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PURCHASE 18 April 2011
Art Art of Styling Styling Steel Steel
Tech
nica
l Art
icle
Conventional
abrasive
construction
TMTrizact
Abrasive construction and
wear out pattern
of STYLING STEEL”. The solutions include a wide range of innovative products like
TM TM TMTrizact , Scotch-Brite & Cubitron .
TMA combination of 3M Trizact & 3M TMScotch-Brite products can generate
industry finishes meeting unique satin, hail line & matt finishes. The products come in the disc, belts & brush form that can be used in a simple and comfortable way by operators and requires lesser polishing skills.
TM3M Trizact abrasives, unlike a conventional abrasive, is an engineered abrasive product, designed to achieve uniform finish giving the edge to stainless steel fabricators. Due to the unique construction of the abrasives, produced by
TMMicro-replication Technology the Trizact abrasives cuts in a similar pattern, provides uniform finish, throughout the life of the product, as can be seen in the picture alongside. By generating uniform scratch pattern, it helps achieve the uniform finishes in subsequent stages.
Stainless steel, a matchless metal in both properties and usage, has
slowly and steadily made an influence in our daily life, be at our home, at our office, at shopping malls, travelling in a metro or even the new bus shelters sprouting up in major metros. In any given day we come across many products that are now using stainless steel, starting from bathroom fittings to office chairs, building interiors to street furniture’s and artifacts. The unique properties of stainless steel have been known and major factors which have influenced its extensive usage are its non rusting properties, no painting & beautiful finishes that can be achieved on it. These unique properties help it get desired prescriptions from many engineers and architects in their designs. Some interesting trends indicate extensive usage of stainless steel in architectural, building, construction and equipments industry replacing conventional choices of wood, mild steel & even plastic in certain cases due to inherent advantage of Stainless Steel.
is the in-factor as it reflects the trend shift from conventional to new choices of finishes that increases the aesthetic appeal to the end customer. Fabricators of Stainless Steel are looking for solutions and systems that can help them to achieve these customer requirements. These finishes look very attractive but achieving UNIFORM and UNIQUE FINISHES is an extremely challenging job for the fabricators of stainless steel.
A typical stainless steel fabrication steps includes cutting, bending, welding, weld grinding & blending, including the corner weld finishing, followed by series of finishing sequence. At every stage of fabrication, stainless steel poses some challenges i.e, preserving & restoring the finish of stainless. Abrasive products are used to not only to generate and repair the, but also provide solutions for the grinding and blending of the weld as well, which not only helps improve the finish, but also help achieving consistent and better output as well.
3M through their abrasive ranges of products have been upgrading metal fabricators to the latest products & techniques through an interactive approach which is know as “Art
“New and trendy Finishes and Style’s”
TMScotch-Brite
Construction TMForms of Scotch-Brite
PURCHASE 20 April 2011
Machine ToolsINDUSTRY FOCUS
Post the generation of uniform TMscratch pattern by the Trizact ,
TMScotch-Brite product range provide the final finishing to the surface so as to generate the desired finishes. Due to their open construction of Scotch-
TMBrite , finish generation is consistent & prevents any heat build up on the substrate. Simple
TMconstruction of the Scotch-Brite , allows this universal product to be available in many forms, as depicted in the pictures
3M provides a unique and a quick way to finish the corner
TMwelds using the 3M Roloc abrasive products, available in
TMScotch-Brite and coated abrasives. The proper sequence of usage, not only helps blend the weld effectively, it also ensures that the corners and other portions of the base material have similar finish. This helps reduce the rework time and improves the overall productivity.
Over the period of time, abrasive industry has developed many products that help achieve better finishes and improve productivity, apart from other benefits to the fabricators.
Promising the brand value of 3M in developing innovative products that are effective and relevant for the customers, for the first time, 3M has developed revolutionary product that contain a SHAPED ABRASIVES.
The new mineral used in the 3M TMCubitron II abrasive products is made up of
precisely shaped triangles of mineral oriented to direct the cutting points toward the work surface. These self sharpening triangles are designed to fracture as they wear, continuously forming new, super-sharp
points and edges that slice cleanly through the metal like a knife, instead of gouging or plowing. This prevents heat from building up in the work piece – reducing heat-related stress, cracks and discoloration. And, because the abrasive itself stays cooler and sharper, it gives a much better life as compared to conventional ceramic grain products.
TMThe 3M Cubitron II products are shaping the future of abrasive solution for all metal fabrication solutions weather it is grinding or finishing. The products made from this mineral, when used with a proper backing and
PURCHASE 22 April 2011
Machine ToolsINDUSTRY FOCUS
Conventional Ceramic Grain
TMPrecise Shaped Grain - Cubitron II
an appropriate tool just excites the user by helping complete his job much faster and increases the comfort level of usage leading to a much lesser fatigue.
3M, with its engineered, practical and ergonomically designed solutions, and pioneering way the Stainless Steel is finished, not only helps provide solutions to achieve new and trendy finishes, but also is making conscious efforts to ensure that latest technology reaches the market and educate the fabricators to make their lives simpler.
To know more about the Art of styling steel and the exciting products for metal fabrication, please log into our website to find out more details www.3m.com/in/abrasives.
