摘 要

回转窑是水泥工业的大型核心关键生产设备，它主要由筒体、轮带，支撑装置托轮、传动齿轮等部件组成。在水泥工业生产中，回转窑会不断产生沿着筒体轴线方向的上下位移，如何监测以及控制回转窑的轴向位移位置，一直是回转窑运行的重要参数之一。由于回转窑作为大型重载工业设备，其工况恶劣，工作环境一般有高温、多砂尘、高扰动等问题，轴向位移的距离约在80mm左右，因此检测也变得比较困难。近年来，单片机因其功能强、可靠性高且价格实惠，在很多领域都有着广泛的应用。运用单片机技术结合回转窑的轴向检测技术，使对回转窑轴向窜的测量更加方便可靠并且成本低廉，将成为今后发展的主要方向。本文主要研究内容如下：

1. 分析研究目前已有的对窑轴向位移的各种检测方案，在现有方案的基础上设计一套以处理芯片AD598以及单片机系统为核心的回转窑轴向位移在线测量装置，对该装置整体进行了元件的比较与选型，以及硬件部分测量支架的设计，为回转窑轴向窜动的动态在线测量装置研发提供了一条新思路。
2. 在线测量装置由电子测量系统和机械支架结构两部分组成，电子测量系统分为传感器件、处理电路及激励源、AD转换及信号采集四个部分。电气测量系统用于测量回转窑的轴向位移，测量时位移量先经过电感式接近开关转换为模拟量输出至处理电路，经过数模转换模块转换为数字量后，最终处理信号在单片机进行输出。
3. 机械支架结构用于固定，校准传感器。机械支架由主支架、液压缓冲、测头部分、挡板四部分组成，其中液压缓冲装置用于降低回转窑现场测量时传感器的扰动，测头部分则用于夹紧传感器，在安装调试时可微调传感器进行对准。

关键词：回转窑;动态测量;轴向位移;接近开关

Abstract

As a large cement production equipment, Rotary kiln is mainly composed of barrel, wheel tire, supporting device supporting wheel, transmission gear and other components. In industrial production, the rotary kiln will produce irregular channeling along the axis of the shell. How to monitor and control the axial channeling of the rotary kiln has always been an important issue concerned by the rotary kiln industry. As a large heavy-duty industrial equipment, rotary kiln works under harsh conditions and generally has problems such as high temperature and high disturbance in the working environment, so it is difficult to detect the axial displacement. In recent years, single chip microcontroller has been widely used in many fields because of its powerful function, high reliability and affordable price.The application of single chip microcomputer combined with the rotary kiln axial detection technology makes the measurement of the rotary kiln axial channal more convenient and reliable and the cost is low, which will become the main direction of development in the future. The main contents of this paper are as follows：

1. Analysis and study the existing on axial displacement detection scheme, on the basis of the existing scheme to design a set of processing chip AD598 and SCM system as the core of the rotary kiln axial displacement online measuring device, the device has carried on the comparison and selection of components, and the design of hardware part measurement bracket, for rotary kiln axial channeling in the online dynamic measurement device research and development has provided a new way of thinking.
2. The on-line measuring device is composed of an electronic measuring system and a mechanical support structure. The electronic measuring system is divided into four parts: sensor, processing circuit and excitation source, AD conversion and signal acquisition.The electrical measurement system is used to measure the axial displacement of the rotary kiln. During the measurement, the displacement is first converted into analog quantity by inductance proximity switch and then output to the processing circuit. After being converted into digital quantity by the DIGITal-analog conversion module, the final processing signal is output in the single chip microcomputer.
3. The mechanical support structure is used to fix and calibrate the sensor. The mechanical support is composed of the main support, hydraulic buffer, probe part and baffle, among which the hydraulic buffer device is used to reduce the disturbance of the sensor during the field measurement of rotary kiln, and the measuring head is used to clamp the sensor, and the sensor can be fine-tuned for alignment during installation and debugging.

Key words: rotary kiln;  dynamic measurement; axial movement; approach switch

目 录

第一章 绪论 1

第二章 对回转窑轴向位移规律的分析 4

2.1.1托轮的结构 5

2.1.2 轴向力与回转窑轴向位移的关联 6

2.2 轴向力对回转窑可能的影响 6

第三章 测量装置的介绍 7

3.1 测量装置的组成 7

3.2 传感器 7

3.3 处理电路及激励源 10

3.4 数模转换模块 10

整体系统图 11

第四章 支架结构设计 12

4.1 设计要求 12

4.2 设计思路图 13

4.3 整体结构与工作原理 14

4.4 主支架 17

4.5 液压缓冲装置 19

4.6 测头部分 22

4.7 挡板 24

第五章 测量前的准备工作安装与调节 25

5.1 传感器的安装 26

5.2 实际的监测阶段 27

5.3 本章小结 27

第六章 总结与展望 28

参考文献 29

致谢 30

绪论

1.1 回转窑发展概况

自1824年英国人Joseph和Aspdin获得称之谓波特兰水泥专利权算起，短短170余年，水泥生产几乎遍及全世界，可见，水泥是一种很有发展前途的建筑材料。水泥回转窑，作为水泥生产的心脏设备，必然伴随着水泥工业的发展而发展^[1]。水泥回转窑的自身发展：

水泥回转窑诞生以来，伴随着水泥生产技术的不断发展，自身也经历了发展、完善和逐步解体异化的过程。逐步增大窑筒体的尺寸，以降低窑尾废气温度，提高富的生产能力。局部扩大窑筒体的尺寸，包括烧成带扩大、分解带扩大、窑尾扩大或两端同时扩大，以增强燃烧能力、碳酸盐分解能力和预热能力。

我国水泥产量已连续十多年位居世界第一，据报道，中国在 2011 ~ 2013 年消耗了 66.51 亿吨水泥。2013 ~ 2014 年间，中国水泥产量达到了48.6 亿吨。

在长期生产过程中，由于回转窑有载荷大，自重大，转速高，生产周期长等特点，会产生各种生产安全隐患，例如：支撑点处地面的下沉，托轮调整不当导致轴线平行度无法保证、支承件的过度磨损等。并且由于回转窑筒体一般采用倾斜放置以便于物料流动，筒体自身重力会产生一个在轴向的分力、此分力长时间存在，导致托轮与筒体无法在轴向上不产生相对运动，有效解决回转窑的轴向移动的装置有机械装置和液压装置两种形式，称为机械挡轮和液压挡轮。液压挡轮是国内、外近些年来发展起来的新技术，技术水平比较先进。而回转窑筒体轴向上的受力作为设计调节合理的挡轮装置所需要的重要参数则必须被计算得出,一方面它关系到托轮和筒体的轴线所处状态,相对角度,另一方面它关系到回转窑轴线方向运行阻力大小和整个回转窑转动的能量消耗。轴向力很大,会使托轮轴承(或轴瓦)负荷增大,最终导致筒体变形，引起耐火砖脱落，而窑体衬砖的脱落会引发“红窑”，烧瓦或翻瓦事故,使设备过早破坏,严重影响生产。