Industrial Kiln

KILN/DRYER VIBRATION & Dryer Group TM

There are a number of plausible mechanisms to explain
kiln/dryer vibrations. Below are a few to review:

1. The transfer of load from one pinion tooth to the following tooth may have an
impact component. Drive system vibration is sustained by the abrupt transfer of load
from the engaged pinion tooth to the following tooth. The transfer of load may be
abrupt because of a) wear of the tooth profiles or b) excessive root clearance.

2. The helical design of gears guarantees smooth tooth to tooth load transfer
because the load is shared by two adjacent teeth at the time of the load transfer.
For this load overlap to be possible there has to be a minimum 80% contact over the
width of the gear teeth. The pinion to main gear contact is often less than the required
80% because a) the main gear axial runout decreases gear to pinion contact and b)
the pinion is not set to optimize contact for a given axial runout. The gear has an
axial runout that follows a sine wave pattern. Optimum pinion alignment requires full
contact at one of the extremes of the gear runout sine wave. This allows the maximum
average percent contact for a given main gear axial runout.

3. There is often sufficient leverage on the pinion support mechanism to allow the
pinion to move toward the kiln/dryer axis in response to pinion tooth pressure.
Such a move results in stresses in the pinion base. These stresses are relieved by
the movement of the pinion back to the “at rest” position whenever tooth pressure
conditions allow. (For example, such stress relief can occur when one gear hits a worn
spot on the other gear profile). If the resulting tooth pressure fluctuation is in phase
with the kiln/dryer resonance frequency, vibration amplitudes become extremely high
at unpredictable locations on the kiln/dryer axis. Torsional vibration can take place
far from the gear and brick spiraling typically occurs at these locations. Shell radial
vibration can occur on the drive pier, causing serious wear of the gears, low speed
coupling, the gear reducer teeth, and the bearings on the gear box low speed shaft.

4. On a kiln, drive vibration can be caused by a shell dogleg condition on units

with three or more piers. Such a condition causes pier load variation in the course of a
kiln rotation. If the pier load on the drive pier falls below a minimum threshold, the pier
loses the ability to dampen radial shell movement. (Without pressure from the roller to
the tire to the shell, the very long shell span between the two piers uphill and downhill
of the drive pier is radially unstable). Radial shell movement results in tooth pressure
variations and load cycling. Vibration is then inevitable.

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KILN/DRYER VIBRATION & Dryer Group TM

5. It is important to note that resonance vibration only occurs if the tooth contact
frequency is close to the resonance frequency of the kiln/dryer system. That means
that the condition is very sensitive to speed of rotation. The kiln/dryer may be very
stable under normal speeds but may have damaging vibrations at transition speeds,
perhaps when the kiln is cooled or brought up to operating temperature.

6. The vibration frequency of a body is a function of the inverse of the square root
of its weight. This means that vibrations of unacceptable amplitude may occur over
isolated time periods when there is high buildup of product in the kiln/dryer.

7. If the kiln drive motor control system responds to a speed change in a time
period that is close to the time interval between two adjacent gear teeth, drive load
cycling can occur with resonance characteristics. Some motor control systems have
a variable resistor that can change the system response time to pinion speed change. If
possible, the response should be dampened to half the tooth contact time interval. That
way, the motor control system would be biased to dampen drive vibration rather than
amplify it.

8. The maximum vibration amplitude at the peak of the condition can be so low
that if one does not look for it, it goes undetected. The vibration is however typically
accompanied by tooth pressure fluctuations, where the maximum tooth pressure can
exceed the design pressure by an order of magnitude. Such tooth pressure fluctuations
cause severe pitting and premature wear. A gear system can be ruined in six months
if the tooth pressure fluctuations are of sufficient magnitude. (Most gear wear is caused
by high tooth pressure fluctuations and inadequate gear lubricant viscosity). Drive
vibrations are best detected by measuring the movement of the pinion bearings with a
dial indicator. (The indicator has to be anchored independent of the pinion base).

RECOMMENDATIONS

1. To assure smooth load transfer from tooth to tooth, maximize the tooth contact
between the pinion and the main gear by setting the root clearance low at
operating temperatures. Contrary to popular opinion, the pitch lines separate as the
kiln/dryer temperature increases.

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The pitch lines must be set even or at a slight overlap when the unit is cold. As the
unit temperature increases, the 12 o’clock position of the shell at the gear can move up
about 3/8” depending on the diameter of the unit and its temperature; the elevation of
the 6 o’clock position of the shell does not change; this would result in the shell center
elevation moving up 3/16”. Since the gear is centered on the shell center line, it moves
up as the unit diameter increases (due to thermal expansion). As the gear moves up the
gear and pinion pitch lines separate. The bottom line: Faith based procedures to the
contrary, the pitch line separation on a cold kiln has to be a maximum of zero.

2. Stabilize the pinion base to prevent its possible motion perpendicular to the unit
axis. Such motion occurs in response to tooth pressure fluctuations. The stabilization
can be accomplished by welding kickers on the base at the pinion bearing locations.

3. Check a kiln for doglegs that may interfere with the dampening of shell radial
movement at the drive pier. The best way to check for doglegs is by measuring the
lateral movement of the tire centers as the kiln rotates. Such measurements should be
part of the scope of work for every kiln alignment. Shell profile analysis is a procedure
that is useless for the purpose of measuring dogleg symptoms, (or for any other
purpose for that matter), contrary to the claims of companies selling the service.

4. Explore the possibility of dampening drive vibrations via settings of the motor
control system variables.

Proper analysis of problems pertaining to kiln/dryer stability requires in depth

knowledge of the variables involved. If the above information is something you
have not seen before, you need Industrial Kiln & Dryer Group as your rotary
equipment service provider. Please contact us at 877-316-6140 for state of the
art solutions to all kiln related problems. We are your best source for technical
opinions that make sense.

Authored by Lou Lovas, expert at kiln alignment theory, with 40+ years of experience
repairing, servicing and installing industrial processing equipment.

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877-316-6140