Mr. Vijay Krishnan
PURCHASE 24 April 2011
Machine ToolsINDUSTRY FOCUS
The machines installed in a plant must have a overall thought about reliability
and energy efficient design. The reduction of mechanical linkages like belts, gear boxes will result into power saving of anything from 20% to 54%. Further the use of motors with efficiency higher by 5 to 10% and power factor improvement will lead to a multiplied effect. Consider the following diagram:
Through the research and many experiments in Europe the discovery of permanent magnet brushless motors in high torque and low RPM has given way to both the above arguments. The brushless motor, like any other motor, is built up on the delivered torque and not on the yielded power.
As a consequence, in any application a low speed of the motor will correspond to a low specific power and a low yield. Nevertheless we must point out that the brushless motor contemplates no minimum speed (it purely depends on the sensor; some applications are available with axle speed of 1 revolution per
year).Consequently, the decision to act on the transmission to allow a high rotating speed of the motor is acceptable only when it is important to minimize the size of the motor (i.e. with electric traction) or to Maximize the yield; on the contrary.
Thus using Torque motors and the Brushless servo motors introduced by Compage Automation systems Pvt. Ltd. You can get rid of many mechanical linkages and
calculate your per hour saving as follows:Saving in Rs pr hour = KW saved per hour x 4.5KW saved = hp x L x 0.746 x 100 - 100Where: hp = Motor nameplate ratingL = Load factor or percentage of full operatingLoadEstd = Standard motor efficiency under actual Load conditions multiplied with the efficiency of belt drive/gear boxEHE = New-efficiency of motor and without gearing arrangement underActual load conditions
PURCHASE 78
Tech
nica
l Arti
cle
April 2011
Gearless Drivesand Efficient Motors
Introduction of
for the Machines
Energy
By Mr Anil Aggarwal, MD
Does the failed production volume come
as a surprise to you? Many times you
feel that had your main stream CEO known
about the factory problem in time, the break
down could have been corrected by the
right people in time.
PURCHASE 79April 2011
Tech
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ProductionRemote
Monitoring
Production Status Monitoring
How much was produced in last shift? Which product is under production?
Alarm
Can get SMS for type of alarm- (a) Electrical power not present
(b) Motor running at low speed. i.e. roll change time higher than normal.
© Electrical or Mechanical breakdown.
Report Generation
Break down history, shut down time in each shift. Production data of the day/week.
Connectivity
Online monitoring helps in: Supply chain Management & Timely customer deliveries.
Akshay Aggarwal, Director, Compage
Automation Systems Pvt. Ltd. Faridabad
introduces the company’s value added
solution at very low cost.
With the advent of information
technology - the world has changed the way
we bank, record data and register our
complaints on customer care 24X7. SCADA
has been long in our process industry to run
and monitor the production output, speed
achieved etc in whichever format we want.
Food packing industry which is the almost
largest and the most essential industry is still
in the nascent stage of adoption of
automation and online monitoring systems in
our country. For now at many places the
machine speed and average running hours
are the only parameters to calculate the
machine production of the day. But the trend
is changing fast to upgrade and attain the
perfection and accuracy.
To break free from individual’s
dependence on production monitoring,
Compage introduces an SMS service for the
machine owners who would like to receive
the information of the day’s production in
exact number of packages/bags. GSM/GPRS
service is independent to any
communication or internet services being
utilized in the factory infrastructure. The data
is taken to a centralized server where it is
compiled and translates into useful
information for the beneficiary of the
production. This type of topology is the best
method to receive factual data in safe hands.
We can monitor any parameter such as –
day’s production, machine average running,
machine speed, wastage (empty pouches,
boxes), component failure, breakdown time
etc.
Moreover, with the help of GPRS
technology the machine can be connected to
with remotely. Any failure in the machine can
be solved by remote assistance. This makes
the troubleshooting process faster and thus
cheaper. In today’s world of all the complex
technologies it is not possible for the expert
to maintain the machine in the plant.
Whereas a team of people can support multi
locations sitting from one help desk. For now
we see this technology penetrated in the IT
industry for troubleshooting the IBMs and
the DELLs. Fortunately now the need for this
value added service is being felt in the
manufacturing industry also. Compage has
introduced the PLC/CNC controllers of the
machinery with the capability of uplink.
Hence the customers have option to fulfill
their planned production.
PURCHASE 80
Industrial AutomationIndustry Watch
April 2011
Pro-Active Maintenance is a system or a life style of keeping the system healthy
and is actually a Life Extension System which supplants the philosophy of ‘Failurereactive’ with the ‘Failure Pro-Active’ by avoiding the conditions that lead to machinefaults and degradation. The Pro-Active Maintenance technique consists of actionsthat abolish the root cause of the failures, not just symptoms. Pro-Active maintenance is now receiving the recognition as the only means of reducing and saving on the burgeoning maintenance cost, for extending the performance life of systems, conservation of oil and conservation of energy without much expenditure on the system or equipments.
It’s a known fact that over 75% of the breakdowns and the maintenance expenses in any industry is because of hydraulic and lubrication oil system failures which isattributed to excessive contamination level In the system fluid which has a clear cutindication towards the necessity of Pro-Active Maintenance. In fact without properlyunderstanding and adopting the Pro-Active Maintenance Techniques, we can not becompetitive and grow faster.
