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

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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

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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.

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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