The supporting wheel of a rotary kiln, serving as the fulcrum for kiln operation, bears three major loads: heat load, material load, and kiln weight. The supporting wheel shaft, as the main structural element of support, is directly related to the kiln's operation, and its safe and stable performance is particularly important. However, overheating of the shaft is a common issue during operation. Monitoring the temperature changes of the supporting wheel shaft in advance is one of the most critical factors for improving the operational efficiency of the rotary kiln.
Excessive temperatures of the rotary kiln shaft and bearing bush can even lead to tile blasting, causing an unscheduled shutdown of the kiln. There are many reasons for the temperature rise of the bearing bush, including axial movement, poor lubrication, wear, and material issues. Analysis and research have shown that localized overheating is typically caused by temperature changes in the supporting wheel shaft. The shaft's temperature usually increases gradually from the front to the end, and once it reaches a certain threshold, it causes a temperature rise in the terminal equipment and oil pool. Therefore, an early indicator of such an abnormal condition is a change in the surface temperature of the shaft. Real-time monitoring of shaft surface temperature can effectively help prevent such accidents.
However, the supporting wheel shaft of the kiln is installed inside a closed casing and is a rotating component, making traditional temperature measurement methods difficult to apply. Currently, most facilities rely on handheld temperature measurement guns and thermal imaging devices for periodic measurements. These tools do not support real-time online monitoring and therefore cannot detect early-stage faults promptly. Moreover, contact-based temperature measurement is not feasible in this case, necessitating the use of non-contact methods. Attempts have been made using thermocouples and temperature-sensing optical fibers, but these can only monitor the ambient temperature in the vicinity rather than the actual temperature of the shaft surface. As a result, there is a significant temperature discrepancy, and the readings are not accurate.
The system adopts non-contact infrared thermal imaging technology to measure the temperature of the rotary kiln supporting wheel shaft surface in real time. The temperature data is acquired online and transmitted via a wired connection to a receiving device located near the kiln, enabling local display. Additionally, the temperature signal can be transmitted to the central control system or the plant's DCS (Distributed Control System) for continuous monitoring and management. The system also supports cloud connectivity, allowing real-time temperature data to be accessed remotely via a mobile phone.
The system consists of three main components: an infrared temperature acquisition device, a local display unit, and a background management system.
The detailed technical parameters of the infrared imager can be found in the product center.
The cabinet houses an industrial personal computer, a display, a data collection switch, and the local receiver for the infrared camera data. It runs embedded STM series temperature measurement software that supports intuitive split-screen display and regional settings directly on the screen. This enables accurate identification of high-temperature zones and provides alarm notifications for timely intervention. Additionally, temperature data can be viewed directly on a mobile phone.
Inside the cabinet, there is a temperature information processing device that can transmit the maximum temperature data from each probe to the background system or the factory's DCS system via wired or wireless communication.
By installing this system, on-site personnel no longer need manual inspections. They can regularly observe the temperature of each axle surface on the local display device and remotely view real-time temperature changes on mobile phones. This allows early prediction of temperature rises, timely alarm detection, root cause analysis, and prompt response.
The system provides accurate temperature readings and comprehensive functionality, reducing the labor intensity of patrol personnel and ensuring the normal operation of equipment. This contributes to enterprise safety production and supports the development of intelligent manufacturing and smart monitoring.
The detailed technical parameters of the infrared imager can be found in the product center.
