Engineering Service

Department
ESD

VRV
Maintenance
Maintenance – To maintain
Engg
core
Strategies
Reactive
maintenance
The strategy of repairing parts or
equipment only after the asset has
broken down or been run to the point of
failure
Preventive
maintenanc
e
Preventive maintenance is the act of performing regularly
scheduled maintenance activities to help prevent
unexpected failures in the future.
Put simply, it's about fixing things before they break
Condition
based
CBM is a maintenance strategy that monitors the actual
condition of an asset to decide what maintenance needs to
be done.
Predictive
maintenance
Predictive maintenance,
also referred to as
condition-based
maintenance, involves
performance monitoring
and equipment condition
monitoring during regular
operations to reduce the
chances of a breakdown.
Comparison
Time study
Prescriptive
maintenanc
e
Prescriptive maintenance is the asset maintenance strategy
that uses machine learning to adjust operating conditions
for desired outcomes, as well as intelligently schedule and
plan asset maintenance
Maintenance
prevention
Maintenance Prevention refers to “design activities carried out
during the planning and construction of new equipment, that
impart to the equipment high degrees of reliability,
maintainability, economy, operability, safety, and flexibility,
while considering maintenance information and new
technologies, and to thereby reduce maintenance expenses and
deterioration losses
CLIT
Maintenance Prevention refers to “design activities carried out
during the planning and construction of new equipment, that
impart to the equipment high degrees of reliability,
maintainability, economy, operability, safety, and flexibility,
while considering maintenance information and new
technologies, and to thereby reduce maintenance expenses and
deterioration losses
KPI
Key Performance indicator
Define
Key performance indicators
(KPIs) measure the performance
of a person, department, project,
or company over time, and how
effective they are at achieving
their aims.
Maintenance KPIs measure how
well your operation is doing at
achieving its maintenance goals,
like reducing
downtime or cutting costs.
Metrics
Maintenance metrics are
measurements that give you
insight into how everything and
everyone is operating at your
facility.
They quantify the daily activity of
maintenance, and in doing so,
paint a picture of how people and
assets are working.
These numbers also allow you to
compare the impact of these
actions on the ultimate goals of
your department.
 Asset performance metrics
• Mean time to repair
• Mean time between failures
• Overall equipment effectiveness
Operational metrics
Metric • Planned Maintenance Percentage
• Preventive Maintenance Compliance
classification Inventory metrics
• Turnover ratio
• Slow-moving parts percentage and obsolete
parts percentage
 Breakdown hours
MTTR = ----------------------------------
MTTR --
Number of occurrence

MTTR – Mean Time To Repair is a maintenance metric that measures the average time
required to troubleshoot and repair failed equipment.

• Notify technicians
• Diagnose the issue
• Fix the issue
• Reassemble, align, and calibrate the asset
• Set up, test, and start up the asset for production

MTTR always denoted in Hours

 In a plant there are 60 no. of M/c’s, in that if you
have spent 160 hours on Breakdown for an asset that
has broken down 27 times over the month, then what
is the MTTR?

How to MTTR = 160/27 = 5.925Hrs.

calculate DIY
Consider there are 5 M/c’s in a department, named
MTTR has Mc1, Mc2, Mc3, Mc4, Mc5, those M/c was
stopped for some time of 5min, 25min, 120min,
8min, 0min respectively & total occurrences is 19.
Find the MTTR for following data.
 Duration b/w 1st & 2nd
failure is called MTBF
4
2
MTBF 0
Apr May Jun Jly

Mean time between failures (MTBF) is the average time between

system breakdowns.
(No. of days x no. of M/c)-(Breakdown hours)
MTBF = ----------------------------------------------
No. of occurrence

MTBF always denoted in Days

 DIY – Calculate MTBF for below data
Working
No. of M/c Breakdown hrs Occurrence
days