In absence of Pro-Active Maintenance Technology the normal approach is FailureReactive rather than Pro-Active, and the contamination is not controlled andremoved from the system oil, it becomes contaminated and the looses its properties;resulting the replacement of oil. The disposal of discarded oil damages theenvironment. Also the contaminations enter into the gap/clearance between themoving parts and the parts start scoring, damaging and restricting the movement,resulting malfunctioning, Loss of production, Loss of Energy and frequentbreakdowns.
Many industries carry planned activities of Preventive Maintenance associated withPredictive maintenance. Under Preventive Maintenance the repair/replacement ofparts and components is done when often nothing is broken. This is a scheduledactivity, expecting that the life of part, component or system is over and can give
away any moment. This approach allows the failure of parts and system as a routineand normal, permitting the crisis of failure and maintenance. While under PredictiveMaintenance diagnosing, assessment, investigations and testing are carried out tofind the condition and life span of the parts and components. Lot of money and timeis spent for prediction of the condition and life of the components. Alternatively thePro-Active Maintenance protects the system against the Degradation and Failures;and hence Preventive and Predictive Maintenances are practically not required.
It is easy to understand the Pro-Active Maintenance by putting parallel with our body and health, for the reason that human body is very similar to a Hydraulic/Lubrication oil system. We all know that by simply Morning walk and taking healthy fibrous foods, fruits & vegetables in place Fried, Junk foods and Animal Fats which lead to generation of bad Cholesterol (being Contaminations in the blood); to keep us healthy, extend our life and improve our efficiency & performance. Similarly keeping the system fluid clean and free from contaminations (Dirt, Moisture/water and heat etc. being the main Contaminations in the System Fluid) by adopting the SystematicApproach to Pro-Active Maintenance; to keep our Plant, Machinery and Systemshealthy, extend the life of Hydraulic and Lubrication Systems & Componentsmanifold times and improves the efficiency, performance & Productivity of our Plant,Machinery and Systems and also to conserve the Energy and costly oils.
In view of the above facts, one must choose the Pro-Active approach in place of the Failure Reactive approach. Er. Ashok Kumar Gupta the founder and Chairman of the Crane-Bel Group has taken a challenge of promoting the Pro-Active Technology inIndian Industries through Seminars, Workshops, Presentations and PracticalTraining to achieve the following important and significant results:lConservation of Oil: Resulting up to
90% saving on oil Procurement and
Tech
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Pro-ActiveMaintenance
PURCHASE 122 April 2011
Environmental Protection.lConservation of Energy: Resulting
saving on the Power Bills and also saving the Environment.lMinimising the Breakdowns: No
Breakdown Maintenance and No loss of production.lImprovement in the Efficiency of
Plant, Machinery and Systems.lProtection and Retention of Additives
so that no deterioration of hydraulic and Lubrication oils is there, resulting No degradation of oil.lIncrease in the Operational Life and
Performance of systems and components.lNo undue wear and tear of parts and
components and saving on Maintenance cost.lManifold times increase in the life of
systems including hydraulic pumps etc. Resulting the huge saving in the money spent for procurement of costly hydraulic pumps and systems.lIncreased efficiency of machinery and
systems result in Higher Productivity, Higher Profits, Competitiveness and Growth of business.lMaintaining Clean & Healthy
Environment, Ecological Balance,Protection of Lakes, Rivers & Underground water and subsequently thePlanet Earth.
When it comes to implementation of Pro-Active Maintenance, the Japanese may bethe global leaders. They have clearly taken a ‘Do-it, Don’t-just-talk-about-it’approach. Evidence of this comes from reports by two of the world's largest steelmills, Nippon Steel and Kawasaki Steel, both in Japan:lAfter Nippon Steel implemented the
Pro-Active Maintenance program plantwide, involving contamination control both improved filtration and rigorous fluid cleanliness monitoring, pump replacement frequencies were reduced to one fifth and the cumulative frequency of all failures related to wear and contamination was reduced to one tenth.lLike wise the implementation of Pro-
Active Maintenance Technology in the lubricating systems involving both journal and roller bearings and maintaining the system fluid clean through proper contamination control program, Nippon Steel reported after the three-year period study, that they have successfully achieved a 50 percent reduction in the bearing purchase plant-wide.l International Paper Company reported
Implementation of Pro-Active Maintenance System
nearly a 90 percent reduction in bearing failures in just six months after the implementation of Pro-active Maintenance System and improved filtration and contamination control in their paper mill.l? Likewise, Kawasaki Steel, not to be
outdone, implemented a similar Pro-active Maintenance program and achieved an almost unbelievable 97% reduction in hydraulic component failures.l? The British Hydromechanics Research
Association (BHRA) conduct their own controlled studies for three years and carefully monitored 117 Hydraulic Machines including Injection Moulding, Machine Tools, Material Handling, Mobile, Construction, Marine, Metal Working and Test Stands, to establish the benefits of Pro-Active Contamination Control Maintenance. The results of the study showed a dramatic relationship between fluid contamination levels and service life. Improved system cleanliness achieved extended the time between failures from 10 to 50 times depending on cleanliness.lA study by the Naval Air Development
Centre in Warminster. Pennsylvania performed on aircraft hydraulic pumps showed nearly a 4-fold wear-life extension with a 66 percent implementation of Pro-active Maintenance and improved filtration and a 13-fold wear-life extension with a 93 percent implementation of Pro-active Maintenance and improvement in filtration.l? The benefits associated with the Pro-
Active Maintenance Technology in theDiesel Engine lubrication oils are great. Historically, there have been manymisconceptions regarding the influence of contamination of engine service life.Hence, filters with very poor efficiencies have been, and are still specifiedfrequently for engine oils. However, from a number of important new field andlab studies, we have concluded that lubrication oil contamination is the primarycause of engine wears that begins what is referred to as the chain-reaction tofailure.
