TomTom-Tools GmbH

Wiesenstrasse 15 5400 Baden

Switzerland

Phone 1: +41 79 774 06 42 Phone 2: +41 79 774 06 44 VAT ID: 698 468 www.tomtom-tools.com Info@tomtom-tools.com

User Manual: (Draft Version)

OVALITY SENSOR

1. INTRODUCTION: The Ovality Sensor is a measurement tool for rotary kilns, which measures the changes of the roundness / curvature in the kiln shell during operation. This elastic deformation is called Ovality and is primarily present in the area of a kiln tire. The measurement gives accurate information about the degree of mechanical loads in the refractory / kiln shell and allows defining the countermeasures in advance to increase the lifetime of the kiln components. The Ovality Sensor is small, easy to use and comes along with a tough transport case.

1.1

Safety:

Rotary kilns or dryers, where this tool is used, are huge rotating equipments with many pinch points, they can cause serious injuries. Therefore only specialized and trained personnel shall work close to these machines. To use the Ovality Sensor, follow strictly the local safety rules given by the respective plant / factory / local authorities and discuss the application with the safety engineer in charge. The tools provided by TomTom-Tools Ltd have proven their functionality in various applications; nevertheless TomTom-Tools Ltd does not take any responsibility for the application on site regarding safety. The plant is responsible for the safety, according to the local law, in a way that nobody can be hurt or injured. The application and safety instructions below are guidelines, which include the experience from previous measurement campaigns and might need to be adapted to the local safety requirements.

7 June 2011

....1 7....................................................................6 Components: ..............................................................................................................................................................................................2 7.............. 13 Annex ..................................................... 3......................... 5......................................................6 Features:..............................................4 6.........................................................................................................................................................................................................................................................................................................3 5.................7 Start the Tool:..................................5 Ovality Sensor...... 1..... 12 Temperature Resistance........................................................................................................................................................8 Flexing of the Deflection Plate ................................................................. 10 Place Tool on Kiln....................7 Bluetooth Adapter....................................1 4.................................................................2 4..............................................................6 Software:........................................................7 Installation:...............3 Introduction:.....................................1 2.................................................................................................................................................................................................................................................................................................................................9 Measurements ......................................................1 3............................................2 3............................................................ 2.................... 16 ....................................... 13 Report............................................................................................................................................................................................... 7.........................1 Measuring Principle:............................................................2 1............................................................2 4................................2 5.......................................1 5........................... 4.... 15 Drawing.1 6............................... 6.................4 Tool Kit includes: .........................................................................................................................................2 7..... 13 Export to Excel ................................................................................................................................ 14 Ovality Report.....8 Calibration of Integrated Orientation Sensor .......................1 Safety:........................................3 5........... 11 Results......................................................... 10 Set Up the Measurement Window.................. 2011 TABLE OF CONTENT 1...........................................................1 1.......3 2........................ 13 Create a report .......................................................................... 14 Export to Excel ............... Page 2 Juni 7...................................................8 Connect Ovality Sensor with Laptop .....................

Otherwise the box may get damaged. the magnets might be very hot. dirt. switch it off. Do not keep the tool unnecessary in operation. which prevent burning the hands. Let the tool cool down before stowage. Especially for attaching. Page 3 Juni 7. Radio Waves: Be aware of the radio waves (Bluetooth) which are emitted from the tool as well from the Bluetooth adapter on the computer. . Gloves: Wear proper gloves. Magnet Fields: Be aware of the strong magnet field on the magnet surface. especially not the magnets. Do not stand in the area and keep it clear. Keep the tool away from people with pace makers or any other sensitive item as credit cards or magnetic data carrier. There is the risk for clamping or pinching. if it is not properly attached. Dust. Use the T-handles and do not touch the downside of the tool. after usage. when it is hot. roughness or high surface temperature (>330°C) increase the risk. due to the strong magnetic force. Hot Surface: After using the tool. where the tool might fall down Helmet: Wear a proper helmet while using the measurement tool. removing and handling the tool. corrosion. Clamping: Do not put fingers between the magnets and magnetic surface. 2011 Caution: Falling: The tool might fall off the attached surface.

