TomTom Inductive Distance Measurement Tool Kit II User manual

TomTom-Tools GmbH Phone: [phone]
Zelgli 20
8905 Arni [e-mail]
Switzerland www.tomtom-tools.com
4 April 2022
User Manual:
I nductive D istance M easurement (IDM) Tool Kit II
1. INTRODUCTION:
The Inductive Distance Measurement (IDM) Tool Kit is a multi-purpose measurement tool. Typically
it is used to check the condition of rotating parts during operation (e.g. on Rotary Kilns, Dryers, Ball
Mills). It measures variation of distances of moving metal surfaces without contact (typically steel
surfaces) with high accuracy and high speed (up to 1000 measurements per second).
It can be considered as a contactless dial gauge.
Typical applications:
•Run-out measurement of girth gears on rotary kilns, rotary dryers and ball mills
•Run-out measurement of kiln tires
•Roller shaft bending measurement of support rollers on rotary kilns
•Shaft movements in gear boxes and drives
•Roundness and run out check of trunnions on ball mills
More applications:
The IDM II Controller can be used for any kind of sensor with an output of 0…10V or 0…20mA
(supplied from January 2020)
Hence there are much more applications possible. E.g.:
•High speed hydraulic pressure measurement on vertical roller mills and roller presses
•Shell deformation measurement on rotary kilns or ball mills with laser distance sensors
•Verification of values of any installed sensor output signal directly on site
•……..

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TABLE OF CONTENT
1. Introduction:..........................................................................................................................1
1.1 Safety:.................................................................................................................................3
1.2 Measuring Principle: ...........................................................................................................4
1.3 Tool Kit includes:.................................................................................................................5
1.4 Components:.......................................................................................................................5
2. The Sensors ..........................................................................................................................6
2.1 Features:.............................................................................................................................7
3. IDM2 Controller: ....................................................................................................................7
4. Software:................................................................................................................................8
4.1 Bluetooth Adapter ...............................................................................................................8
5. Start the Tool:........................................................................................................................9
5.1 Connect IDM Controller with Laptop...................................................................................9
6. Raw Data Acquisition:........................................................................................................11
6.1 Purpose.............................................................................................................................11
6.2 Starting the Software Application......................................................................................11
6.3 Take Measurements.........................................................................................................12
7. Roller Shaft Bending: .........................................................................................................13
7.1 Measurement Principle .....................................................................................................13
7.2 Place the Sensor...............................................................................................................13
7.3 Start The Software Application .........................................................................................14
7.4 Take Measurements.........................................................................................................15
7.5 Interpretation of Results....................................................................................................17
8. Gear Run out: ......................................................................................................................18
8.1 Measurement Principle .....................................................................................................18
8.2 Place the Sensor...............................................................................................................18
8.3 Start The Software Application .........................................................................................20
8.4 Sampling Rate (Frequency) Adjustment...........................................................................21
8.5 Take Measurements.........................................................................................................22
8.6 Results ..............................................................................................................................23
8.7 Limits.................................................................................................................................25
9. Optional Sensor to measure Shaft movement in Gearboxes ........................................26
10. Report...................................................................................................................................26
10.1 Export to Excel..................................................................................................................26
10.2 Create a report..................................................................................................................27
10.3 Adding a New Sensor Scaling ..........................................................................................27

Page 3 April 4, 2022
1.1 Safety:
Rotary kilns, dryers and mills, where this tool typically is used, are huge rotating equipments with
many pinch points, they can cause serious injuries. Therefore only specialized and trained
personnel shall work close to these machines. To use the tool, 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 plant 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 and not
exhausted which include the experience from previous measurement campaigns and might need to
be adapted to the local safety requirements.
Caution:
Pinch Points:
Do not put your hands nor any items close or into pinch points
(e.g. girth gear / pinion, kiln tires / support rollers,…)
Keep safe distance to avoid getting caught by moving parts.
For gear run out measurements, never place sensors on the side where
the teeth are engaging; place them always on the out running side, to
avoid the items get caught between
Magnet Fields:
Be aware of the strong magnet field of the magnet stands.
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.
Gloves:
Wear proper gloves to protect your hands from hot and rough surfaces and
sharp edges.

