Alignement Of The Main Transmission, Gear Ring And Pinion
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16/06/2017
OPERATIONS / MAINTENANCE KILNS MECHANICAL MAINTENANCE Code..
Chapter 11
ALIGNMENT OF THE MAIN TRANSMISSION, GEAR RING AND PINION 11.1 OBJECTIVE AND REACH The main objective of this procedure is to maintain the transmission aligned, in order to have a good contact between the gearing teeth, to have a more silent transmission and increase the transmission running life.
11. 2 METHOD BASIS OR FOUNDATION The transmission objective is to transmit the motor spinning momentum from the kiln reducer to the kiln tube. A pinion and a sprocket, in two or four parts, compose the transmission. The sprocket is fastened to the kiln tube through the sprocket springs. The problems occurring with the pinions and gear rings of the kiln are generally originated by the following: -
Sprocket axial warping.
-
Sprocket radial warping.
-
Lubrication.
The faults previously mentioned, are normally due to a permanent or thermal deviation in the kiln tube, causing an overload of the gear rings teeth as a consequence of the support reduction in the teeth width and teeth height.
11.3 METHOD DEVELOPMENT 11.3.1 Equipment and tools to be used - Three stopwatches, two for axial measuring and one for radial measuring, with the necessary brackets, magnetic bases, vises, etc. 11.3.2 Periodicity The recommendation is to perform this measuring operation once a year, or every time the kiln alignment is performed.
CHAPTER 11 Kilns Maintenance Manual
Page 1 of 5
16/06/2017
OPERATIONS / MAINTENANCE KILNS MECHANICAL MAINTENANCE Code..
11.3.3 Procedure, calculation methods and results In the sprocket, 12 visible marks must be painted in the kiln shell, at a distance of 30° between each of them. Number the marks from 1 to 12. The position 1 must be located at level with the inspection or man entrance holes, for future references. During these measuring operations the kiln must be spin, as much as possible through the transmission, as this provides the safest results. Three people perform the measuring operations at the same time, in a same kiln revolution. Continue the slow spinning during a whole additional revolution, and control that the measuring operations results provide the same deviations level. 11.3.1 Radial eccentricity measuring. For radial eccentricity measuring a stopwatch or depth measuring device is utilized, as illustrated in the Figure 11.1. During both methods of execution it is important that the measuring operation is performed from a persistent bracket, firmly fastened to the base plate, in order to prevent vibrationreading mistakes. First is measured the distance to the turned measuring face of the sprocket.
Figure 11.1 Spin the kiln tube one turn and read the stopwatch / depth meter in front of every mark in the kiln shell. Write the values, by utilizing Form 11.1. Trace a polar diagram based on the measuring operations. The radial eccentricity sense and size will be detached from the diagram; this will also show if the big deviations are caused by ovality or eccentricity. When adjusting the sprocket a distortion by tightening it must not be provoked. I.e., when tightening one side the other side must be equally loosened.
CHAPTER 11 Kilns Maintenance Manual
Page 2 of 5
16/06/2017
OPERATIONS / MAINTENANCE KILNS MECHANICAL MAINTENANCE Code..
11.3.2 Axial warping (run out) measuring The axial warping can be measured during the same spin of the sprocket. Two stopwatches must be utilized for the axial warping measuring operation. They are placed on each kiln side, displaced 180° one from each other, but on the same side of the sprocket (both stopwatches will be placed in the entrance or exit side). See Figure 11.2.
Figure 11.2 Both brackets, where the stopwatches are placed, must have good stability, in order to have a good measuring result. Both persons necessary to read the stopwatches must be standing up in a bracket or platform, independently from the bracket where the stopwatches will be located, so that the persons movements do not influence the measuring operations. The reason why two stopwatches are utilize, is in order to compensate for failures generated as consequence likely to the kiln tube axial misalignment, during the slow spinning. Which can be better appreciated by seeing the Figure 11.3. The Figure 11.3 shows that the sprocket counts with a total eccentricity W, meaning that if the kiln is spun 180°, “A” will generate a positive deviation (+W) and “B” a negative deviation (-W), i.e. if the kiln has not been displaced in axial sense during the slow spinning.
+W
-W
W A
B
A
B
Figure 11.3
Now suppose that the kiln, during a slow 180° spinning has been displaced (F) mm in the sense indicated by the arrow in Figure 11.4. CHAPTER 11 Kilns Maintenance Manual
Page 3 of 5
16/06/2017
OPERATIONS / MAINTENANCE KILNS MECHANICAL MAINTENANCE Code..
