Abstract
Rotary kiln is key equipment widely used in the cement, metallurgical and environmental protection industry. The operation state of the rotary kiln was largely determined by the working condition of supporting rollers. This paper models the vibration mechanism of the supporting rollers under the rotary kiln crank caused by the internal thermal process. Based on the numerical analysis, a methodology based on empirical mode decomposition (EMD) for the fault diagnosis of the supporting rollers was proposed. By using EMD, the complicated vibration signal of the kiln can be decomposed into a number of intrinsic mode functions (IMFs). An analysis was made over the energy moment of IMF components to indicate the energy variation of the kiln harmonic and the roller harmonic of the vibration signals. Simulation and in field experiment results proved that the proposed method provided a validity of the approach for the condition monitoring and fault diagnosis of the low-speed machinery like the rotary kiln.DOI: http://dx.doi.org/10.5755/j01.mech.22.3.13072
Highlights
Rotary kiln is a typical large slow-speed running (2-6 rpm) mechanical equipment
According to the numerical analysis for the supporting rollers, it can be found that the vibration signal mainly includes the harmonic component caused by the kiln crank and the harmonic component caused by the deflection of the roller shaft
The specific physical meanings of each intrinsic mode functions (IMFs) component are as follows: IMF5 is harmonic component caused by the kiln crank; IMF4 is the vibration component caused by the supporting roller shaft deflection; according to [17, 18], IMF3 is the ripple deformation component of the supporting roller’s surface; IMF2 is the harmonic component of the supporting roller’s surface roughness; IMF1 is the harmonic component of microscopic deformation
Summary
Rotary kiln is a typical large slow-speed running (2-6 rpm) mechanical equipment. As key equipment, rotary kiln is widely used in the cement industry, metallurgical industry and environmental protection industry. Et al presented that dynamic change of the operating axis of the rotary kiln will lead to complex vibration of the equipment, so as to speed up fatigue failure of the supporting rollers They used transfer matrix method to establish a kinetic model of the rotary kiln’s cylinder [8]. In order to explore the impact of the crank of the rotary kiln’s cylinder on the supporting rollers as well make fault diagnosis, this paper put forward the dynamic model of the supporting rollers and made a numerical simulation analysis. As the vibration signals of the supporting rollers are normally characterized with nonstationary behaviour, to analyze the vibration signals with nonstationary properties, we presented features extraction and fault diagnosis method of the rotary kiln supporting rollers based on empirical mode decomposition (EMD), so as to realize the condition monitoring of the low-speed operation rotary kiln.
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