TomTom-Tools GmbH

Zelgli 20 Phone: +41 79 774 06 44

8905 Arni www.tomtom-tools.com
Switzerland www.tomtom-tools.com

User Manual:

OVALITY SENSOR II
(For units manufactured from July 2016)

1. INTRODUCTION:
The Ovality Sensor is a measurement tool for rotary kilns, which measures the changes of the
roundness / curvature in the kiln shell during operation. This elastic deformation is called Ovality
and is primarily present in the area of a kiln tire. The measurement gives accurate information
about the degree of mechanical loads in the refractory / kiln shell and allows defining the
countermeasures in advance to increase the lifetime of the kiln components.
The Ovality Sensor is small, easy to use and comes along with a tough transport case.

1.1 Safety:

Rotary kilns or dryers, where this tool is used, are huge rotating equipment with many pinch points;
they can cause serious injuries. Therefore, only specialized and trained personnel shall work close
to these machines. To use the Ovality Sensor, follow strictly the local safety rules given by the
respective plant / factory / local authorities and discuss the application with the safety engineer in
charge.
The tools provided by TomTom-Tools GmbH have proven their functionality in various applications;
nevertheless, TomTom-Tools GmbH does not take any responsibility for the application on site
regarding safety. The user is responsible for the safety, according to the local law, in a way that
nobody can be hurt or injured. The application and safety instructions below are guidelines, which
include the experience from previous measurement campaigns and might need to be adapted to
the local condition and safety requirements.

5 February 2018
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TABLE OF CONTENT

1. Introduction: ..................................................................................................................................1
1.1 Safety: ....................................................................................................................................1

1.2 Measuring Principle: ..............................................................................................................4

1.3 Tool Kit includes: ...................................................................................................................5

2. Ovality Sensor ...............................................................................................................................6

2.1 Components: .........................................................................................................................6

2.2 Features:................................................................................................................................6

3. Software: ........................................................................................................................................7
3.1 Bluetooth Adapter..................................................................................................................7

3.2 Software Installation: .............................................................................................................7

4. Start the Tool: ................................................................................................................................7

4.1 Connect Ovality Sensor with Laptop ....................................................................................8

4.2 Signal from the Deflection Plate............................................................................................9

5. Measurements ............................................................................................................................ 10
5.1 Set Up the Measurement Window..................................................................................... 10

5.2 Marking the Kiln Shell......................................................................................................... 11

5.3 Place Tool on Kiln............................................................................................................... 11

5.4 Measurement of Kiln Shell Temperature........................................................................... 12

5.5 Temperature Resistance.................................................................................................... 13

6. Report .......................................................................................................................................... 13
6.1 Export to Excel ................................................................................................................... 13

6.2 Create a report ................................................................................................................... 13

7. Annex ........................................................................................................................................... 14
7.1 Typical Graphs ................................................................................................................... 14

7.2 Results ................................................................................................................................ 15

7.3 Typical Ovality Value Limits ............................................................................................... 15

7.4 Ovality Report ..................................................................................................................... 16

7.5 Drawing............................................................................................................................... 16
 Page 3 Februar 5, 2018

Caution:

Falling:
The tool might fall off the attached surface, if it is not properly attached.
Dust, dirt, corrosion, roughness or high surface temperature (>330°C)
increase the risk.
Do not stand in the area and keep it clear, where the tool might fall down

Helmet:
Wear a proper helmet while using the measurement tool.

Hot Surface:
After the measurement, the magnets might be very hot.
Use the T-handles for holding and do not touch the downside of the tool,
especially not the magnets.
Let the tool cool down before stowage. Otherwise the box may get damaged.

Gloves:
Wear proper gloves, which prevent burning the hands.
Especially for attaching, removing and handling the tool, when it is hot.

Magnetic Fields:
Be aware of the strong magnet field on the magnet surface.
Keep the tool away from people with pace makers or any other sensitive item
as credit cards or magnetic data carrier.

Clamping:
Do not put fingers between the magnets and magnetic surface. There is the
risk for clamping or pinching, due to the strong magnetic force.