F+W
F-W
W A
B
Figure 11.4 The stopwatch A indicates F+W and the stopwatch B indicates F-W. In order to find the W value, the value we are interested in, the following method is utilized: The deviation of stopwatch B (F-W) indicates a negative symbol, it means -(F-W) = -F+W and it is added to the deviation (F+W) in the stopwatch A. Indication in stopwatch B: Indication in stopwatch A: Adding
-F+W +F+W 2W
W is obtained by dividing by two. The method is also valid when the kiln is spun any number of degrees instead of 180°, and as it is compensated mathematically by the axial displacement; the displacement “sense” does not have any sense. If the sprocket is flat, the curve will always have a sinusoidal form. In the Form 11.2, the measuring operations results are written. The axial warping must not exceed +/- 0.75 mm.; despite in recent dates (new kilns) a higher demand exists (to increase even more the transmission life), as this value must not be higher than +/- 0.5 mm. 11.3.4 Interpretation of results The gearing teeth must be absolutely examined, before determining the definite kiln alignment. Whenever it is necessary to align the gear ring, this must be made immediately, and the gearing of gear ring with pinion must be revised by following Procedure H-010.
11.3.5 Safety aspects
CHAPTER 11 Kilns Maintenance Manual
Page 4 of 5
16/06/2017
OPERATIONS / MAINTENANCE KILNS MECHANICAL MAINTENANCE Code..
It is always dangerous to work close to a rotary kiln. To measure and control the parallelism and flotation of kilns it is required to work very close to it; appropriate clothing, safety goggles, safety shoes, gloves and safety shield must be utilized. 11.3.6 Condemning or permissible limits The radial eccentricity must not exceed +/- 1.50 mm, which is the mounting tolerance. The axial warping (run out) must not exceed +/- 0.75 mm.; despite in recent dates a higher demand exists, as this value must not be higher than +/- 0.5 mm. In case of exceeding the previous values, a correction must be immediately made.
11.4 COMMENTS AND OBSERVATIONS The kiln transmission alignment revision is basic for its good running operation, and in order to assure the measuring operations are correct, special care must be given to fix correctly (and never move them during the measuring operation) the dial watches or stopwatches, to prevent erroneous readings.
11.5 ATTACHMENTS AND FORMS UTILIZED Form 11.1 Radial eccentricity calculation. Form 11.2 Sprocket axial warping calculation.
11.6 REFERENCES - Manual: Transmission type 82 with a pinion, F.L. Smidth 18114-13 - Manual: Transmission type DL-5, SL-5, DL-7 and SL-7, F.L. Smith 18111-17 - Manual: Rotary kilns, kiln alignment, F.L. Smidth 669800
CHAPTER 11 Kilns Maintenance Manual
Page 5 of 5
OPERATIONS / MAINTENANCE KILNS MECHANICAL MAINTENANCE Code..
Chapter 11
ALIGNMENT OF THE MAIN TRANSMISSION, GEAR RING AND PINION 11.1 OBJECTIVE AND REACH The main objective of this procedure is to maintain the transmission aligned, in order to have a good contact between the gearing teeth, to have a more silent transmission and increase the transmission running life.
11. 2 METHOD BASIS OR FOUNDATION The transmission objective is to transmit the motor spinning momentum from the kiln reducer to the kiln tube. A pinion and a sprocket, in two or four parts, compose the transmission. The sprocket is fastened to the kiln tube through the sprocket springs. The problems occurring with the pinions and gear rings of the kiln are generally originated by the following: -
Sprocket axial warping.
-
Sprocket radial warping.
-
Lubrication.
The faults previously mentioned, are normally due to a permanent or thermal deviation in the kiln tube, causing an overload of the gear rings teeth as a consequence of the support reduction in the teeth width and teeth height.
11.3 METHOD DEVELOPMENT 11.3.1 Equipment and tools to be used - Three stopwatches, two for axial measuring and one for radial measuring, with the necessary brackets, magnetic bases, vises, etc. 11.3.2 Periodicity The recommendation is to perform this measuring operation once a year, or every time the kiln alignment is performed.
CHAPTER 11 Kilns Maintenance Manual
Page 1 of 5
16/06/2017
OPERATIONS / MAINTENANCE KILNS MECHANICAL MAINTENANCE Code..
11.3.3 Procedure, calculation methods and results In the sprocket, 12 visible marks must be painted in the kiln shell, at a distance of 30° between each of them. Number the marks from 1 to 12. The position 1 must be located at level with the inspection or man entrance holes, for future references. During these measuring operations the kiln must be spin, as much as possible through the transmission, as this provides the safest results. Three people perform the measuring operations at the same time, in a same kiln revolution. Continue the slow spinning during a whole additional revolution, and control that the measuring operations results provide the same deviations level. 11.3.1 Radial eccentricity measuring. For radial eccentricity measuring a stopwatch or depth measuring device is utilized, as illustrated in the Figure 11.1. During both methods of execution it is important that the measuring operation is performed from a persistent bracket, firmly fastened to the base plate, in order to prevent vibrationreading mistakes. First is measured the distance to the turned measuring face of the sprocket.