Page 4 April 4, 2022
1.2 Measuring Principle:
The Tool Kit is equipped with different inductive distance sensors. These sensors use the physical
effect of the change of a resonance circuit, which is caused by eddy current losses in conductive
materials. The losses depend on the distance between the coil in the sensor head and the
conductive surface. The circuit measures the losses and converts them into a linearized 0…10V
output signal.
The signals of maximal six sensors can be measured by the IDM2 Controller, which converts them
into numeric values and sends them via Bluetooth to a PC.
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 IDM Controller.
There are already 4 types of applications available in the software:
•Raw Data Acquisition:
In this mode the data are one to one displayed in real time on the computer screen.
•Roller Shaft Bending Measurement
This application is used on rotary kilns with 3 or more stations. It calculates automatically
the variation of shaft deflections, which are caused by a crank in the kiln shell.
•Gear Run Out Measurement
The application is calculating automatically the radial and axial run out (eccentricity and
roundness) of rotating parts. (typically girth gears and mill trunnions)
•Tire Run Out Measurement
The application is calculating automatically the axial run out (wobble) of a kiln tire
Measurement of Girth Gear Run-Out
Measurement of Girth Gear Run-Out
Measurement of Roller Shaft Bending

Page 5 April 4, 2022
IDM2 Controller
6 input channels
Bluetooth connection
Magnet Stand
Inductive Sensor
Software on
USB drive
IDM
Cotroller
Magnetic
Switch Flag
Inductive
Sensors
Dial Gauge
1.3 Tool Kit includes:
1. IDM2 Controller
With six input channels 0…10V or 0…20mA, integrated battery and 24VDC power supply
for the sensors, Bluetooth connection to PC
2. Inductive Sensors
2 Sensors Ø12mm, 2 Sensors Ø18mm, 2 Sensors Ø30mm,
1 Sensor 40x40mm, 1 Sensor 30x14mm
3. Sensor Cables with 2m and 5m length
4. Magnetic Stands
Including connectors, extension rods and sensor holders
5. Dial Gauge for reference measurements
6. Magnetic switch flag with heat resistant magnet (up to 300°C) and extension rods
7. Transport Case with foam cushioning
extra tough, water and dust seal (suitable for air cargo)
8. Manual and Software for Windows on USB memory
TomTom-Tools Measurement Studio
9. Bluetooth adapter to connect the controller with the PC
1.4 Components:
Transport Case
Type: Peli 1495
54.9x43.8x12.4cm
Weight total:
10kg

Page 6 April 4, 2022
2. THE SENSORS
Any sensor with 0…10V or 0…20mA output can be connected to the IDM controller
(maximal power consumption of all connected sensors together: 400 mA @ 24VDC)
Sensor Name:
IFM D12
(0.4…4mm)
IFM D18
(0.8…8mm)
IFM D30
(1…15mm)
IFM 40x40
(1…25mm)
Turck 30x14
(3…8mm)
Dimension: ∅12mm ∅18mm ∅30mm 40x40mm 30x14mm
Operating
Range
0.4…4mm 0.8…8mm 1…15mm 1…25mm 3…8mm
Slope (gradient)
0.36 mm/V
0.72 mm/V
1.4 mm/V
2.4 mm/V
0.5 mm/V
Y
-
Intercept
0.4
mm
0.8
mm
1
mm
1
mm
3
mm
Minimal Target
12x12mm
24x24mm
45x45mm
90x90mm
40x40mm
Linearity Error
±
3% of UA max
±
1% of UA max
±
1
% of UA max
±3
% of UA max
±
3% of UA max
Repeatability
±2
% of UA max
±
1% of UA max
±1
% of UA max
±2
% of UA max
±
1% of UA max
Temp.
Coefficient
±10% of UA
max
±5% of UA max ±5% of UA max
(-25…70°C)
±10% of UA
max (70…80°C)
±10% of UA
max
(-25…70°C)
±10% of UA
max
(-25…70°C)
Response Time
< 10 ms
< 10 ms
< 20 ms
< 20 ms
7 ms
Operating
Temperature
-25…80°C -25…70°C
Output
0…10VDC (analog)
Operating
Voltage
15…30VDC
Current
Consumption
< 20 mA
Protection
IP 67
Correction
Factors
Mild Steel = 1
Stainless Steel = approx. 0.5
Aluminum = approx. 0.4
Copper = approx. 0.3
Display Within operating range: yellow (permanently lit)
Outside the operating range: yellow (flashing)
Mounting:
Non
-
flush mountable
Flush mountabl.
Wiring Special adapter
cable required
(M8 M12)
with pin change
(pin4pin2)
brown
white
blue
black
Not connected