Radio Waves:
Be aware of the radio waves (Bluetooth) which are emitted from the tool as
well from the Bluetooth adapter on the computer.
Do not keep the tool unnecessary in operation; switch it off, after usage.
 Page 4 Februar 5, 2018

1.2 Measuring Principle:

The Ovality Sensor consists of a Deflection Plate, which will be attached with heat resistant
magnets to the kiln shell close to a tire. Due to the strong magnetic connection, the deflection in the
Deflection Plate follows the deflection of the kiln shell below. Strain gauges are measuring the
deflection in the Deflection Plate. The electronic converter is amplifying and conditioning the signals
from the strain gauges and sending them together with the values of the orientation sensor via
Bluetooth connection to a laptop.
The software TomTom-Tools Measurement Studio (for Windows), which comes together with the
measurement tool is made to receive, store and process the values from the Ovality Sensor.
During the measurement, the values are displayed and calculated directly in real time.
There are different display, zoom and report printing options available.
Ovality Sensor

Advantages
 Measurement during kiln operation
 High accuracy
 User friendly software
 Small size (mostly pass easily between heat shields or thrust roller and kiln shell)
 Small weight (Sensor: ~1.5kg / Total incl. Case ~3.5kg)
 Convenient for travelling
 Measurement directly displayed on computer

Ovality Sensor on Kiln Sensor removing from Kiln

 Page 5 Februar 5, 2018

1.3 Tool Kit includes:

1. Ovality Sensor
2. Battery Charger with different plug adapters (100…240VAC)
3. Bluetooth USB Adapter (high range)
4. Transport Case with foam cushioning,
extra tough, water and dust seal (suitable for air cargo)
5. Software (TomTom-Tools Measurement Studio) on USB Flash Drive
6. Manual

Transport Case
Type: Peli 1400
33.9x29.5x15.2cm
Weight total: 4.2kg
 Page 6 Februar 5, 2018

2. OVALITY SENSOR

2.1 Components:

Fig. 2.1.1 4 8
LED 6
1. Deflection Plate
1
2. Fixed Magnets
3. Lateral Movable Magnets
4. Converter
5. Heat Shield
6. T-bar Handles
7. Charger Plug (9…25VDC) 3
3 2
8. Power Switch 7
9 5
9. Infrared Thermometer (50…450°C)
(to measure the temperature of the kiln shell)

2.2 Features:

The Ovality Sensor gets charged by the charger, which is included in the tool kit or by any power
source from 9 to 25VDC (center pin positive).
With the power switch, the tool can be switched on and off.
The light (LED) indicates the condition of the Ovality Sensor.
A constant green light shows that the tool is switched on and is in normal operation.
Slowly green blinking indicates battery charging
Slowly yellow blinking indicates a warning as high temperature or low battery status. If the tool is
connected to the PC, a warning window will appear on the screen as well. Ongoing Measurements
can be completed without problems.
Fast red flashing shows an alarm as dangerous high temperature in the sensor or battery
completely empty. In case of temperature alarm, the tool has to be removed immediately from the
kiln to prevent damage. It creates also an alarm window on the PC screen.
A constant blue light indicates that the tool is measuring.
 Page 7 Februar 5, 2018

3. SOFTWARE:
3.1 Software Installation:

The software (TomTom-Tools Measurement Studio), which is used for

the Ovality Sensor and for all others of our tools, comes along with the tool
kit on a USB memory stick. Nevertheless it is recommended to install the
software from www.tomtom-tools.com , where always the latest version
is available.
During any start of the Measurement Studio, it is checking for updates if
the computer is connected to the internet. In case of available upgrades
the user gets asked if they should be downloaded and installed.
Please keep your PC up to date. 52 MB

3.2 Bluetooth Adapter

To ensure, the data connection between the Ovality Sensor and the PC is reliable, even in the
difficult environment around a rotary kiln, a Long Range Bluetooth adapter (Sena Parani UD100)
comes along with the tool kit.

Note:
 The TomTom-Tools are designed to communicate only with the generic Windows
Bluetooth Stack. If there is another Bluetooth software installed (e.g. Toshiba, Widcomm,
Intel, ThinkPad,…), deactivate it in the Device Manager as shown below:
 Page 8 Februar 5, 2018

 Then plug the Bluetooth adapter UD100.

Windows will recognize the new hardware
and automatically install the suitable Windows driver
(Windows generic Bluetooth)

 The Device Manager will show the following:

- Generic Bluetooth Radio
- Microsoft Bluetooth Enumerator
- the not required Bluetooth is down
(indicated by the small arrow at the Bluetooth icon)

4. START THE TOOL:

4.1 Connect Ovality Sensor with Laptop

When the software installation is completed, it starts automatically.