Case ~3. The software TomTom-Tools Measurement Studio (for Windows).5kg / Total incl. which will be attached with heat resistant magnets to the kiln shell close to a tire. store and process the values from the Ovality Sensor. the values are displayed and calculated directly in real time. the deflection in the Deflection Plate follows the deflection of the kiln shell below. During the measurement. Ovality Sensor Advantages • Measurement during operation • High accuracy • User friendly software • Small size (mostly pass easily between heat shields or thrust roller and kiln shell) • Small weight (Sensor: ~1. The electronic converter is amplifying and conditioning the signals from the strain gauges and sending them together with the values of the orientation sensor via Bluetooth connection to a laptop. Strain gauges are measuring the deflection in the Deflection Plate. There are different display.2 Measuring Principle: The Ovality Sensor consists of a Deflection Plate. zoom and report printing options available.5kg) • Convenient for travelling • Measurement directly displayed on computer Disadvantages • Kiln need to rotate • Laptop required Application: • Ovality Sensor attached to the kiln shell Ovality Sensor on Kiln Ovality Sensor ready to measure . Page 4 Juni 7. which comes together with the measurement tool is made to receive. Due to the strong magnetic connection. 2011 1.

3 Tool Kit includes: 1. 4. 3.5 x 15. 2011 1.2 cm) Software (TomTom-Tools Measurement Studio) Manual 5 2 6 1 4 3 .9 x 29. 6. 2. Page 5 Juni 7. 5. Ovality Sensor Battery Charger with different plug adapters (100…240VAC) Bluetooth USB Adapter (high range) Tough transport case (Dimensions: 33.

the tool has to be removed immediately from the kiln to prevent damage. Lateral Movable Magnet 4. Fixed Magnet 3.2 Features: The Ovality Sensor gets charged by the charger. the tool can be switched on and off. LED 2 (Tool Condition) OK Warning Alarm . Converter 5. 2. Note: The sensors made before September 2010 have to be switched on for charging. Charger Plug (8…25VDC) 8. Ongoing Measurements can be completed without problems. Heat Shield 6. a warning window will appear on the screen as well. LED 1 (Battery Charger / Measurement) Battery full Battery charging Measurement The light (LED2) indicates the condition of the Ovality Sensor. 2011 2. It creates also an alarm window on the PC screen.1 1. Page 6 Juni 7. A constant green light shows that the tool is switched on and is in normal operation. If the tool is connected to the PC. With the power switch 7. In case of temperature alarm. Slowly yellow blinking indicates a warning as high temperature or low battery status.1. Fast red flashing shows an alarm as dangerous high temperature in the sensor or battery completely empty. Deflection Plate 2. The light (LED 1) indicates the battery charging or if the tool is measuring as shown in the following table. Power Switch 3 2. OVALITY SENSOR 2. which is included in the tool kit or by any power source from 8 to 25VDC (center pin positive). T-bar Handle LED 1 4 LED 2 8 6 3 1 2 5 7 7.1 Components: Fig.

2011 3. even in the difficult environment around a rotary kiln.1 Bluetooth Adapter To make sure.g. which comes along with the Sensor.com . • Then plug the Bluetooth adapter UD100. it is recommended to use the Bluetooth adapter (Parani UD100). If there is an other Bluetooth software installed (e. where always the latest version is available. Note: • The TomTom-Tools are designed to communicate only with Windows Bluetooth Stack. Widcomm). Nevertheless it is recommended to install the software from www. which is used for the Ovality Sensor. Toshiba. deactivate it or uninstall it. SOFTWARE: 3. During any start of the Measurement Studio. Windows will recognize the new hardware and automatically install the suitable Windows driver 3. In case of available upgrades the user gets asked if they should be downloaded and installed. it is checking for updates if the computer is connected to the internet. Page 7 Juni 7. the data connection between the Ovality Sensor and the PC is reliable.tomtom-tools.2 Installation: The software (TomTom-Tools Measurement Studio). Click to download the Software Click to install the Software . comes along with the equipment on a CD.

the Sensor gets connected. After clicking the “connect” button. it might take up to one minute.1 (Device Window) Device can be connected. it can be verified.1. Out of this elongation value. Note: With this simple Test. Whenever the Measurement Studio is started it will search for known devices. which are attached to the Deflection Plate (see Fig.1. if the flexing measurement is correctly taken: • Hold the Ovality Sensor on the electronic box horizontal that the magnet look downwards (do not touch the magnets nor the handles) then click “Set zero” • Turn the Ovality Sensor 180° that the magnets look upwards Due to the own weight of the magnets. Click onto the device. switch on the Ovality Sensor (LED2: green).1. Page 8 Juni 7. for TomTom-Tools. it is shown as changes in the elongation of its surface (see in Fig. it will be displayed in the “Overview” Window under devices. the ovality will be calculated. START THE TOOL: 4.2 Flexing of the Deflection Plate The main Sensors in the Ovalily Sensor are the strain gauges. 4. (here the Ovality Sensor) and the device window will open. When the Deflection Plate gets deformed. If a TomTom-Tool is detected.1 Connect Ovality Sensor with Laptop After the software installation is completed. which will be indicated in the Device List. 2011 4. Fig. when displayed here To connect click here To calibrate click here Elongation Value shows the deformation in the flexing plate Shows 0° if Sensor lays horizontal after calibration 4. Note: Depending on the search speed of the computer.1). the Deflection Plate gets slightly deformed and an Elongation of about 20…24 um should be displayed . 2. which has to be connected.1). 4.

