DALOG Cement English

DALOG® S-550 Monitoring System for Vertical Roller Mills
Greater and greater demands are being made of modern machinery and plant with respect to
automation, reliability, and availability. One important means for meeting these demands is
the use of high-performance, reliable monitoring and diagnostic systems. They enable the
plant or machine manufacturer to obtain an overview of the status of the equipment at any
time–regardless of its location. In this way, necessary maintenance and repair can be planned
and initiated in good time.
Yet another gearing monitor? Yes, but much more as

well. The developer of the DALOG® systems worked
for years in the R & D department of a major German
gearing manufacturer. Therefore, we have particularly
deep knowledge of this field. And because we are not a
subsidiary of a gearing manufacturer, we can "afford"
to be strictly impartial. That makes discussions more
relaxed, and is particularly important for those users
who find gearing from a wide range of manufacturers
in their equipment inventory.
Today, all technical systems are operated with the help

of control systems that make a large number of items
of data available which are of interest for machinery
diagnosis. Whether it be operating hours, operating
modes, or fault messages: only effective recording and
evaluating of the data makes measures to prevent dam-
age effectively possible.
Integrated diagnostic systems are a component of the electronic control systems of the plant. They
serve to register and signal faults in the electronic circuitry, the sensors, or the actuators. With these
integrated systems, malfunctions outside the control system can also be detected to a certain extent
without additional instrumentation. For a comprehensive diagnosis, the existing sensors and the
evaluation and processing mechanisms of the control systems are usually not sufficient. Extended
diagnosis requires highly developed sensors and data logging and information processing systems that
are coordinated with them.
In a modern monitoring system, not only is vibration analysis performed over time and frequency, but
an envelope analysis is performed, as well. Various characteristics are generated from these signals,
permitting a general evaluation of the plant, and allocation to individual components, such as bearings
and gear wheels, by frequency-selective evaluation.
DALOG® S-550 Monitoring System

The DALOG® S-550 Monitoring System is an independent, high-performance, inexpensive system
for vibration monitoring. The system is installed on site, and does unmanned monitoring of bearings,
shafts, gear teeth, complete gearboxes, and other units around the clock. DALOG® systems have al-
ready been installed in cement mills, crushers, conveyor-belt facilities, etc.
The DALOG® S-550 Monitoring System has two major advantages over conventional systems:
It monitors not only rolling bearings, but also the gear teeth of a gearbox. In addition to the recording
of vibration signals, a reliable torque measurement system is also installed. And besides a frequency-
selective evaluation of the vibration signals, a frequency-selective evaluation of the torque signals is
also performed. Thus it is possible to assess the signals and characteristic values according to the duty
point.
The DALOG® Monitoring System differs from other solutions in its great flexibility, and permits
individualized, plant-specific solutions. All the options for vibration monitoring and production data
acquisition can be combined. This is especially important, since informative analyses are only possible
from an overall picture of many values.
The sensor systems

A wide variety of measurements, such as accelera-
tion, torque, r.p.m., pressure, as well as process
data such as material feed, height of the milling
bed, and motor current, are logged by different
sensors. This provides substantially greater accu-
racy of the information on the state of the plant.
Commercially available piezo-electric acceleration

transducers with integrated amplification, torque
and speed sensors, position encoders, pressure and
temperature sensors, and others can be connected
to the DALOG® S-550 Monitoring System.
Torque telemetry sensor

The torque is recorded reliably and without contact via
telemetry.
For this purpose, a full-bridge strain gauge, a signal am-

plifier, and an antenna ring are mounted on the drive
shaft. The antenna ring is split, so that it can also be in-
stalled in existing facilities.
The supply voltage is fed in and the reading signal taken

off via an antenna head fastened to the machine bed.
The torque signal is one of the most important signals. It

gives indications of
 the operating mode of the plant
 dangerous overloads
 torsional frequencies
Filters
A four-pole analogue anti-aliasing low-pass Butterworth filter (24 dB/octave) is employed for the data
logging. The filter limit values are adjustable, so that optimum values can be set for the particular appli-
cation.
Adjustable band-pass filters (high-pass and low-pass) are available for the envelope-curve analysis,
which is employed in particular for the diagnosis of rolling bearings, but also of gearboxes.
Analysis & Monitoring