For any further questions please contact:Er. Ashok Kumar GuptaChairmanCrane-Bel GroupE-7, Kavi Nagar Industrial Area,Sector-17, Ghaziabad-201002, (NCR), INDIAE-mail: [email protected] , [email protected]
PURCHASE 123April 2011
Oil, Lubricants & Gas Special Industry Review
Past and Present Technology Traditional
bevel gear cutting blade inspection
machines have three linear axes for setup.
One of the three axes is used for advancing
the blade towards a mechanically or opto-
electronically functioning measurement
probe. In many cases the blade is inclined
versus the major measurement plane by the
angle of the cutter head slots of the
particular blade type and perpendicular to
the sides of the blade shank. This results in
three linear freedoms of blade movements in
connection with one to five probes and one
inclination (commonly realized with a
tapered block).
Figure 1: Dr. Hermann J. Stadtfeld is Vice
President of Bevel Gear Technology of the
Gleason Works. His team of Research &
Development scientists in Rochester, New
York developed together with Gleason
Metrology Systems in Dayton, Ohio the most
modern CMM measurement for gear cutting
blades, including closed loop corrections.
Gleason is represented in India with Gleason
Works (India) Pvt Ltd. in Bangalore.
The Gleason No. 562, shown in Figure 2
is an example of a manually operated blade
inspection device as described above. The
blades are inclined at the same angle of the
slot inclination in the respective cutter head.
The blade geometry is described in the offset
plane of the cutter head. The offset plane in
face milling cutters is approximately the
normal plane to the cutting velocity (offset
plane ˜ cutting plane). In face hobbing
cutters, the offset plane is designed to be
close to the cutting plane for the majority of
the gear designs considered to be cut with
the particular cutter.
The No. 562 device measures up to 5
points, three on the cutting edge and two on
the clearance side of the blade. With such a
measurement it is possible to determine all
of the following blade features, which are
important to the final part geometry, as well
as the clearance side definition:lClearance AnglelBlade Top Width
PURCHASE 54
Tech
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April 2011
Dr. Hermann J. Stadtfeld, Vice President – Gleason Corporation
Bevel Gear Cutting Tool Inspection and
Closed Loop Corrections
No. 562 Blade inspection device
lPressure AnglelBlade DistancelTOPREM Position (rise) on Cutting
EdgeIt seems that the measurement results of
the No. 562 are highly operator dependent.
An interesting phenomenon that applies to
the No. 562 unit is that the absolute accuracy
of the results is well suited for a correction of
blades in order to establish cutting blades
within the accepted tolerance. However, the
repeatability from blade to blade seems
rather fair, which has its cause to the largest
part in the aforementioned operator
dependency.A complimentary fixture, shown in Figure
3 is used for the comparison from blade to
blade within one set. The so called
comparison checker in Figure 3 uses
mechanical dial indicators with an anvil, that
allows a sideways blade location on its two
datum surfaces. A reference blade is gently
pressed towards the anvil and then shifted
axially onto the blade top location stop. In
this position, the probe tips (linked to the dial
indicators) are adjusted e.g. to top and flank
points on the cutting edge as well as the
clearance side. The probe tips are pointed
and therefore have to be located slightly
behind the cutting edge. Now, the indicators
are set to “zero” with a probe deflection
equivalent to about 2 pointer revolutions on
each indicator. This assures the elimination
of stick-slip and provides an adequate
pressure between indicator stem and linkage
as well as probe tip and blade contacting
point. Even though, the blade comparison
fixture has an obvious dependency on the
way the operator feeds the blades into the
stop position and holds it there, it still is the
most used device for comparing the blades
in a set with the reference blade. Blade
comparison utilizing the device in Figure 3 is
straight forward and fast and delivers a
sufficient accuracy level in order to prepare
blades to be accurately build in a cutter
head.
It is a desirable goal to present a blade to
a measurement sensor on a stiff and
temperature stable structure. The
arrangement should have a minimum of
slides and rotary axes. The lowest possible
motion travel of the machine axes promises
the most accurate and repeatable measuring
results. Also the elimination of operator
influence would result in a high repeatability
and improve the absolute accuracy in terms
of GR&R evaluations. Finally, the speed of a
complete blade measurement is a
substantial factor for the success of a cutting
blade measurement apparatus. An
acceptable measurement time for an
average blade lays in the vicinity of 30
seconds to one minute.
