Masters Degree Dissertations

Permanent URI for this collectionhttps://hdl.handle.net/20.500.12504/93

Browse

Browsing Masters Degree Dissertations by Subject "Bearings"

Filter results by typing the first few letters
Now showing 1 - 1 of 1
  • Thumbnail Image
    Item
    A kalman filter based algorithm for enhancing accuracy of kiln roller bearing temperature measurements in cement production at hima cement plant
    (Kyambogo University (Unpublised work), 2025-10) Ahebwa, Samuel
    A rotary kiln is an integral component of a cement production plant mounted on tire/roller assemblies and supported by partial journal bearings. Temperature monitoring of the bearings is necessary to prevent unexpected damage. The rotary kiln (RK3) at Hima Cement Factory operates with a discrepancy in roller bearing temperature measurements typically between Hand Pyrometer Readings and Control room readings, ranging from 0.1◦C to 44◦C. This deviation in measurements can be attributed to abrupt sensor failures caused by power issues, loose contacts, or data system flaws as well as flying particulate matter inside the kiln system obscures the sensor. While there is a potential risk of tripping the kiln main drive on interlock due to undetected temperatures that are out of operational range, kiln roller bearings are also likely to deteriorate when operated at high temperatures for a long time. The intention of the research was to create a Kalman Filter-based algorithm that provides more accurate estimates of kiln roller bearing temperatures.The proposed method's accuracy was validated by comparing actual measurements obtained under controlled test conditions with ground truth obtained by HPR. The experiment then tested whether the Extended Kalman Filter can reduce noise, adapt to dynamic changes, and provide estimates that are close to the ground truth. The study showed a 94% improvement in temperature measurement accuracy under noisy conditions, reducing the initial RMSE from 8.656°C towards 0.523°C and MAE from 8.060°C towards 0.445°C after Kalman correction. This increased the reliability of temperature monitoring in dynamic environments. Implementing a real-time monitoring system is critical to ensuring that the Kalman filter functions with current and correct data while configuring a comprehensive alarm system to ensure safety and efficiency in the cement rotary kiln operations.