Page 7 April 4, 2022
2.1 Features:
The IDM II controller is equipped with a Li-Ion Battery pack and a power convertor to supply the
sensors with 24VDC.
The battery gets charged by the charger, which is included in the tool kit or by any power source
from 9 to 30VDC (center pin positive).
With the power switch, the controller is switched on and off.
The light (LED) indicates the condition of the controller.
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 increased 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 or battery completely empty. In
case of temperature alarm, the tool has to be removed immediately for cooling to prevent damage.
It creates also an alarm window on the PC screen.
A constant blue light indicates that the tool is measuring.
The sensors* are also equipped with LEDs near their plugs, which indicate the function of the
sensor. A constant light indicates that the sensor is working and is in normal range. A blinking
light shows that the sensor is out of range. This means, that the surface to measure is too far away
or too close to the sensor. *(except low profile sensor)
3. IDM2 CONTROLLER:
The following schematic shows the main components and wiring of the IDM Controller.
The pins 1 and 3 supply the 24VDC for the sensors
The analog signal from the sensor is fed back to the controller either via pin 2 or 4; depending on
the sensor. The sensors, which are included in the tool kit, have a 0…10V output on pin 2.
(Sensors with orange heads from IFM)
In case a sensor with mA output or with the signal on pin 4 is used, configure the respective
channel accordingly via Measurement Studio.

Page 8 April 4, 2022
1 brown: sensor power supply (+24VDC)
2 white: default sensor input (0-10V, 0...20mA)
3 blue: GND (-)
4 black: optional sensor input (0-10V, 0...20mA)
-
+
5
4
3
6
1
24
3
+
-
U
Inductive Sensor
2
1
3
4
-
+
2
1
A/D Converter
6 inputs
0...10V
or
0...20mA
Bluetooth
DC/DC Converter
Power Output 24V, 10W
Li-Ion Battery Pack
2S2P, 7.4V, 5.2Ah
Charge
Controller
-+
Power
Switch
Charger
Plug
9...30VDC
4. SOFTWARE:
The software (TomTom-Tools Measurement Studio), which is used for
the IDM Tool Kit and for all others of our tools, comes along with the tool
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 for download.
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.
4.1 Bluetooth Adapter
To ensure, the data connection between the Ovality Sensor and the PC is reliable, even in difficult
industrial environment, 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:
Fig. 4.1.1 (Device Manager)
70 MB

Page 9 April 4, 2022
•Then plug the Bluetooth adapter UD100.
Windows recognizes 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)
Fig. 4.1.1 (Integrated Bluetooth down)
5. START THE TOOL:
5.1 Connect IDM Controller 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 IDM2 Controller (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 IDM2) and click “OK”
Fig. 5.1.1
(Add Device)
The size of the buttons
can be changed here

Page 10 April 4, 2022
Fig. 5.1.2
(Connect Device)
•IDM2 gets added to the Device List
•To connect it, select it and click on the
“Connect” Button
Fig. 5.1.3
(Device Window)
To connect
click here
Click here to change
the sampling rate
Device can be
connected, when
displayed here
(in black letters)
Battery Status
To change the pin
of the input signal
or from V to mA
Add here the
scaling of a
new sensor

Page 11 April 4, 2022
6. RAW DATA ACQUISITION:
6.1 Purpose
The Raw Data Acquisition is a universal application to measure any kind of value. Either
distances can be measured with the inductive sensors, included in the tool kit or other sensors can
be connected with an output of 0…10V or 0…20mA.
This application is typically used, when measurements have to be taken, where no specific
application is available in the Measurement Studio.
The values are directly displayed in the screen, where different zoom functions can be used.
For further analysis, the data can also be exported to Excel or into other software.
6.2 Starting the Software Application
To start it, click “Projects / Add Raw Data Acquisition”
The computer screen will show the graph window with the empty sensor window below.
Click to add a channel and select the required sensor.
Fig. 6.2.1
(Add Channel)
Fig. 6.2.2
(Select Scaling)

