Function Block for Rotary Kiln Coating Disintegration Detection

Abstract

Condition monitoring is an important field that can boost manufacturing processes to produce high quality and more quantities. This work presents the design of new Programmable Logic Controller (PLC) Function Block (FB) dedicated to the instantaneous detection of any coating piece disintegration from the wall coating formed by the processed material sticking naturally on the inner side of the cement rotary kiln. The detection is based on the on-line analysis of the kiln spinning electrical motor’s signal. The FB makes use of differences between the adjacent signal’s measurements values and logic functions to hide false alarms for the user whenever they break out due to kiln velocity set point abrupt changes. In steady state process operation, the technique provides highly reliable and accurate detection. Its application can be extended to any similar instantaneous abrupt changes occurring in other manufacturing processes.