摘 要

回转窑是水泥生产行业中的核心设备，其主要由筒体、轮带、支撑装置、传动装置等部件组成。回转窑大齿圈的偏摆和振动故障是影响回转窑正常生产的一个重要问题，大齿圈径向偏摆的检测一直是各个回转窑使用企业重点关心的问题之一。由于回转窑属于大型重载设备且常在高温环境下进行工作，故大齿圈的径向偏摆和振动便时常发生，对大齿圈径向跳动的检测也因此变得十分重要。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。将单片机技术与回转窑大齿圈径向跳动检测相结合，使大齿圈的径向跳动在线检测及监测装置更为可靠、方便而低成本，是今后发展的方向。本文主要研究内容如下：

1. 了解了回转窑的主要结构及其当前各种检测手段，着重研究了目前回转窑大齿圈径向偏摆位移量及振动方位的测量方法，并分析了其中的不足之处，在此基础上研究了一套以AT89C51为核心的回转窑径向偏摆及振动位移的在线测量装置，对该装置整体进行了总体技术路线及框图的设计，它包括各个硬件部件及相配套的软件的设计，为回转窑大齿圈振动方位的动态在线测量装置研发提供了一条新思路。
2. 该在线测量装置由霍尔开关、电涡流位移传感器以及带A/D转换器的一个AT89C51单片机构成。其中，霍尔开关负责发送大齿圈径向偏摆“测量开始”、“测量结束”的信号，其也为其振动方位的测量确定了一个初始“0”方位的位置。单片机接受霍尔开关所发出的信号，控制了位移传感器的测量周期。电涡流位移传感器是一种非接触式的位移传感器，电涡流传感器应用电磁感应效应，测出传感器探头与被测大齿圈齿顶部金属之间的距离。电涡流传感器测得数据为电压信号，可以经过A/D转换模块，用单片机获得其位移的数字信号并显示在LED屏幕上，这样便能很清楚的得到大齿圈径向偏移量，并对大齿圈的振动位移数据做出分析处理。若其偏移量超过标准值，则单片机会给中控室上位机发出报警信号。
3. 在配套软件方面选取C语言来对单片机的功能实现进行编程控制，C语言编程简单可靠，通过它来编译A/D转换程序、数字转换程序及控制蜂鸣器等的报警程序，从而使整个装置达到了在线测量回转窑大齿圈径向偏摆及振动方位的目的。

关键词：回转窑；大齿圈；径向偏摆；单片机

Abstract

The rotary kiln is the core equipment in the cement production industry, which is mainly composed of barrels, wheels, support devices, transmission devices and other components. The yaw and vibration failure of the large gear ring of the rotary kiln is an important issue that affects the normal production of the rotary kiln. The detection of the radial deflection of the large gear ring has always been one of the key concerns of enterprises using rotary kilns. Because rotary kilns are large heavy-duty equipment and often work in high-temperature environments, radial deflection and vibration of the large gear ring often occur, and the detection of the radial runout of the large gear ring becomes very important. In recent years, MCUs have been widely used in many fields because of their strong functions, high reliability and affordable prices. Combining the single chip microcomputer technology with the detection of the radial runout of the large gear ring of the rotary kiln, the on-line detection and monitoring device of the radial runout of the large gear ring is more reliable, convenient and low cost, which is the direction of future development. The main research contents of this article are as follows:

(1) Understand the main structure of the rotary kiln and the current various detection methods, focus on the current measurement method of the radial deflection displacement and vibration orientation of the large gear ring of the rotary kiln, and analyze the shortcomings in it. On this basis, a set of online measurement devices for radial deflection and vibration displacement of the rotary kiln with AT89C51 as the core were studied. The overall technical route and block diagram of the device were designed. It includes various hardware components and supporting software. The design provides a new idea for the development of a dynamic online measuring device for the vibration orientation of the large gear ring of the rotary kiln.

(2) The online measurement device is composed of a Hall switch, an eddy current displacement sensor, and an AT89C51 single-chip computer with an A / D converter. Among them, the Hall switch is responsible for sending the signal of "measurement start" and "measurement end" of the radial deflection of the large gear ring, and it also determines an initial "0" position for the measurement of its vibration orientation. The single chip microcomputer accepts the signal from the Hall switch and controls the measurement period of the displacement sensor. The eddy current displacement sensor is a non-contact displacement sensor. The eddy current sensor uses the electromagnetic induction effect to measure the distance between the sensor probe and the metal on the top of the tooth of the large ring gear. The data measured by the eddy current sensor is a voltage signal, which can be passed through the A / D conversion module, and the digital signal of its displacement can be obtained by the single-chip microcomputer and displayed on the LED screen, so that the radial offset of the large gear ring can be clearly obtained Analyze and process the vibration displacement data of the large gear ring. If the offset exceeds the standard value, the single-chip microcomputer will send an alarm signal to the upper computer in the central control room.

In the supporting software, the C language is selected to program and control the function of the single chip microcomputer. The C language programming is simple and reliable. It uses it to compile the A / D conversion program, digital conversion program, and alarm programs to control the buzzer, etc. The purpose of online measurement of the radial deflection and vibration orientation of the large gear ring of the rotary kiln is achieved.

Key word：Rotary kiln；Large gear ring；Radial runout；Single chip microcomputer

目录

第一章 绪论 1

1.1回转窑的应用及发展 1

1.1.1回转窑的应用及分类 1

1.1.2回转窑的发展历程 1

1.2回转窑的结构 1

1.2.1传动结构 2

1.2.2非传动系统 3

1.3课题研究背景及意义 4

1.3.1研究背景 4

1.3.2研究意义 4

1.4国内外研究现状 5

1.4.1回转窑故障及检测方法研究现状 5

1.4.2大齿圈故障及检测方法研究现状 5

1.5本文研究内容与章节安排 6

1.5.1本文结构安排 6

1.5.2本文各章节内容 7

第二章 回转窑传动系统分析 8

2.1齿轮故障分析 8

2.2回转窑大齿圈故障分析 8

2.2.1回转窑大齿圈 8

2.2.2回转窑大齿圈故障分析 9

2.3回转窑大齿圈径向偏摆检测 10

2.3.1当前先进的检测技术 10

2.4第二章小结 12

第三章 回转窑大齿圈振动方位的测量方案设计 12

3.1整体方案构想 12

3.1.1大齿轮转速计算 12

3.1.2测量系统整体框架 13

3.2系统硬件设计 13

3.2.1计时模块 13

3.2.2数据中间处理模块 15

3.2.3测量模块 17

3.2.4数据处理及显示模块 19

第四章 总结与展望 22

致谢 22