Page 12 April 4, 2022
Change the sampling rate by clicking on the number
Fig. 6.2.3 (Edit Sampling Rate)
To add a sensor channel, click the button “Add Channel” (see picture above).
Select an existing scaling or create a new one (as described above)
See the green bar; it indicates the Sensor Value (here; distance between roller surface and
sensor).
6.3 Take Measurements
To start the measurements push the Start button or [F5].
Fig. 6.3.1 (Start Button)
After starting the measurement, the values will appear on the computer screen. Each channel has
its own curve with its own color. The lines can be hided or displayed by clicking to the tick mark.
To stop the measurements push the Stop button or [F6].
To extract the data in to Excel click: “File / Export to Excel…”
Actual
Sensor Value
Edit Channel
Click here to
change window
Click on number
to edit sampling

Page 13 April 4, 2022
Fig. 6.3.2 (Raw data graph)
7. ROLLER SHAFT BENDING:
7.1 Measurement Principle
On a kiln support roller, the variation of the deflection of the roller shafts show possible cranks.
Cranks are straightness errors in the kiln shell, which are affecting the loads on the roller stations
with each kiln revolution.
There are two types of cranks:
•Permanent / Mechanical Crank:
Caused by plastic deformations in the kiln shell or errors during the kiln construction.
•Thermal Crank:
Caused by uneven temperature distribution / thermal expansion around the kiln shell
circumference. (most severe close to the middle tire)
The load changes caused by cranks can be very strong and overload the tires and rollers, which
results in cracks in tires, rollers and roller shafts.
The crank pushes the roller down; hence the distance between the sensor and the roller surface is
reduced. Half a kiln revolution later, the crank turns up and the load gets reduced on this station;
hence the distance to the sensor is getting bigger.
7.2 Place the Sensor
To measure the effect of a crank, an inductive sensor, typically Ø12mm is placed under the support
roller in the line of force. That means on the opposite side of the contact to the kiln tire.
(See pictures below)
Due to the high stiffness of the roller shafts, these movements are very small (within tenths of
millimeter), therefore it is recommended to use the smallest sensor of the IDM Tool Kit (Ø12mm) to
have the highest accuracy
Stop Button (F6)
Set Mark (F9)
to generate time staps
Click mouse right to
change the X and Y axis

Page 14 April 4, 2022
7.3 Start The Software Application
The Measurement Studio includes a specific application to measure and calculate the variation of
the roller shaft bending.
To start it, click “Measurements / New / IDM / Roller Shaft Bending”
Low Load High Load Low Load High Load Low Load High Load
Roller High Loaded
Inductive Sensor
(gap reduced)
Roller Low / Not Loaded
Inductive Sensor
(gap increased)
Line of
Force
Inductive
Sensor
Inductive
Sensor
IDM
Controller

Page 15 April 4, 2022
Right Click to
add more
Select the roller
to measure
Sensor
Type
Input
Cannel
Sensor
Distance
Edit Sensor
Settings
Sampling
Frequency
10
The computer screen will show a kiln tire with two rollers (top view).
To add more tires, click right mouse button and select “Add Pier” (see picture below)
See the green bar, which indicates the Sensor Distance (gap between roller surface and sensor).
It should be approximately in the middle of the sensor range, at least never go to one of the
extreme positions.
Software for Roller Shaft Bending Measurement:
7.4 Take Measurements
To start the measurement, select the roller on the computer screen and push the
Start button or [F5].
Fig. 7.4.1/2
After starting the measurement, the values will appear on the computer screen (green curve)

Page 16 April 4, 2022
Note:
To be able to calculate the roller shaft bending value and its position around the kiln, the software
needs a reference signal, when the reference point is passing the roller, which is measured.
Typically the manhole in the kiln shell is used as reference point.
Each time when this reference point is passing the direction of the measured roller, push the
button [F9] to indicate the kiln rotation. A yellow line in the graph will show the position of the
reference point.
Fig. 7.4.3
The green curve shows the measured values
The blue curve is sinusoidal and shows the variation of roller shaft bending coming from a
crank in the kiln shell
The red curve indicates the roundness of the support roller and is the difference
between the measured curve (green) and the shaft bending curve (blue).
After about 3 kiln revolutions, sufficient data are collected and the measurement can be stopped.
To stop the measurements push the Stop button or [F6].
Roller Shaft
Bending
Value
Position of
Crank
Roller Shaft
Bending Curve
Curve
Reference Lines
(when F9 was pressed)
Hide / Unhide
curves