A fast minimum measurement has to be
able to capture three points on the cutting
edge and two points on the clearance edge,
based on a coordinate system which has its
Goals for a Fast and Reliable Blade Measurement
Desired Measurement Features
Blade comparison checker
Blade measurement coordinate system
PURCHASE 55April 2011
Gears & Motors Industry Spotlight
orientation from the cutting plane and the
two seating surfaces of the blade shank
(Figure 4). Such a minimum measurement
would correspond closely to the No. 562
apparatus and use the least possible amount
of measuring time. A complete
measurement of all blade features would
require a cutting edge scanning and a
technique to capture the location and shape
of the blade front face as well as the relief
surfaces of cutting and clearance side. In both cases, minimum or complete
measurement, it is most important to relate
all measured points to the correct blade
coordinate system X10-Y10-Z10 as shown in
Figure 5. This coordinate system is used to
define the “tooth forming contour” of the
blade which defines together with the basic
settings the particular bevel gear geometry.
The Y10-Z10-axes are aligned to reflect the
cutting plane, while the Y10-axis is collinear
with the cutter head axis. The plane X10-Z10
is tangent to the top of the blade. The
coordinate origin on the X10-axis lays on the
front wall of the blade shank, which is
towards the cutter head center. The X10-axis
is collinear with the cutting velocity direction,
which is not the direction of the front face
distance. The normal distance from the
extended front blade shank wall to the
theoretical blade point defined by the blade
front face distance determines the location of
the front face (in blade thickness direction);
this is the definition of the front face distance
as shown in Figure 5 [1].
The following list includes all global blade
features (also shown in Figure 6 and Figure 7):lSide Rake Angle (Figure 6)lTop Rake Angle (Figure 6)
Blade Features to be Verified
PURCHASE 56 April 2011
Gears & MotorsIndustry Spotlight Gears & MotorsIndustry Spotlight
Blade coordinate system and front face distance
Global blade features [2]
lCutting Edge Hook Angle (Figure 6,
right)lBlade and Slot Inclination Angle
(Figure 6)lSide Relief Angle (Figure 6)lTop Relief Angle (Figure 6)lTop Slope Angle (Figure 7)lTop Width (Blade Point) (Figure 6)
Specific features of the “tooth forming
contour” are shown in Figure 7 and Figure 6:lPressure Angle lClearance AnglelBlade DistancelFront Face Distance (Figure 6)lEdge Radius Pressure Angle SidelEdge Radius Clearance SidelToprem DepthlToprem AnglelBlended Toprem Radius (not shown)lFlankrem DepthlFlankrem Angle
lFlankrem Radius (not shown)lBlade Curvature Radius
A more advanced and automated
Blade Coordinate Measurement with Gleason GBX
measurement was
developed on the
basis of a three-
dimensional coordinate
measurement machine using a
three-dimensional scanning probe.
Figure 8 shows the Gleason GBX, a
coordinate measurement machine,
dedicated to cutting blade measurementThe measurement of the GBX
machine takes place at or behind the
cutting edge, inside of the side relief
surface with the spherical tip of a
measurement probe. The blade front face
is measured along a triangular path,
which establishes the front face surface
as a plane using an approximation
method (Figure 9). The knowledge of the
approximate shape and orientation of the
relief surface angles allows the
calculation of the theoretically correct
path behind the cutting edge (adjusted
nominals). The accuracy of this
[email protected] features of tooth forming contour
Gleason GBX
Measurement principle of front faceand below the blade edge
PURCHASE 57April 2011
Gears & Motors Industry Spotlight
procedure is significantly above the
measurement results of the No. 562 device.
Beyond that, it is possible to evaluate
additional blade features versus the No. 562,
such as blade curvature radii, Toprem rise,
edge radii and front face distance.Metrology devices, as shown in Figure 1
and 8 are not really suited for a production
measurement (comparison) of complete sets
of blades after the blade grinding and in
order to qualify sets of blades for being
assembled in cutter heads. The duration of a
blade measurement is in the vicinity of the
time it takes to grind a blade which is not
easily acceptable for a production
measurement.Figure 10: Universal GBX blade
holding fixture, RSR® blade left, Pentac®
blade rightThe strength of the Gleason GBX is the
fact, that it represents a CNC controlled,
highly accurate metrology device which is an
integral unit together with the blade
mathematical software (GEMS) and the
control software. The components of the
integral unit work together in a semi real
time mode which allows the different
measurement steps, like the cutting edge
measurement being influenced by the
previously conducted front face scanning.A prismatic V-block fixture with a spring
loaded arm for holding rectangular blades
(Figure 10, left) as well as Pentac® blades
(Figure 10, right) has been developed. The
probe will scan the seating surfaces of the
fixture during a setup/calibration mode. No
blade datum surface scanning is required
during the regular blade measurement cycle.
Studies with the newly developed GBX blade
holding fixture have shown that the achieved
accuracy is high and the repeatability is
excellent. Those attributes are combined
with a rather short measuring time because
of the elimination of individual datum surface
measurements.
