Girth Gear Monitoring System

Girth Gear Monitoring System Basic

Main assumptions of the system.

The main propose of system installation is to provide constant monitoring of girth gear position during kiln operation, which is the most important and most expensive mechanical component of the kiln.

Both parameters, axial run-out and radial run-out are directly related with the kiln shell. In case of sudden temperature change on the shell circumference close to girth gear, e.g. due to brick lining failure or coating collapse, some thermal crank in the kiln shell can appear. This crank in the kiln shell change the geometrical position of girth gear which is directly attached to the kiln shell. Correct operation of meshing between girth gear and pinion is at risk.

Misalignment of girth gear during operation creates uneven and unstable stress concentration on teeth leading to its damage.

Misalignment of girth gear very often is a subject of high vibration on the station. Which even increase the damages not only on teeth but also other components located at nearest pier.

If the cause of misalignment is not observed and removed in time, it may even lead to the need to replacement of girth gear.


The system is composed of two analog linear inductive sensors which are responsible for girth gear radial run-out and axial run-out measurement.

Direct reading from the sensor will be visible directly on the kiln station.

Type of data display: screen or LED panel.

Due to axial balance of the kiln - monitoring of axial run-out possible only at kiln lower position.

Key Benefits

- Constant monitoring of girth gear alignment.

- Longer lifetime of girth gear and pinion.

- Locate problem long before malfunction

- Lower number of unplanned kiln stoppages – less component damages.

- Save money – the need to change or repair girth gear (or fixation) reduced to minimum.

- Protection not only girth gear but also other components – tire, thrust roller, support rollers.

Sensor example specification


Non-contact distance measurement of metallic objects

Analog Voltage output 0-10 VDC

Also available in current O/P models like 4-20 m A , 0-20 m A

Increased sensing distance

Analog data can be directly sent to measuring systems

M 18 & 30mm threaded cylindrical housings

Protection degree IP 67: dust tight and protection from the effects of immersion.


Power supply : 15V DC

Current Consumption : <15mA

Load Resistance : >= 4K7 Ohm

Ambient temperature : 0 deg. C. to 70 deg. C

Size : M 18, M 30 Nickel chrome plated brass enclosure

Output : 0...10V DC(over Full range)

Output Type : Analogue

Response frequency Hz : 100 Hz

Hysteresis : 3 to 15%

Linearity Error : 3 to 3.25%

Repeatability : 0.03

Ambient humidity : 35 - 95% RH

Sensing distance (mm) : 2....7 mm, 4-12 mm, Non flush type, flush type also available


Hot kiln alignment - the main area of our actions shall be to conduct mechanical inspection and to specify activities (measurements, exchanges, repairs, modifications, etc.) which should be performed to attain and maintain high effectiveness of the rotary kiln's operation.


We hold a specialist hardware and software used for professional measurements. Application of relevant tools allows for effective diagnosis and monitoring of machinery and equipment operation.


We developed high precision measurement systems to allow to monitor current status of equipment and to plan maintenance activities. Hence, malfunctions and breakdowns can be reduced both in respect of their intensity and frequency.


We provide a wide scope of measurement services addressed to many industry branches. Highly precise measurements are the starting point for analyses and regulations supporting the work of machinery and equipment.