KHD/Scanex – A Temperature Diagnosis System for Rotary Kilns
Initial situation and project task
A manufacturer of cylindrical rotary kilns for the production of chalk and cement was faced with the problem of replacing some formerly used hardware components of great importance. These components had been in use for data acquisition in temperature diagnosis systems and had become overage.
Therefore, it was necessary to develop new hardware components that could be adapted to the hardware of the existing diagnosis system. In addition to that, the existing software solution had to be modified and adapted to the new hardware, as well.
The diagnosis system should be suitable for single furnace solutions as well as for multi-furnace systems with a large mechanical width of the oven and a high data bandwidth due to a large number of integrated measuring heads.
Implementation and challenge
Our major task was the development of an interface card that could cope with the required signal conditioning and the galvanic isolation of the electronics inside the monitoring PC on the one hand and the sensor system inside the facilities on the other hand. By means of this interface it is possible to connect different magnetic and inductive sensors to the system, conducting temperature capturing inside the ovens. At the same time, the interface protects the measurement electronics inside the PC by means of optoelectronic couplers.
The greatest challenge we faced was the integration of new hardware components into the existing complex software system including numerous dependencies between its various parts.
Having developed the system successfully, we are now producing the new and completely modified diagnosis system and integrating it into an electrical cabinet at NOFFZ. We are also responsible for the delivery and assembly of the revolving cylindrical furnace and its components, for the initial operation of the system, for further technical support and for local employee trainings.
Subsequently, several additional features have been integrated such as an OPC interface for the connection to control centre systems in modern industrial facilities.
A manufacturer of cylindrical rotary kilns for the production of chalk and cement was faced with the problem of replacing some formerly used hardware components of great importance. These components had been in use for data acquisition in temperature diagnosis systems and had become overage.
Therefore, it was necessary to develop new hardware components that could be adapted to the hardware of the existing diagnosis system. In addition to that, the existing software solution had to be modified and adapted to the new hardware, as well.
The diagnosis system should be suitable for single furnace solutions as well as for multi-furnace systems with a large mechanical width of the oven and a high data bandwidth due to a large number of integrated measuring heads.
Implementation and challenge
Our major task was the development of an interface card that could cope with the required signal conditioning and the galvanic isolation of the electronics inside the monitoring PC on the one hand and the sensor system inside the facilities on the other hand. By means of this interface it is possible to connect different magnetic and inductive sensors to the system, conducting temperature capturing inside the ovens. At the same time, the interface protects the measurement electronics inside the PC by means of optoelectronic couplers.
The greatest challenge we faced was the integration of new hardware components into the existing complex software system including numerous dependencies between its various parts.
Having developed the system successfully, we are now producing the new and completely modified diagnosis system and integrating it into an electrical cabinet at NOFFZ. We are also responsible for the delivery and assembly of the revolving cylindrical furnace and its components, for the initial operation of the system, for further technical support and for local employee trainings.
Subsequently, several additional features have been integrated such as an OPC interface for the connection to control centre systems in modern industrial facilities.
Conclusion and future prospects
After the successful modification of the diagnosis system according to the new hardware requirements we have already produced 20 replicas of the initial system. 13 of these systems have been installed and launched by our employees at the end-customer’s facilities all over the world.
Among these systems, there have been some special solutions that had to contain several diagnosis systems for a whole group of ovens. Therefore, these systems had to be integrated into a single, central, air-conditioned electrical cabinet.
Multi-oven applications have been implemented and installed for customers in different countries all over the world with great success. The longer oven systems contain 4 to 6 measuring heads. Due to the timely transmission of measurement data to the control centre an ideal control of the whole system can be achieved. The highest possible product quality is guaranteed by means of the Scanex System.
By now, several orders of further replicas have been received. Furthermore, we have to carry out more system launchings in the near future.
In the course of continuous perfective maintenance and modernization our customer has ordered a modern revision of the software’s GUI, which is going to be implemented at NOFFZ as well.
Further models of the system, which could lead to an increased competitiveness of the product, have been developed by our engineers, autonomously. They have introduced their innovative ideas to the customer because – due to the local launchings of the systems – they got the best insight into the end-customer’s needs and the performance of the competing companies.
After the successful modification of the diagnosis system according to the new hardware requirements we have already produced 20 replicas of the initial system. 13 of these systems have been installed and launched by our employees at the end-customer’s facilities all over the world.
Among these systems, there have been some special solutions that had to contain several diagnosis systems for a whole group of ovens. Therefore, these systems had to be integrated into a single, central, air-conditioned electrical cabinet.
Multi-oven applications have been implemented and installed for customers in different countries all over the world with great success. The longer oven systems contain 4 to 6 measuring heads. Due to the timely transmission of measurement data to the control centre an ideal control of the whole system can be achieved. The highest possible product quality is guaranteed by means of the Scanex System.
By now, several orders of further replicas have been received. Furthermore, we have to carry out more system launchings in the near future.
In the course of continuous perfective maintenance and modernization our customer has ordered a modern revision of the software’s GUI, which is going to be implemented at NOFFZ as well.
Further models of the system, which could lead to an increased competitiveness of the product, have been developed by our engineers, autonomously. They have introduced their innovative ideas to the customer because – due to the local launchings of the systems – they got the best insight into the end-customer’s needs and the performance of the competing companies.