In a measurement cycle, the front face is
scanned first along a triangular path (Figure
9). The knowledge of the front face location
and orientation is used by the blade
mathematical software to calculate the
nominal cutting edge function, considering
the actual front face. The knowledge of the
side relief surfaces is used in order to
calculate a scanning path between 0 to 15
?m behind the cutting edge (adjusted
GBX Measurement Cycle and Correction
PURCHASE 58 April 2011
Gears & MotorsIndustry Spotlight
Universal GBX blade holding fixture, RSR® blade left, Pentac® blade right
Nominal-actual bladecontour and No 562 points
nominals). Next, the cutting edge blade tip
and clearance side of the blade is scanned.In cases of complicated blade contours,
large blade distortions or the requirement of
highest accuracy, a software option allows
the use of the actually measured blade edge
coordinates as “distorted nominals” and
repeat the blade edge scanning. The results
will be more accurate since the probe
deflection is minimized in this mode. The
blade evaluation module receives a
measurement result in the absolute blade
coordinate system and compares this with
the adjusted nominal blade contour behind
the cutting edge. The difference between the
actual and the adjusted nominal contour is
used to compute blade corrections.Figure 11 shows the nominal bade
contour (black line) and the actually
measured blade contour (red line) in one
graphic, together with the No. 562
measurement pin locations. The No. 562 pins
are only for reference or comparison with
older developments. The experience gained
during many measurement studies indicates,
that a real comparison between the No. 562
and the GBX is not very useful because the
significantly higher accuracy of the GBX
leads in cases of small blade deviations to
different, but more correct results. In case of three-face ground blades, the
misslocation of the actual front face results
in a front face distance, side rake and top
rake angle (blade hook angle) correction
output. In case of two-face ground blades,
the cutting edge and clearance side
corrections are calculated such that the
correct tooth slot is cut, considering the
wrong front face location and orientation.
Figure 12 shows the correction output
screen of the GBX-GEMS software.
[1] Stadtfeld, H. J.
Handbook of Bevel and Hypoid Gears -
Calculation, Manufacturing, Optimization
Rochester Institute of Technology, Rochester,
New York, 1993
[2] Stadtfeld, H. J.
The New Freedoms - Three- & Four-Face
Ground Bevel Gear Cutting Blades, Gleason
Company Publication, June 2007
Literature
Blade correction output screen
PURCHASE 59April 2011
Gears & Motors Industry Spotlight
PURCHASE 60
Tech
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April 2011
PREMIER CNC GEARSHAPING MACHINE,MODEL: PSC-250 WITH ELECTRONIC GUIDE:
Introduction:
In Gear shaping, the gear shaping cutter &
workpiece axes are rotating parallel in
mesh (conjugate generating motion)
according to the number of teeth in both
cutter & the workpiece, while gear shaping
cutter reciprocates on the spindle for the
metal removal action (cutting motion).When cutting helical gear, on gear
shaping machine, an additional spiral motion
is introduced to the gear shaping cutter by
the helical guide. During return stroke (relief
stroke), the gear shaping cutter is removed
away from the workpiece to prevent flank
contact (back-off direction motion)These motions are basic functions of the
gear shaping process. The CNC Gear
Shaping Machine is equipped with radial
motion of Work Table (X-Axis), cutter
generating motion (C-Axis), Work Table
generating motion (E-Axis), stroke
positioning motion of gear shaping cutter (L-
Axis).In case of manufacture of Spur Gears on
Gear Shaping Machines, Spur Hydrostatic or
Spur Mechanical Guides are used and for
manufacture of Helical Gears, Mechanical or
Hydrostatic Helical Guides with required
Leads are used.Changing the mechanical/Hydrostatic
Helical guide in gear shaper cutter spindle
unit takes an enormous amount of time &
has to be carried out without restriction,
particularly when changing between
workpieces with straight, left-hand & right-
PURCHASE 61April 2011
Gears & Motors Industry Spotlight
hand teeth.To counteract the drawbacks of a
restricted helix angle & of inflexible tooth
trace modifications, the
Mechanical/Hydrostatic helical guide has
been replaced in the design by a Electronic
guide. This is possible due to the latest
development in high-performance torque
motors and by exploiting the maximum
dynamics of modern NC controls. This
electronic helical guide allows back lash free
generating drive of the gear shaping cutter
which can perform all the additional
rotational movements of the cutter. This
feature enormously increases the efficiency
of the Gear Shaping machines. In newly designed gear shaping machine,
the desired helix angle can be entered in the
software dialogue programme on a flexible
basis. This means even a small correction to
the helix angle, resulting from changing
corrections due to heat treatment distortions
are easy to change without the gear shaper
cutter or the helical guide. Any helical gear
with different helix angle & helix direction in
one setting is possible with this innovative
concept which reduces set up time.
The CNC Gear Shaping Machine with
electronic guide, which is adopted for
finishing gears up to 250 mm dia & having 5
module & helix angle upto 45o consists of
the following main components.Machine Bed:The Machine Bed supports the Sub Base
& Table Slide. The machine bed also
incorporates the coolant reservoir. The
machine bed is made of high grade ferrous
casting & is double wall construction rigid in
design to absorb all the cutting forces
without any distortion, during gear shaping
operation.Table Slide:The Table drive indexing is an integrated
part of the table. A separate AC servomotor
is provided for table rotation. The table
rotation & gear shaper cutter rotations are
synchronized for gear generation through
electronic gear box. The table slide is moved
in & out by AC servo motor & preloaded ball
screw for accurate depth & radial feed
control.
Machine Construction:
Upright:Upright is mounted on the sub base
which is mounted on machine bed. Upright
is made of high grade casting & well
proportionately ribbed to enhance the
machine rigidity.
Cutter Head:The cutter head rotation is provided by a
separate AC servo motor. The gear shaping
cutter spindle reciprocates during rotation
through the electronic guide mounted in the
cutter head. A separate motor is provided to
get infinitely variable cutter stroke per
minute.A separately designed back off cam
relives the cutter during every return stroke.