Figure 11.1 Spin the kiln tube one turn and read the stopwatch / depth meter in front of every mark in the kiln shell. Write the values, by utilizing Form 11.1. Trace a polar diagram based on the measuring operations. The radial eccentricity sense and size will be detached from the diagram; this will also show if the big deviations are caused by ovality or eccentricity. When adjusting the sprocket a distortion by tightening it must not be provoked. I.e., when tightening one side the other side must be equally loosened.
CHAPTER 11 Kilns Maintenance Manual
Page 2 of 5
16/06/2017
OPERATIONS / MAINTENANCE KILNS MECHANICAL MAINTENANCE Code..
11.3.2 Axial warping (run out) measuring The axial warping can be measured during the same spin of the sprocket. Two stopwatches must be utilized for the axial warping measuring operation. They are placed on each kiln side, displaced 180° one from each other, but on the same side of the sprocket (both stopwatches will be placed in the entrance or exit side). See Figure 11.2.
Figure 11.2 Both brackets, where the stopwatches are placed, must have good stability, in order to have a good measuring result. Both persons necessary to read the stopwatches must be standing up in a bracket or platform, independently from the bracket where the stopwatches will be located, so that the persons movements do not influence the measuring operations. The reason why two stopwatches are utilize, is in order to compensate for failures generated as consequence likely to the kiln tube axial misalignment, during the slow spinning. Which can be better appreciated by seeing the Figure 11.3. The Figure 11.3 shows that the sprocket counts with a total eccentricity W, meaning that if the kiln is spun 180°, “A” will generate a positive deviation (+W) and “B” a negative deviation (-W), i.e. if the kiln has not been displaced in axial sense during the slow spinning.
+W
-W
W A
B
A
B
Figure 11.3
Now suppose that the kiln, during a slow 180° spinning has been displaced (F) mm in the sense indicated by the arrow in Figure 11.4. CHAPTER 11 Kilns Maintenance Manual
Page 3 of 5
16/06/2017
OPERATIONS / MAINTENANCE KILNS MECHANICAL MAINTENANCE Code..
F+W
F-W
W A
B
Figure 11.4 The stopwatch A indicates F+W and the stopwatch B indicates F-W. In order to find the W value, the value we are interested in, the following method is utilized: The deviation of stopwatch B (F-W) indicates a negative symbol, it means -(F-W) = -F+W and it is added to the deviation (F+W) in the stopwatch A. Indication in stopwatch B: Indication in stopwatch A: Adding
-F+W +F+W 2W
W is obtained by dividing by two. The method is also valid when the kiln is spun any number of degrees instead of 180°, and as it is compensated mathematically by the axial displacement; the displacement “sense” does not have any sense. If the sprocket is flat, the curve will always have a sinusoidal form. In the Form 11.2, the measuring operations results are written. The axial warping must not exceed +/- 0.75 mm.; despite in recent dates (new kilns) a higher demand exists (to increase even more the transmission life), as this value must not be higher than +/- 0.5 mm. 11.3.4 Interpretation of results The gearing teeth must be absolutely examined, before determining the definite kiln alignment. Whenever it is necessary to align the gear ring, this must be made immediately, and the gearing of gear ring with pinion must be revised by following Procedure H-010.
11.3.5 Safety aspects
CHAPTER 11 Kilns Maintenance Manual
Page 4 of 5
16/06/2017
OPERATIONS / MAINTENANCE KILNS MECHANICAL MAINTENANCE Code..
It is always dangerous to work close to a rotary kiln. To measure and control the parallelism and flotation of kilns it is required to work very close to it; appropriate clothing, safety goggles, safety shoes, gloves and safety shield must be utilized. 11.3.6 Condemning or permissible limits The radial eccentricity must not exceed +/- 1.50 mm, which is the mounting tolerance. The axial warping (run out) must not exceed +/- 0.75 mm.; despite in recent dates a higher demand exists, as this value must not be higher than +/- 0.5 mm. In case of exceeding the previous values, a correction must be immediately made.
11.4 COMMENTS AND OBSERVATIONS The kiln transmission alignment revision is basic for its good running operation, and in order to assure the measuring operations are correct, special care must be given to fix correctly (and never move them during the measuring operation) the dial watches or stopwatches, to prevent erroneous readings.
11.5 ATTACHMENTS AND FORMS UTILIZED Form 11.1 Radial eccentricity calculation. Form 11.2 Sprocket axial warping calculation.
11.6 REFERENCES - Manual: Transmission type 82 with a pinion, F.L. Smidth 18114-13 - Manual: Transmission type DL-5, SL-5, DL-7 and SL-7, F.L. Smith 18111-17 - Manual: Rotary kilns, kiln alignment, F.L. Smidth 669800
CHAPTER 11 Kilns Maintenance Manual
Page 5 of 5
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