4. as shown in the next sketch.1. Note: First the orientation sensor has to be calibrated. Fig. Nevertheless it is recommended to re-calibrate the sensor after a long period not in use. An error of 2° will not influence the accuracy of the sensor. table.2. floor). A re-calibration is required when the tool is placed onto a horizontal surface and the angle value does not show values close to 0°. resp. which can be seen in the moving numbers in the Device Window. 4. it already transfers its orientation values and the deflection values from the deflection plate to the computer. Note: There is no high accuracy of the surfaces required. Hence the calibration has not to be done before each measurement.1 This calibration will be saved and remain in the registry of the computer.1 Push “next” and hold the sensor onto a vertical surface (e. hold onto a vertical surface and the value is not close to 90° or 270° (see Fig.1) . Page 9 Juni 7.3 Calibration of Integrated Orientation Sensor When the Ovality Sensor is connected. Push the button “calibrate” and the following sketch indicates to place the sensor on a horizontal surface (e.2. wall). Fig. 4.g. 2011 4.g.

1 • Set Up the Measurement Window To start a new measurement.1.1 • • • The first pier will be displayed per default. MEASUREMENTS 5.1.2 Put some additional useful information about the measurement into the “Settings Window” Fig. 5. 5. 5. 2011 5.2 Enter Additional information Put in the kiln inner diameter Note: the sense of numbering can be switched by right mouse click on “uphill downhill” .1. click on “Measurement / New / Ovality” as shown in Fig. More piers can be added by mouse right click to “Add Pier” as shown in Fig.1.1 Fig. 5. Page 10 Juni 7.

For example the manhole position or the split of the girth gear can be used for defining the position of point A. make sure the surface. Normally A is the zero or reference position around the circumference. 2011 5. Respect the local safety rules and see the chapter 1.2) . which should be the same reference as for other type of measurements as well. where the sensor will be placed. the measurements should not been taken too far away from them. Page 11 Juni 7. that the ovality is most dominant under the tires. 5.2.5m from the tires are ok and give normally negligible errors.2 • Place Tool on Kiln Preferable mark the measurement positions (A. is free of excessive corrosion and dust layers or debris and local deformations. To start the measurement.B.2. In order to get a sufficient hold of the tool.C with 120° to each other) on both sides of each tire. Distances within 1m…1. select the position to measure in the kiln schematic and push the start button or F5 (see Fig. On the other hand. measuring close to stiff tire fixation blocks can have an impact on the ovality value. • • Place the Ovality Sensor during normal operation onto the kiln shell at the marked position.1 C A B Note: Due to the fact.1 Safety. • Fig. 5.

Page 12 Start Button / F5 Juni 7. Out of experience the following table can be taken as an example but might need to be adjusted to the specific case: Fig. 2011 Double Click on a frame will enlarge the selected window Mouse right click to change from line to point display To reset the window layout Fig. The measured points are displayed continuously until the tool reaches the second time the top point.3. after the tool reaches the top point. 5. does not provide guide lines about acceptable ovality values or limits.2 Measurement Window • • Select the position to measure Switch from Polar to Linear Graph The measurement will be taken. how much ovality can be allowed. it might overheat after a while 5.3 Results TomTom-Tools Ltd.1 . 5. Do not let the instrument unnecessary attached to the hot kiln. It has to be discussed with the refractory suppliers. Remove the tool. when the measurement is taken.2.

• The temperature of one of the magnets and the battery status are measured and displayed in the right lower corner of the Measurement Studio Fig 5. therefore it is protected by the heat shield and by insulators.com info@tomtom-tools.1. 2011 5. All additional information from “Setting Window” is included in the report as well. the tool will alarm you (LED2 red flashing and pop up window). To cool down the tool.1 6. 6. let it cool on the fresh air or by a ventilator (e. REPORT 6. the Ovality Sensor has to be removed from the kiln and cooled down as fast as possible. kiln shell cooling fan). In this case. If the temperatures reach 65° in the electronic board or 330°C at the magnet.6.2. never use water. nevertheless it has to be kept as cool as possible to prevent damages.1 Export to Excel All data can easily be exported to excel.g. The magnets are heat resistant up to 330°C.tomtom-tools. Fig. The electronic board in the sensor is temperature resistant up to 65°C.3 208 6.com .1 TomTom-Tools Ltd Switzerland www.2.4 Temperature Resistance The Ovality Sensor is made for hot applications. a warning will be given by the LED2 (yellow blinking) (see chapter 2.2). Also a pop up window in the Measurement Studio will indicate the increased temperature. The measurement still can be finished.2 Create a report The measurements can be extracted into a report. If the internal temperature reaches 60°C or the magnet temperature reaches 300°C. Page 13 Juni 7. Fig.

