Time Reduction and Upgrading of Balancing Machine for Impeller
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The document discusses an upgrade to a balancing machine aimed at reducing operation time and increasing productivity, specifically for balancing impellers. It details the implementation of external arrangements such as an L-angle plate and a guide key to streamline the alignment process, significantly decreasing the time needed for calibration and balancing tasks. The enhancements ensure that more impellers can be balanced efficiently without compromising accuracy.
![INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY
VOLUME 5 ISSUE 2 – MAY 2015 - ISSN: 2349 - 9303
108
ACKNOWLEDGMENT
The authors thank Prof. Saravanavel M.E. and
Mr.Anilappukuttan M.E. for their contribution.
REFERENCES
[1] Steel Construction Manual, 8th Edition, second
revised edition, American Institute of Steel
Construction, 1986, ch. 1 pages 1–5.
[2] "MatWeb A36 steel bar". MatWeb. Retrieved 21
January 2012.
[3] Degarmo, E. Paul; Black, J T.; Kohser, Ronald
A. (2007), Materials and Processes in
Manufacturing (10th ed.), Wiley, ISBN 978-0-
470-05512-0.
[4] Groover, M. P., 2007, p. 105-106, Fundamentals
of Modern Manufacturing: Materials, Processes
and Systems, 3rd ed, John Wiley & Sons, Inc.,
Hoboken, NJ, ISBN 978-0-471-74485-6.
[5] Smith, William F.; Hashemi, Javad
(2001), Foundations of Material Science and
Engineering (4th ed.), McGraw-Hill,
p.394, ISBN 0-07-295358-6.](https://image.slidesharecdn.com/icser068-150928062241-lva1-app6892/85/Time-Reduction-and-Upgrading-of-Balancing-Machine-for-Impeller-5-320.jpg)
Time Reduction and Upgrading of Balancing Machine for Impeller
- 1. INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY VOLUME 5 ISSUE 2 – MAY 2015 - ISSN: 2349 - 9303 104 Time Reduction and Upgrading of Balancing Machine for Impeller M.I.Mohamed Asif1 Z.Mohamed Jameer2 1 K.Ramakrishnan College of Engineering, 2 K.Ramakrishnan College of Engineering, Trichy, Trichy, Mechanical Department, Mechanical Department, asifmechengg8@gmail.com jameermohamed.93@gmail.com Abstract—The aim of our project was to upgrade a balancing machine. By making suitable external arrangements in the existing balancing machine, the operation time of the machine is curtailed, which in turn increases the productivity of the machine as well as dwindle human effort. It took minimum of a few hours to align the base of the motor bed in the balancing machine. L-angle plate, with a guide, key and disc brake are the extraneous arrangements in balancing machine. Keywords—Alignment, balancing machine, impeller, l-angle plate. —————————— —————————— INTRODUCTION Balancing is the process of attempting to rotate the rotor with equal mass without any uncompensated centrifugal forces, which is placed on the bearings. This is usually done by adding or removing compensating masses to the rotor in prescribed locations. The rotor tends to vibrate if an uneven mass is distributed. The vibration is produced by the interaction of an unbalanced mass component with the radial acceleration, due to rotation, which together generates a centrifugal force and so the rotor rotates along the line of action of the force. Excessive vibration in rotating machinery can cause unacceptable level of noise and further substantially diminish the life of the shaft bearings. The entire procedure takes approximately sixteen hours per impeller. BALANCING MACHINE A balancing machine is a measuring tool used for balance the rotating machine parts such as impeller rotor for electric motors, fans, turbines, disc brakes, disc drives, propellers, crankshafts, wheel rims, and pumps. The machine usually consists of two rigid pedestals, with suspension and bearings on top supporting a mounting platform. The unit under test is bolted to the platform and is rotated either with a belt-, air-, or end- drive. As the rotor is rotated, the vibration in the suspension is detected with sensors and that information is used to determine the amount of unbalance in the rotor. Along with phase information, the machine can determine how much and where to add weights to balance the rotor. The parts of the balancing machine are motor, gearbox, universal joint, bearing supports, and abro balancing software. In this balancing machine, the impeller is to be balanced.
