Inductive analog sensors from Proxitron offer an efficient solution for measuring displacement of rollers on kiln of cement plants. It accurately measures up to 100 °C ambient temperature. Manual operation is minimized with the help of RS485 or software program. |
Measuring displacement of rollers on kiln
Pilger mill in tube rolling mills - hot and cold pipe detection
- Measuring range 0 -200 mm, 0-10V, 4-20mA output signal
• Waterproof plug connection
• Measuring accuracy up to 0.01 mm
• Variations up to 100°C ambient temperature
• Comfortable RS485 interface
Challenges
In modern cement plants, cement production is a continuous dry process, where the rotary kiln plays a key role. In the first step raw materials such as limestone, clay, sand, and iron ore are crushed in a cone mill and dried.
This raw meal, or slurry, is then fed to a rotary kiln – an enormous rotating pipe – and heated at a temperature of 1.400–1.450°C to become clinker; in the cooling equipment the new compound is quickly cooled down to a temperature under 200°C. In the second step Gipsum or anhydrite are added to these grey-brown grains and ground in a ball mill to obtain cement as final product.
Solution
Inductive analogue sensors from Proxitron are mainly used at the drive of the rotary kiln or of the cone mill to check the rollers wear condition; to do this they continuously measure a defined distance: if this distance is not reached, rollers replacement or service is required. Inductive measuring sensors from Proxitron can be programmed via software to deliver an analogue output corresponding to a freely adjustable measuring range.
According to sensor size, measurement range can go from 0 up to 200 mm max, and ambient temperature up to 100°C. Parameters can be set via RS485 interface and software, or directly at the device.
Products and Accessories
Case Study Number
- TP3
Challenge
- The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity.
- In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C.
- After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter.
Previous solution / Competitor product
- N/A
Solution
- The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19.
- The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase.
- An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions.
- The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C.
- Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling.
Customer Benefits
- Maintenance-free
- High temperature stability
- Recognition of hot objects at big distances
- Self adjustment with Auto-Teach or step switch for the response temperature
Product Part number
- OKA 2038.38 G
Brand
- Proxitron
Accessories
- Piros swivel stand HM2
- Tube OL 19
- Pilot light unit (for alignment) DAK 308 + OL 26
- Different cable lengths (e.g. 15 m)
Customer Testimonial
compared to previous solution or competition
Case Studies
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Sample case study title lorem ipsum here
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