The stroke length required for a particular
face width can be adjusted by the eccentric
mechanism in the crank head. The Gear Shaping cutter head has
been completely redesigned with backlash
free direct drive for the cutter spindle in
order to deliver higher flexibility & operating
ranges than earlier Gear Shaping Machines.
This new technology provides the user
with huge potential for savings:lNo investment in Helical guides required.l? Elimination of lead times needed to
purchase mechanical guides.l? Zero set up timel? Flexible setting of any helix angle upto 45
degree.l? Simple helix angle corrections (e.g. lead
angle errors due to hardening)lReduced machining times through
accelerated return stroke.lUse of direct drive servo spindle motor
for cutter spindle allowing for a nearly
constant cutting speed, this improving tool
life Vs the non constant velocity of eccentric
drives.This newly designed concept of adopting
Electronic Guide on CNC Gear Shaping
Machine was developed by Premier and
after thorough testing of machine, the said
machine was displayed in 15th Indian
Machine Tool Exhibition (IMTEX) 2011. FIE
Foundation authorities visited our stall and
understood the unique feature of
development of Electronic Guide on Gear
Shaping Machine and Premier won FIE
Foundation Award for this new
development.
Benefits to User:
PURCHASE 62 April 2011
Gears & MotorsIndustry Spotlight
Approximately a million paid
visitors—and many a passerby—visit
the Hoover Dam eachyear to take photos or tour the area to learn
more about the dam’s operation andappreciate its incredible engineering. Its
primary purpose, however, is to provide
flood control on the lower Colorado River as
well as deliver water and power to residents
and businesses in the region.“The reservoir impounded by the
dam, Lake Mead, stores ColoradoRiver water for delivery to users insouthern Nevada, California,Arizona and northern Mexico,” saidBob Walsh, Regional ExternalAffairs Officer, Bureau ofReclamation, Lower Colorado
Region. “As this water is releasedfrom the Hoover Dam, hydroelectricpower is generated; this power isdistributed to southern Nevada,southern California and Arizona.”
The Bureau of Reclamationcompleted the Hoover Dam in 1935—with
power generation beginning the followingyear—and now operates and maintains it.
This includes coordinating water and poweroperations, as well as managing water
releases to protect two endangered fish
species in Lake Mohave, immediately
downstream of Hoover Dam.With the dam operating around-the-clock,
it is important to continuously monitor manypieces of equipment. This had proven
challenging to perform cost-effectively with
the previously installed
video projection system.That video system
utilized 12 projectors,
each with a 42-day
defined bulb life. Thesebulbs needed to be
replaced frequently, at a
cost of several hundred
dollars each—andif a bulb failed while in a
projector, the projector
was damaged. Plus, the
video systemdid not focus clearly
when translated onto the
screens in the dam’s
control room, making
PURCHASE 82
Tech
nica
l Arti
cle
April 2011
Hoover Dam OperatorsUsingMonitor Processes
Red Lion PAX MetersDynamic Mapboard with
them somewhat difficult to read.To address this issue, Reclamation
decided to replace the video monitoring
system. Following a request for bids, a
contract for a dynamic mapboard was
awarded to MonitorMapboard Systems based in Dayton,
Ohio. This mapboard provides a dynamicrepresentation of the system in use—from
power generation to water levels—in realtime, allowing operators in the control room
to view system status information at aglance. Combined with more than 75 PAX
meters by Red Lion, it delivers a reliablemonitoring solution in a cost-effective,
simple-to-use design.The mapboard displays all standard
operating indications—megawatts of power
beingproduced by each unit, as well as VARS and
voltage. It shows whether a unit’s breakeris open or closed, how much power is being
requested from the system and how muchpower is produced. This information is
displayed for the 17 commercial generators,
as well as for the two power plant station
service units and the station service
distributional breakers and switchgear.Gene Hosler, Production Operations
Manager for Monitor Mapboard Systems,said the mapboard has delivereddependable results with little maintenanceneeded.
“Managing the Hoover Dam is an
amazing job, with operations running 24
hours a day—and since video has a shorteroperational life, it was costing Reclamationthousands of dollars a year to maintain andreplace equipment,” Hosler said. “Amapboard gives you more than what youcan observe on a video screen. It providescrisp images, LED indicators, and real-timestatus readouts of all collected informationusing Red Lion’s easy-to-read PAX meterswith a half-inch digital display.”
The integrated PAX meters connect
simply to SCADA systems and use Rs232communications to deliver real-time
readouts of all collected system data. Thecombination of the dynamic mapboard and
PAX meters has offered operators at theHoover Dam “system at a glance”
information with less upkeep and
replacements, facilitating simple monitoring
and allowing them to easily perform
preventative maintenance on the mapboard
when required.“The mapboard’s enhanced readability
assists the operators in monitoring allequipment,” said Vince Blaeser, Vice
President of Sales and Marketing for MonitorMapboard Systems. “The reliability and low
maintenance cost, combined with thegraphics, dynamic indicators and readouts
supplied by Red Lion’s PAX meters, makesthis dynamic mapboard an awesome
operational tool.”To learn more about the Hoover Dam and
the Bureau of Reclamation, visitwww.usbr.gov/lc/hooverdam. For more
information on Monitor Mapboard Systems,
LLC, visit www.mapboard.com.Red Lion Controls, Inc. is a leading
manufacturer of industrial control solutionsworldwide. Products include digital/analog
control, monitoring and panel meters, PIDcontrol, human-machine interface panels,
and signal conditioning. For more
information,or to find the Red Lion distributor nearest
you, go to www.redlion.net or contact: RedLion Controls, Inc., 20 Willow Springs Circle,
York, PA 17406; (717) 767-6511.
