Recently, a cement manufacturer contacted Datum Electronics after experiencing an unexpected shaft breakage of one of the motors (used for the rotation of the kiln).
The cost of closing down the kiln whilst awaiting a replacement shaft, along with the value of the parts and the emergency maintenance was estimated in the £ millions – directly impacting the production efficiency of the quarry.
To prevent future machinery failures, the company decided to invest in an on-shaft torque and power monitoring solution.
Power Monitoring Solution
Such a solution would allow them to monitor these values in real time and trigger an alarm, facilitating early detection of damage to the shaft line and improve maintenance scheduling. However, the customer had several challenges that would make a standard torque sensor not viable for this application:
Firstly, the kiln was operating in an extremely dirty and harsh environment. Furthermore, the intended area for installation was located directly under the cement kiln (which is subjected to extremely high temperatures). On top of that, the shaft line was protected by a steel guard, restricting the space available to fit a torque sensor. Despite the unusual and hostile operating environment, Datum Electronics’ were able to supply them with an ideal sensor solution.