is included in the tool kit or by any power source from 9 to 30VDC (center pin positive). -
Page 8: Software
Note: • The TomTom-Tools are designed to communicate only with the generic Windows Bluetooth Stack. If there is another Bluetooth software installed (e.g. Toshiba, Widcomm, Intel, ThinkPad,…), deactivate it in the Device Manager as shown below: Fig. 4.1.1 (Device Manager) -
Page 9: Start The Tool
Page 9 April 4, 2022 • Then plug the Bluetooth adapter UD100. Windows recognizes the new hardware and automatically install the suitable Windows driver (Windows generic Bluetooth) • The Device Manager will show the following: - Generic Bluetooth Radio - Microsoft Bluetooth Enumerator - the not required Bluetooth is down (indicated by the small arrow at the Bluetooth icon) - Page 10 Page 10 April 4, 2022 Fig. 5.1.2 (Connect Device) • IDM2 gets added to the Device List • To connect it, select it and click on the “Connect” Button Fig. 5.1.3 (Device Window) To connect click here Device can be connected, when displayed here (in black letters)
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Page 11: Raw Data Acquisition
Page 11 April 4, 2022 RAW DATA ACQUISITION: Purpose The Raw Data Acquisition is a universal application to measure any kind of value. Either distances can be measured with the inductive sensors, included in the tool kit or other sensors can be connected with an output of 0…10V or 0…20mA. -
Page 12: Take Measurements
Page 12 April 4, 2022 Change the sampling rate by clicking on the number Fig. 6.2.3 (Edit Sampling Rate) Edit Channel Actual Click here to Click on number Sensor Value change window to edit sampling To add a sensor channel, click the button “Add Channel” (see picture above). Select an existing scaling or create a new one (as described above) See the green bar;... -
Page 13: Roller Shaft Bending
Page 13 April 4, 2022 Fig. 6.3.2 (Raw data graph) Stop Button (F6) Set Mark (F9) to generate time staps Click mouse right to change the X and Y axis ROLLER SHAFT BENDING: Measurement Principle On a kiln support roller, the variation of the deflection of the roller shafts show possible cranks. Cranks are straightness errors in the kiln shell, which are affecting the loads on the roller stations with each kiln revolution. -
Page 14: Start The Software Application
Page 14 April 4, 2022 Low Load High Load Low Load High Load Low Load High Load Roller High Loaded Roller Low / Not Loaded Inductive Sensor Inductive Sensor (gap reduced) (gap increased) Line of Force Inductive Sensor Inductive Sensor Controller Start The Software Application... -
Page 15: Take Measurements
Page 15 April 4, 2022 The computer screen will show a kiln tire with two rollers (top view). To add more tires, click right mouse button and select “Add Pier” (see picture below) See the green bar, which indicates the Sensor Distance (gap between roller surface and sensor). It should be approximately in the middle of the sensor range, at least never go to one of the extreme positions. - Page 16 Page 16 April 4, 2022 Note: To be able to calculate the roller shaft bending value and its position around the kiln, the software needs a reference signal, when the reference point is passing the roller, which is measured. Typically the manhole in the kiln shell is used as reference point.
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Page 17: Interpretation Of Results
Note: TomTom-Tools GmbH does not provide guide lines about roller shaft limits. It has to be according to the equipment manual or discussed with the suppliers, how much roller shaft bending can be allowed. -
Page 18: Gear Run Out
Page 18 April 4, 2022 GEAR RUN OUT: Measurement Principle Most rotary kilns and many ball mills are driven by open gear drives (pinion and girth gear). Due to difficulties during the installation or later during the operation, the girth gears might do not run concentrically nor straight. - Page 19 Page 19 April 4, 2022 Sensor Size: In this application it is also recommended to use the smallest possible sensor to have the highest accuracy. Unfortunately often is the sensor range not sufficient, hence a bigger sensor with more range has be used, especially on kilns.
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Page 20: Start The Software Application
Page 20 April 4, 2022 Start The Software Application The Measurement Studio includes a specific application to measure and calculate the run-out of gears. It can also be used for measuring the axial run-out of kiln tires. To start it, click “Project / Add Gear Runout” The computer screen will show the graph window with the value window below. -
Page 21: Sampling Rate (Frequency) Adjustment
Page 21 April 4, 2022 Fig. 8.4.1 (Gear Runout Measurement) Switch to Radar Chart To adjust sampling rate Surface Type Switches (radial) Radial Sensor Distance Sampling rate Input Surface Type Edit Sensor Sensor Axial Sensor Cannel Switches (axial) Settings Type Distance Sampling Rate (Frequency) Adjustment... -
Page 22: Take Measurements
Page 22 April 4, 2022 Take Measurements To start the measurements push the Start button or [F5]. After starting the measurement, the values will appear on the computer screen (green curve) Note: To be able to calculate the run-out value and its position, the software needs a reference signal, when the reference point is passing the sensors position. -
Page 23: Results
Page 23 April 4, 2022 green graph shows the measured values from the radial sensor green curve is the calculated sinus from the radial readings blue graph shows the measured values from the axial sensor blue curve is the calculated sinus from the axial readings After 2 to 3 kiln revolutions, sufficient data are collected and the measurement can be stopped. - Page 24 Page 24 April 4, 2022 The following values are calculated and shown as numbers: Radial: • Eccentricity: shows how much the girth gear is out of the center of rotation, it is the distance between the center of rotation and the center of the girth gear (blue arrow) •...
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Page 25: Limits
Total Run-Out Limits TomTom-Tools GmbH does not provide guide lines about acceptable run-out limits. It has to be according to the equipment manual or discussed with the suppliers, how much run-out and roundness error can be allowed. Out of experience the following table can be taken as an example for kiln girth gears but might... -
Page 26: Optional Sensor To Measure Shaft Movement In Gearboxes
April 4, 2022 OPTIONAL SENSOR TO MEASURE SHAFT MOVEMENT IN GEARBOXES TomTom has developed a sensor, which can be connected to the IDM Controller and measures the axial movement of floating shafts. It can be installed during normal mill operation. -
Page 27: 10.2 Create A Report
Page 27 April 4, 2022 10.2 Create a report The measurements can be extracted into a report. All additional information from “Setting Window” is included in the report as well. Fig. 10.2.1 10.3 Adding a New Sensor Scaling The four inputs of the IDM Controller measure 0…10V which correspond to the measurement range of the sensors. - Page 28 Page 28 April 4, 2022 TomTom-Tools GmbH Switzerland www.tomtom-tools.com info@tomtom-tools.com...