PURCHASE 73April 2011
Industrial AutomationIndustry Watch
PURCHASE 84 April 2011
PURCHASE 86 April 2011
Process visibility:
While most modern equipment on the
factory floor offers some degree of
performance and productivity monitoring,
tying equipment and devices together for
meaningful and immediate expressions of
productivity often remains a hurdle.
However, overcoming this challenge pays
big dividends. In a landmark presentation of
Overall Equipment Effectiveness (OEE),
Rohm and Haas Corporation found that
OEE is ten times more cost-effective than
adding capital capacity.1 With findings this
dramatic, deploying broad performance
monitoring measures are easy to justify.
OEE is a vital metric that combines three
key performance indicators (KPI) into a
single calculation, measured as a percentage
against an ideal combination of machine
uptime, plus the
quantity and of the
products being
produced. The
percentages of each
of these three KPI are
multiplied together to
provide the OEE rate
quality
(OEE = % Availability
X % Performance X %
Quality).
If the goal is
performance
improvement, OEE is
a concise indicator
that focuses on how
effectively a machine
or process is running at a given moment. An
established benchmark provides a baseline
for operators based upon what’s actually
being produced, tying actual plant floor
realities together with the losses that create
equipment- and process-related wastes.
While it’s unlikely that any plant can operate
at 100% OEE, many manufacturers set a
benchmark of somewhere around 85% OEE
as a goal.
The true goal of measuring OEE is to
improve the productivity of your equipment,
and since operators are the ones most
directly responsible in this effort, they
should have front-row access to OEE data.
OEE should be looked at as a plant floor
Two essential requirements for successful OEE
Tech
nica
l Arti
cle
Scaling real-time OEE from devices to the process levelDavid Harris, Red LionVice-President
improvement tool, and by definition should
be clearly and quickly conveyed to
operators. This relationship with the data not
only helps operators develop the best “feel”
for their machines, but also focuses their
attention on maintaining productivity levels.
In turn, shift or line supervisors receive
better, more timely operator feedback
regarding the equipment status—empirical
data on which to base actions and decisions.
For OEE to be a truly effective tool for
analyzing and improving operations, two
conditions must exist:
The first is visual accessibility. OEE
statistics must be viewable to the plant floor
so that operators in control of the process or
machine may respond immediately to the
displayed calculations. Large overhead plant
floor marquees are often used to display
OEE metrics on the whole, while smaller
display boards might service an individual
work cell or machine.
The second and most critical aspect for
successful OEE is that data must be
displayed in real time. If performance suffers
during a shift but operators are not informed
of this shortfall until an end-of-week
spreadsheet is generated, reconstructing the
cause of the reduction is almost impossible
if problematic conditions have already
passed or the data is incomplete. By
monitoring live performance, an operator
can immediately assess declining OEE rates
and remedy problems, whether they are
mechanical or materials related.
One of the best ways to acquire data for
OEE is to let the production equipment
measure itself, as most
machines today have the intelligence to
measure one or more of the three OEE
parameters. For instance, once
a machine is programmed for an optimized
production rate, most equipment can
monitor throughput against its
designed specifications. Many systems can
also track first pass yield against the total
units started, and as
PLCs are time-based, they can easily track
the amount of operational time.
Most plants use devices made by various
manufacturers, and manufacturers use many
The challenge of consolidating data and
integrating devices
different communication
protocols in order to support legacy
products, accommodate new technologies
or restrict customers to their own
proprietary networks. For example, a
packaging machine may only be
programmed to understand how
many parts are produced in comparison to
its engineered throughput rate, while a piece
of inspection equipment would only know
how many good and rejected parts were
produced. Data from both must be
communicated and consolidated in order to
calculate OEE.
Today, data management devices can
provide seamless communications and
protocol conversion to collect
data from an array of disparate equipment
and PLCs. When used as a host device to
drive plant floor marquees, a data
management device can be a very effective
and versatile solution for delivering real-time
OEE output to a desired visual interface.
In addition to data management
solutions, a number of human-machine
interface (HMI) panels also facilitate
communication of data for OEE while
providing a control interface for operators to
monitor and control
processes. Pairing protocol conversion with
data collection and math capabilities, as well
as providing a direct path from the HMI or
operator interface (OI) directly to the plant
floor display, ensures operators can monitor
OEE values in real time.
Because they are integrated into the
process, advanced data management and
HMI devices bypass the need for
a PC, long wire runs or offline processing.
They can also provide advantages including
the integrated math
function capability required to pre-analyze
hard point data, as well as the capabilities to
manage multi-vendor
equipment (including PLCs, drives, PCs and
PID controllers) and perform data logging.
Some solutions offer the ability to network-
and Web-enable plant floor machinery,
including legacy serial devices. These
capabilities vastly simplify the acquisition
and movement of data to facilitate scalable
OEE.
PURCHASE 87April 2011
Industrial Automation Industry Watch