255 26 856 162

How to 199

79
25

30
721

145
89

34
calculate A plant has 147 M/c runs 26 days in a July month, during those days
plant stopped 269 hours due to breakdown respective to 39 occurrence,
MTBF find the MTBF for July month.
MTBF = (No.of days x No.of M/c)-(Break down Hrs) / No. of
occurrence
MTBF = (26 x 24 x 147) – (269) / 39
MTBF = 91,728 – 269 / 39 = 91,459 / 39
MTBF = 2345.10 hrs
MTBF = 2345.10 / 24 = 97.7 Days
Graphical view
OEE Overall equipment effectiveness is a maintenance KPI that
measures an asset’s level of productivity.
OEE measures product of Availability, Performance & Quality
World’s standard OEE percentage is 85%
How to calculate OEE?
Availability - if a machine Performance - an asset that runs for
was supposed to run for 12 12 hours with a maximum production
hours but suffered a rate of 1,000 units per hour. The
breakdown and only ran maximum throughput would be
for 11 hours, the 12,000. But if that asset only
availability- would be 0.917 produces 11,500 units in that time,
Quality If an asset
or 91.7%. 12,000 units in a the performance score would be
produces
0.958 or 95.8%.
12-hour production time
frame, but 300 of them
have defects that make OEE = 91.7 x 95.8 x 97.5 =
them unusable, then the 85.7%
number of usable units is
11,700. Therefore, the
quality score would be
0.975 or 97.5%.
Documentation
Spare parts management
 Spare Parts Management purpose is to provide “the right parts,
Spare in the right quantity, to the right place, at the right time, with
the right level of quality, and at the least total cost to the
management organization”.

Why
➢Reduced downtime
➢Reduced inventory costs
➢Increased availability of working capital
➢Improved safety
Best Practice
of Spare ➢ Identify all spare parts
➢ Classify all spare parts
management ➢ Utilize and Manage the Bill of Materials (BOM)
➢ Define a stock location for every part
➢ Standardize Spare Parts
➢ Calculating risk of every equipment
➢ Understanding lead times for different parts
➢ Must refer manuals for OEM parts
➢ Check for AMC
Tip for work
MACHINE SAFETY
 OBJECTIVES
• The objective of machine safety is to protect workers from the hazards of machinery
and to prevent accidents.
• Ensuring all machinery for use at work is designed and manufactured to eliminate or
minimize the hazards associated with its use.
• Ensuring that proper workplace safety and health measures are implemented to
identify, eliminate, prevent and control risks arising from the use of machinery.
PRINCIPLES OF MACHINE SAFETY

• Unless a particular hazard is removed, the risk associated with such a hazard can never
be completely eliminated.
• The approach most commonly used is referred to as the hierarchy of controls, from
preferred to least desirable, as follows:
• (a) Elimination;
• (b) Substitution;
• (c) Engineering controls;
• (d) Administrative (procedural) controls;
• (e) Personal protective equipment (PPE).
ENGINEERING CONTROLS ADMINISTRATIVE CONTROLS
HAZARDS

Mechanical hazards
• That can not be eliminated, must be controlled to prevent harm
Non Mechanical hazards
• That can not be eliminated, must be controlled to prevent harmful exposure
Access hazards
• That can not be eliminated, must be controlled to provide safe access (for operation,
maintenance, repair, installation, service, cleaning or decommissioning)
 MECHANICAL HAZARDS

• Machines have moving parts. The action of moving part may have sufficient force in
motion to cause injury to people
 MECHANICAL HAZARDS

Machinery and equipment with moving parts that can be reached by people.
Machinery and objects that can eject objects (Parts, components, waste items) that
may strike a person with sufficient force to cause harm.
Machinery and equipment that have moving parts that can reach people(such as
magazine or ATC arm)
MECHANICAL HAZARDS
MECHANICAL HAZARDS
 NON-MECHANICAL HAZARDS