Page 17 April 4, 2022
7.5 Interpretation of Results
To detect a crank on a 3 Pier Kiln, measuring the roller shaft bending on the middle pier is normally
sufficient. Both rollers of a pier deflect typically the same way.
In case of high values, it is recommended to measure both rollers on the middle pier, to double
check if really a strong crank is present or if some looseness in a bearing or foundation is causing
the high values.
Note:
TomTom-Tools GmbH does not provide guide lines about roller shaft limits.
It has to be according to the equipment manual or discussed with the suppliers, how much roller
shaft bending can be allowed.
Nevertheless based on the experience of different kiln supplier the following guide values were
established.
It has also been seen, that the values are valid for small and for big kilns, because the ratio
between the load on the rollers and the dimensions is for all kilns similar.
Roller Shaft Bending Value:
> ±0.2mm HH Alarm
> ±0.15mm…±0.2mm H Warning
0…±0.15mm Normal
The position of the crank peak is indicated by the angle in ° (deg) relatively to the reference point
on the kiln shell (e.g. manhole).
For example, the value 167° means that the peak of the crank is located 167° after the manhole
(consider the sense of kiln rotation).
Note:
The angle value of the crank peak is not important to judge the severity of a crank, but it helps to
find out, if it is a permanent or a thermal crank.
Thermal cranks occur randomly; hence the peak angle will change.
Permanent / mechanical cranks stay on the same position, hence the peak
angle will stay more or less same (within ±30°), at least in the same quadrant of
the kiln. In case of indication for a permanent crank, it is recommended to perform
the roller shaft bending measurement also in cold kiln condition (~2 revolutions
with auxiliary drive) to be sure; no thermal effect is taking place.
Optional:
For narrow space,
flat sensor to measure
roller shaft bending
1 brown (+24VDC)
2 white (0-10V)
3 blue (-)
4 black (=2)
2
21
34
1
4
3

Page 18 April 4, 2022
8. GEAR RUN OUT:
8.1 Measurement Principle
Most rotary kilns and many ball mills are driven by open gear drives (pinion and girth gear). Due to
difficulties during the installation or later during the operation, the girth gears might do not run
concentrically nor straight.
The so-called axial and radial run-out can be measured, both in the same time, with the IDM Tool
Kit during normal operation.
•Radial Run-Out:
Results in a change of center distance and affects the tooth engagement it is measured on
the tip of the teeth.
•Axial Run-Out:
Affects the load distribution over the tooth width and is measured on a machined side face
of the girth gear or on the side face of the teeth.
8.2 Place the Sensor
To measure the axial and radial run-out, two inductive sensors, typically Ø18mm are placed
somewhere on an inspection window in the girth gear cover where is access to the tooth tip and to
a machined side face of the girth gear.
(See pictures below)
Safety (first see page 3):
Never place sensors where the teeth are engaging; place them always on the out running side
or far away from the pinion, to avoid items get caught between.
Radial Sensor
(on tooth tip)
Axial Sensor
(on side face)
Kiln Girth Gear
Magnet Stand

Page 19 April 4, 2022
Sensor Size:
In this application it is also recommended to use the smallest possible sensor to have the highest
accuracy. Unfortunately often is the sensor range not sufficient, hence a bigger sensor with more
range has be used, especially on kilns.
Note:
The surface which gets measured has to be bigger than the sensor diameter, in order to get the
correct distance value (see picture below). On small surface use small sensor, otherwise the error
has to be evaluated case by case and corrected in the sensor scaling.
Sensor
Ø30mm
Sensor
Ø12mm
Too big
induction field
Correct
induction field
Girth Gear
Kiln
Girth Gear
Inductive
Sensor
Magnet
Stand
Kiln
Girth Gear
Inductive
Sensor
Magnet
Stand
IDM
Controller

Page 20 April 4, 2022
8.3 Start The Software Application
The Measurement Studio includes a specific application to measure and calculate the run-out of
gears. It can also be used for measuring the axial run-out of kiln tires.
To start it, click “Project / Add Gear Runout”
The computer screen will show the graph window with the value window below.
Both types of measurements (radial and axial) are equipped with two buttons to select the surface
type. In case of measuring the run-out on tooth tips, click on the left button; this activates the
measurement filter, which will hide automatically the not useful measurement points between the
teeth. For evaluation this filter function can also after measuring be activated and deactivated.
See the green bar, which indicates the Sensor Distance (gap between measured surface and
sensor). It should be approximately in the middle of the sensor range, at least never go to one of
the extreme positions unless between teeth, where the distance is out of range.
Attention:
For measuring tooth wheels on the tooth tip, adjust the sampling rate to min. 5 times the gear
mesh frequency. (See also chapter 4.4)