To connect a tool for the first time it has to be paired with the computer.
To do so, follow this sequence:
 Switch on the Ovality Sensor (green LED).
 Click on “Tools / Bluetooth Devices / Add a device”
 Wait until the tool got found
Note: Depending on the search speed of the computer, it might take up to one minute.
 Select the device, which has to be connected; (here the Ovality Sensor) and click “OK”

Fig. 4.1.1
(Add Device) The size of the buttons
can be changed here

Fig. 4.1.2
(Connect Device)

 The Ovality Sensor gets added to the Device List

 Page 9 Februar 5, 2018

 To connect the Ovality Sensor, click on the “Connect” Button

Fig. 4.1.3 “Set Zero” Button

(Device Window) To set the deflection
plate to “0”
(not required, is done
To connect automatically later)
click here

Device can be
connected, when
displayed here
(in black letters)

Battery Status

Measures the Kiln

Shell Temperature

Shows 0° if Sensor Elongation Value shows the

lays horizontal deformation in the flexing plate

4.2 Signal from the Deflection Plate

The main Sensors in the Ovalily Sensor are the strain gauges,
which are attached to the Deflection Plate (see Fig. 2.1.1).
When the Deflection Plate gets deformed, it is shown as changes in the elongation of its surface
(see in Fig. 4.1.1). Out of this elongation value, the ovality will be calculated.

Note: With a simple test, it can be verified, if the flexing measurement is working correctly:
 Hold the Ovality Sensor on the electronic box horizontally that the magnets look downwards
(do not touch the magnets nor the handles) then click the “Set Zero” Button.
 Turn the Ovality Sensor 180° that the magnets look upwards
Due to the own weight of the magnets, the Deflection Plate gets slightly deformed and an
Elongation of about 25…28 um should be displayed
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5. MEASUREMENTS
5.1 Set Up the Measurement Window

a. To start a new measurement, click on “Measurement / New / Ovality” as shown in Fig. 5.1.1

b. The first pier will be displayed per default.

c. More piers can be added by mouse right click to “Add Pier”
d. Put some additional useful information about the measurement into the “Settings Window”

Fig. 5.1.2

Type the inner

Kiln Diameter

Enter the
Temperature of
Enter Additional Kiln Shell and Tire
Information

Enter the Relative

Tire Movement

Klick mouse right button to

change the Flow Direction

Klick mouse right button to

add more piers
 Page 11 Februar 5, 2018

5.2 Marking the Kiln Shell

Preferable the kiln shell is marked permanently to make repetitive measurement campaign efficient.
Mark the measurement positions (A,B,C with 120° to each other) on both sides of each tire.
Normally A is the zero or reference position around the circumference, which should be the same
reference as for other type of measurements as well.
For example the manhole position or the split of the girth gear can be used for defining the position
of point A.
If there is no permanent making and it has to be done during kiln operation, the Measurement
Studio gives the possibility to do that easily.
 Look for an area with low temperature, to avoid overheating of the Ovality Sensor
 Place the Ovality Sensor on the kiln shell, in line with the reference point (e.g. man hole)
 Click on Measurement / New / Kiln Marking
 The points to mark are shown in the graph and get highlighted when they reach the six
o’clock position
 Mark the kiln shell with a chalk stick with the corresponding letter A, B, and C

Fig.5.2.2 (Kiln Marking)

Fig. 5.2.3

5.3 Place Tool on Kiln

In order to get a sufficient hold of the tool,

make sure the surface, where the Fig. 5.3.1
sensor will be placed, is free of
excessive corrosion and dust layers or
debris and local deformations

Note: Due to the fact, that the ovality is C

most dominant under the tires, the A
measurements should not been taken
too far away from them.
Distances within 1m…1.5m from the
tires are ok and give normally negligible
errors.
On the other hand, measuring close to
stiff tire fixation blocks can have an
impact on the ovality value.
B
e. Place the Ovality Sensor during normal operation onto the kiln shell at the marked position.
Respect the local safety rules and see the chapter 1.1 Safety.

f. To start the measurement, select the position to measure in the kiln schematic and push the
start button or F5 (see Fig. 5.3.2)
 Page 12 Februar 5, 2018

Fig. 5.3.2 (Measurement Window)

Start Button / F5 To reset the Important
window layout Messages

Switch from Radar

to Linear Chart

Mouse right click to change

from line to point graph

Select the position

to be measured

g. The measurement will be taken, after the tool reaches the top point. The measured points
are displayed continuously until the tool reaches the second time the top point.
h. Remove the tool, when the measurement is taken. Do not let the instrument
unnecessary attached to the hot kiln, it might overheat after a while

5.4 Measurement of Kiln Shell Temperature

The Ovality Sensor II is equipped with an infrared thermometer which measures the kiln shell
surface temperature at the location where the tool is attached to the kiln. The temperature values
are automatically stored in the measurement files.