96 2.07 24.91 24.93 24.96 24.95 24.91 24.93 24.93 -2.96 1.96 24.96 24.60 93 2.48 24.08 24.96 0.68 24.93 24.93 2.92 148 -1.99 323 -0.09 24.99 24.85 24.84 49 1.99 329 -2.96 -0.12 24.96 24.84 24.93 1.44 24.96 24.48 24.33 275 2.96 24.54 24.44 24.93 -5.96 24.22 282 2.12 24.96 24.97 35 -2.26 24.96 -0.96 1.96 24.93 -5.87 24.69 24.70 24.02 29 -3.96 -1.01 296 1.96 Uphill C Angle [°] 11 18 26 34 42 47 55 63 71 77 84 91 99 106 112 118 126 134 140 146 154 161 167 175 181 189 196 202 210 218 224 232 238 246 252 260 266 273 281 287 294 301 307 315 321 329 336 342 350 357 4 Elongation Temperature [°C] -4.96 1.93 -3.43 24.93 3.14 24.70 255 2.65 24.64 24.99 24.93 3.96 0.96 24.37 24.83 106 2.25 135 0.87 212 -2.12 352 -5.35 248 2.11 289 2.96 24.41 24.93 3.93 Uphill B Angle [°] Elongation 13 -5.96 24.93 2.76 24.93 2.93 -4.16 24.96 2.99 24.96 24.96 1.80 24.96 24.93 -1.Pier 1 of 3 Uphill A Angle [°] 14 23 30 36 43 50 59 64 73 80 87 94 101 108 114 122 128 135 141 149 155 163 170 176 184 191 199 205 213 220 227 234 241 248 256 263 269 276 283 289 296 304 311 317 324 331 338 345 354 0 Elongation Temperature [°C] -4.93 0.96 24.96 1.49 24.48 86 2.47 24.93 24.81 24.96 -1.93 2.93 0.91 303 1.72 100 2.48 24.96 24.16 24.36 80 2.96 24.96 2.12 24.96 24.19 64 2.18 24.96 24.93 2.93 -3.93 3.96 .93 2.96 -3.96 3.96 -4.56 24.93 2.07 24.65 24.96 2.59 24. Page 14 Juni 7.96 -3.31 24.93 0.93 2.63 24.15 24.13 197 -0.93 3.52 24.93 2.93 -1.83 24.37 24.96 24.96 24.04 24.35 227 -1.32 24.93 3.84 24.96 -0. ANNEX 7.96 24.01 24.39 24.06 24.51 24.04 191 1.90 163 -1.67 24.74 24.96 24.96 24.35 24.56 42 -0.79 359 -6.93 2.96 24.93 0.49 24.96 1. 2011 7.73 21 -5.93 2.96 1.96 24.96 1.02 121 3.93 0.74 24.55 24.96 3.53 169 -0.80 24.96 24.93 2.93 2.93 2.96 -0.96 24.96 24.96 1.96 -0.65 24.96 24.49 24.87 24.48 24.96 24.96 -2.96 0.28 24.11 7 -6.35 24.67 24.96 24.96 -4.27 24.85 309 1.50 176 1.69 234 -0.41 220 -2.48 24.66 204 -1.96 -2.55 24.93 -0.96 24.56 24.96 24.96 2.50 24.27 24.96 3.96 3.96 -1.96 24.93 2.44 24.26 24.96 0.96 1.47 24.93 -0.25 24.10 24.96 3.93 -4.96 2.96 24.96 3.57 262 2.96 1.96 2.96 24.96 24.93 -1.09 345 -5.96 -4.27 72 2.74 24.80 316 0.96 24.70 338 -4.93 24.96 -1.93 -0.93 -1.96 24.93 2.96 2.33 24.96 -0.96 24.96 24.49 24.10 184 3.10 56 2.00 24.71 155 -1.96 24.93 -0.40 24.25 24.44 240 1.93 -0.96 24.96 0.34 24.31 24.96 24.96 24.06 Temperature [°C] 24.76 24.02 24.13 128 2.17 24.96 24.99 0.44 268 2.06 24.1 Export to Excel TomTom-Tools Measurement Studio Ovality Measurement .94 115 3.96 3.16 24.96 1.77 24.50 24.96 -1.38 141 -0.92 24.93 2.96 -1.00 24.93 3.96 3.37 24.

2 Ovality Report . Page 15 Juni 7. 2011 7.

Page 16 Juni 7. 2011 7.3 Drawing .

Sign up to vote on this title
UsefulNot useful