- 2. INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY VOLUME 5 ISSUE 2 – MAY 2015 - ISSN: 2349 - 9303 105 Fig.1 Balancing machine The impellers are used in the mining operation. L-ANGLE PLATE L-angle plate is a work holding device, which is used as a fixture. The l-angle plate is made of high-quality material that has been stabilized to prevent further movement or distortion. Slotted holes are machined into the surface to enable the secure attachment of four l- angle plates to the base of the motor setup with bolting joints, so that motor setup can be correctly aligned in the keyway, which save the machine calibration time. Four l-angle plates are used at the four corners of the machine. A single l-angle plate has eight drilled holes. Fig.2 L-Angle plate The plate has made on A36 steel has the following characteristics. Physical Properties Table i Physical Properties Content Density 7.85 g/cm3 Chemical Composition Table ii Element Content Carbon, C 0.25 - 0.290 % Copper, Cu 0.20 % Iron, Fe 98.0 % Manganese, Mn 1.03 % Phosphorous, P 0.040 % Silicon, Si 0.280 % Sulfur, S 0.050 % Mechanical Properties Table iii Mechanical Properties Composition Tensile Strength, Ultimate 400 - 550 MPa Tensile Strength, Yield 250 MPa Elongation at Break (in 200 mm) 20.0 % Elongation at Break (in 50 mm) 23.0 % Modulus of Elasticity 200 GPa Bulk Modulus (typically for steel) 140 GPa Poissons Ratio 0.260 Shear Modulus 79.3 GPa GUIDE KEY Guide key is a machine element that moves along the keyway path. The guide, key prevents relative side movement of the balancing machine’s motor base setup. To function the guide, key the machine element
- 3. INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY VOLUME 5 ISSUE 2 – MAY 2015 - ISSN: 2349 - 9303 106 must have a keyway, which is a slot in which the guide, key is fitted to. Fig.3 Guide key Chemical composition of EN 19 steel alloy Table iv Element Content Carbon 0.35-0.45% Mangenese 0.50-0.80% Chromium 0.90-1.50% Molybdenum 0.20-0.40% Silicon 0.10-0.35% Sulphur 0.050%max Phosphrous 0.035%max The guide, key is made of EN19 alloy steel; it is case hardened, and a thin layer of harder metal forms on its surface, but the core of the guide, key remains softer. The outer surface of the guide, key makes contact with the keyway, so that guide, key has to subsist case hardened. As a result of case hardening, the guide, key will not get fractured (because of the soft core that can absorb the stresses without cracking) and provides adequate wear resistance over the surface. Case hardening or surface hardening is the process of hardening the surface of a metal object, thus forming a thin layer of harder metal inthe surface. The case hardening process involves infusing additional carbon into the case. It is usually done after the part has been formed into its final shape. L-angle plate with guide key Fig.4 L-angle plate with guide key 2D view of L-angle plate with guide key Fig.5 2D view of L-angle plate with guide key
- 4. INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY VOLUME 5 ISSUE 2 – MAY 2015 - ISSN: 2349 - 9303 107 Problem description Before making these extraneous arrangements, the balancing machine’s motor base setup is maneuvered forward or backward by clasping it upward with the help of crane hoists. After placing it in the correct position, the alignment of motor base setup has changed because it has no fixtures to locate in the correct position, so that the motor base setup has to be aligned manually by using a dial gauge. This calibration is done with reference to bearing setup support. Fig.6 Before implementation Implementation of l-angle plate Initially, the setup has to be in correct aligned position. Now, the L-angle plate with guide, key is bolted to the four corners of the motor base setup, so that the base setup is placed in the correct position. There is no need of alignment afterwards. Fig.7 After implementation Balancing Machine Fig.8 Balancing machine DISC BRAKE The disc brake arrangement setup has to be fitted betwixt the motor and gearbox by replacing the tyre coupling in the existing balancing machine. Fig. 8 Disc brake Working While balance the impeller in the balancing machine, it took more time for it to become idle. The impeller is running at a speed of 100 RPM during the balancing process. Due to the disc brake arrangement, the impeller rotation can be stopped in a reduced time using a mechanical actuating lever. CONCLUSION By making these external arrangements, the operation time of the balancing machine is reduced so that more number of impeller can be balanced. The productivity of the impeller increases without affecting its accuracy, along with it took minimum hours per impeller balance compared to already existing time.
- 5. INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY VOLUME 5 ISSUE 2 – MAY 2015 - ISSN: 2349 - 9303 108 ACKNOWLEDGMENT The authors thank Prof. Saravanavel M.E. and Mr.Anilappukuttan M.E. for their contribution. REFERENCES [1] Steel Construction Manual, 8th Edition, second revised edition, American Institute of Steel Construction, 1986, ch. 1 pages 1–5. [2] "MatWeb A36 steel bar". MatWeb. Retrieved 21 January 2012. [3] Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2007), Materials and Processes in Manufacturing (10th ed.), Wiley, ISBN 978-0- 470-05512-0. [4] Groover, M. P., 2007, p. 105-106, Fundamentals of Modern Manufacturing: Materials, Processes and Systems, 3rd ed, John Wiley & Sons, Inc., Hoboken, NJ, ISBN 978-0-471-74485-6. [5] Smith, William F.; Hashemi, Javad (2001), Foundations of Material Science and Engineering (4th ed.), McGraw-Hill, p.394, ISBN 0-07-295358-6.