Note:
As the temperature is just measured on small spots below the Ovality Sensor, the temperature
might not be representative for the whole circumference. Therefore it is recommended to double
check the temperature with a traditional temperature gun.
The infrared thermometer is calibrated for an emissivity of 0.9. Dust or corrosion layers might also
influence the temperature readings; hence a typical accuracy of +/-10…20°C can be expected.
The measuring range is between 50…450°C.
Keep the lens of the sensor clean.
 Page 13 Februar 5, 2018

5.5 Temperature Resistance

The Ovality Sensor is made for hot applications; nevertheless it has to be kept as cool as possible
to prevent damages. The magnets are heat resistant up to 330°C. The electronic board in the
sensor is temperature resistant up to 65°C, therefore it is protected by the heat shield and by
insulators. If the internal temperature reaches 60°C or the magnet temperature reaches 300°C, a
warning will be given by the LED2 (yellow blinking) (see chapter 2.2). Also a pop up window in the
Measurement Studio will indicate the increased temperature. The measurement still can be
finished.
If the temperatures reach 65° in the electronic board or 330°C at the magnet, the tool will alarm you
(LED2 red flashing and pop up window). In this case, the Ovality Sensor has to be removed from
the kiln and cooled down as fast as possible.
To cool down the tool, let it cool on the fresh air or by a ventilator (e.g. kiln shell cooling fan), never
use water.

The temperature of one of the magnets and the battery status are measured and displayed in the
right lower corner of the Measurement Studio

Fig 5.5.1

Magnet
Temperature

6. REPORT

6.1 Export to Excel

All data can easily be exported to excel.

Fig.6.1.1

6.2 Create a report

The measurements can be extracted into a report. All additional information from “Setting Window”
is included in the report as well.

Fig. 6.2.1

TomTom-Tools GmhH Switzerland www.tomtom-tools.com [email protected]

 Page 14 Februar 5, 2018

7. ANNEX

7.1 Typical Graphs

a. Low ovality:
Normal flattening on top
Moderate and symmetrical deflection
at contact with support rollers

b. High ovality:
Strong flattening on top
└►Indication for high relative movement
└►Tire shimming seems to be required

High, symmetrical deflection at contact with support rollers

b1.)In case A,B,C have similar shapes
└►indication for possible overload due to
vertical misalignment of kiln axis

B2.)In case A,B,C have very different ovality and roller contact
└►indication for cyclic overload due to crank in kiln shell
└►need verification by roller shaft bending
measurement with IDM Tool Kit

c. Asymmetric roller load:

└►Kiln axis is not aligned in horizontal direction

d. Tilted top area:

└►particles and scuffing between
tire inner diameter and the tire plates

e. Inconsistent readings :
└►In the blue reading, one of the middle magnets
lost the contact to the kiln shell.
└►clean the magnets
and repeat measurement
Note:
Jumps in the graph might also be indications for insufficient
hold of the magnets.
Make sure, the magnets are clean and there is not
eccessive dust or corrosion on the kiln shell
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7.2 Results

The Ovality Values are good and simple indicators, to see whether other investigations or
measurements are required. But the corrective actions on the kiln should never be based only on
the results of the Ovality measurement.
Ovality measurement does NOT replace creep measurement nor measurement of the kiln axis!

TomTom-Tools Ltd. does not provide guide lines about acceptable ovality values or limits.
It has to be discussed with the refractory suppliers, how much ovality can be allowed.
Out of experience the following table can be taken as an example but might need to be adjusted
to the specific case:

7.3 Typical Ovality Value Limits

High Ovality:
Fig.7.3.1 Search the root cause (e.g.
excessive wear of tire pads)
Tire Shimming Required

0.8 Risk for Refractory Failures

Elevated Ovality:
Should be monitored

0.6 Normal Ovality:

Ovality [%]

No action required
0.4
Low Ovality:
Excellent for the refractory,
0.2 but closely monitor the
relative movement of the tire
Risk for Shell Constriction
0.0 Very Low Ovality:
Search the root cause
3 4 5 6 7 e.g. wrong tire shimming,
Kiln Diameter [m]
high shell temperature,
upset kiln condition)
 Page 16 Februar 5, 2018

7.4 Ovality Report

7.5 Drawing