The DALOG® system evaluates
general characteristics from the
acceleration and envelope signals
that give indications of anomalies
and/or changes in operating state,
such as
 r.m.s. value
 crest value
 kurtosis value
and frequency-selective characteristics that gi-

ves indications of the site of the damage, such
as
 tooth frequencies and harmonics
 sideband frequencies
 rolling-bearing frequencies
 shaft rotation frequencies
Besides the characteristics from the acceleration

signals, characteristic values are also formed
from the torque signal, such as
 maximum, mean, and minimum values of the
torque
 tooth frequencies and harmonics
 sideband frequencies
 rolling-bearing frequencies
 shaft rotation frequencies
The characteristics from the acceleration, enve-

lope, and torque, in combination with character-
istics from the process variables, allow the
greatest possible prediction accuracy and sure
fault and damage diagnosis.
Trend analysis
A trend analysis is performed with the charac-
teristic values generated continuously on-line,
and plant-specific limit values are specified.
Alarm limits
The DALOG® Monitoring System can also
provide alarms and messaging, of course.
The alarm limits are determined taking into

account the plant-specific machine dynamics
and the process variables, thus avoiding false
alarms.
Communication
The DALOG® Monitoring
Systems can be operated
individually or intercon-
nected, i.e. a separate local-
area network can be set up
with this system. This per-
mits large, complex plants
to be monitored.
There are several options for communicating with the DALOG® Monitoring System and the control
room:
 PC/notebook and DALOG® via RS-232 interface
 PC/notebook and DALOG® via Ethernet over COM server
 PC/notebook and DALOG® via regular or GSM cellphone modem
 PC/notebook and DALOG® via DALOG® OPC server
Transmission of the data to the control room via DALOG® OPC server is a convenient way for users
to visualize the DALOG® data using their own control-room software, to store them, and to trigger
an alarm and/or message. The convenient DALOG® visualization software is available for further
communication options.
Support & Remote Diagnosis
Experts with many years of experience in moni-
toring cement-mill gearing are available at DA-
LOG® for external support and remote diagno-
sis. They communicate directly with the plant
by polling, read out the data, and analyse them.
The firmware can be updated by polling, and all

parameters adjusted to altered operating condi-
tions by remote access–anywhere in the world.
Service Report – Training – Installation

In order to support the operator on site, DA-
LOG® generates a Service Report. This pro-
vides operators with a comprehensive report on
the condition of their plants in a comprehensi-
ble form.
Peculiarities and anomalies are pointed out

specifically.
Training courses can be provided in-house or on the customer's premises.
The DALOG® company supplies turnkey systems and performs installation and commissioning–
anywhere in the world. Short response times are a matter of course for us, because your output has
top priority as far as we are concerned.
Further Applications in Cement Plant

 Conveyor
 Crusher
 Gearboxes
DALOG® Monitoring System S-550
Technical Data
Analog Inputs 16 Channel / 10Bit

Optional:
Analog Inputs 16 Channel / 12Bit
Analog Input Ranges
(0...5)V, (0...10)V, (0...20)mA, 5V, 10V
Digital Inputs 16 Channel
Frequency Inputs 4 Channel
Digital Outputs 12 Channel
Sum Sampling Rate > 40kHz
Real-Time Clock
Memory Capacity 16 MByte SRAM
Serial Interfaces 2 x RS 232
CAN – Bus 2
Operating Temp. (-30...70)°C
Vibration Resistance (100...1000)Hz<5g
Degree of Protection IP65
Dimensions 240 x 130 x 65mm
Housing Aluminium Casing
DALOG® Diagnosesysteme GmbH  Siemensstraße 2a  D-86356 Neusäß

Tel.: +49 (0) 8 21 - 74 77 711  Fax: +49 (0) 8 21 - 74 77 719  e-mail: info@dalog.net

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DALOG® S-550 Monitoring System for Vertical Roller Mills

Yet another gearing monitor? Yes, but much more as

Today, all technical systems are operated with the help

DALOG® S-550 Monitoring System

The sensor systems

Commercially available piezo-electric acceleration

Torque telemetry sensor

For this purpose, a full-bridge strain gauge, a signal am-

The supply voltage is fed in and the reading signal taken

The torque signal is one of the most important signals. It

Analysis & Monitoring

and frequency-selective characteristics that gi-

Besides the characteristics from the acceleration

The characteristics from the acceleration, enve-

The alarm limits are determined taking into

The firmware can be updated by polling, and all

Service Report – Training – Installation

Peculiarities and anomalies are pointed out

Training courses can be provided in-house or on the customer's premises.

Further Applications in Cement Plant

Analog Inputs 16 Channel / 10Bit

DALOG® Diagnosesysteme GmbH  Siemensstraße 2a  D-86356 Neusäß

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