Non mechanical hazards associated with machinery and equipment

can include harmful emission, contained fluids or gas under pressure,
chemicals and chemical by-products, electricity and noise, all of which
can cause injury if not adequately controlled.
Non-Mechanical Hazards
 Access Hazards
People must be provided with safe access that is suitable for the work
they perform in, on and around machinery and equipment. A stable
work platform suited to the nature of the work that allows for good
posture relative to the work performed, sure footing, safe environment
and fall prevention (if a fall may occur) is a basic requirement.
As an example, cooling towers on building roofs may have poor access,
yet must be attended by a service person at predictable times for
water treatment, chemical dosing or monitoring of automated dosing
equipment. People performing these tasks must be provided with the
means to get themselves and any equipment they require onto the
roof with no risk or minimal risk of fall or injury.
ACCESS HAZARDS
 ACCESS HAZARDS

• Access needs can be predicted and access planning must occur in advance.
• People need access to machinery and equipment in the workplace (either continually
or occasionally) for tasks such as operation, maintenance, repair, installation, service
or cleaning. These tasks are examples of access that can be predicted.
• Access may vary during each stage of machinery and equipment life cycle.
• For example:
• Installation or removal complete access from every area may be required, and involve
• Disconnection or connection of services such water, air, pipes,
• Installation of electrical cable to switch board, etc. access for set-up, operation and
adjustment.
• Maintenance, repair, cleaning, alteration or adaptation access to remote areas may be
required.
 EXAMPLES OF COMMON HAZARDS BY TYPE OF
WORKPLACE ACTIVITY
PEOPLE PROVIDING MAINTENANCE OR REPAIR SERVICES COULD:
• Work in isolation
• Work in confined spaces
• Work on machines and equipment at height or over machinery or equipment to
connect services (such as electricity, air or water)
• Use power tools, welders, extension leads, which present electrical hazards if
damaged or wet.
• Move heavy parts when changing the set-up of machinery and equipment, or
repairing failed parts such as electric motors or gear box assemblies
• Disable or remove normal safety systems to access machines and equipment
mechanism.
 EXAMPLES OF COMMON HAZARDS BY TYPE OF
WORKPLACE ACTIVITY
PEOPLE OPERATING MACHINES AND EQUIPMENT COULD:
• Be required to place their hands close to the mechanism of the machinery or
equipment that does the work, and may be injured if caught or trapped by moving
parts
• Be required to make adjustments to the mechanism of machinery and equipment
while the machine is in motion
• Be required to clear away scrap
• Make minor adjustments or reach into the moving mechanism of the machine they
are operating.
 PERSONAL PROTECTIVE EQUIPMENT

• Personal protective equipment, commonly referred to as "PPE", is

equipment worn to minimize exposure to hazards that cause serious
workplace injuries and illnesses. Personal protective equipment may
include items such as gloves, safety glasses and shoes, earplugs or
muffs, hard hats, respirators, or coveralls, vests and full body suits.

• If PPE is to be used, a PPE program should be implemented. This

program should address the hazards present; the selection,
maintenance, and use of PPE; the training of employees; and
monitoring of the program to ensure its ongoing effectiveness
 PERSONAL PROTECTIVE EQUIPMENT

• Employers must provide personal protective equipment to their workers and ensure
its proper use. Employers are also required to train each worker required to use
personal protective equipment to know:
• When it is necessary
• What kind is necessary
• How to properly put it on, adjust, wear and take it off
• The limitations of the equipment
• Proper care, maintenance, useful life, and disposal of the equipment
 MACHINERY GUARDS
• A guard can perform several functions: it can deny bodily access, contain ejected
parts, tools, off-cuts or swath, prevent emissions escaping or form part of a safe
working platform.
• Guarding is commonly used with machinery and equipment to prevent access to:
• Rotating end drums of belt conveyors
• Rotating shafts
• Moving parts that do not require regular adjustment
• Machine transmissions, such as pulley and belt drives, chain drives, exposed drive
gears
• Any dangerous moving parts, machines or equipment.
Machinery Guards
 Machinery guarding and protection
against mechanical hazards
Moving parts involved in the process
• When a process requires access to a danger zone and a fixed guard is impracticable,
an interlocking guard should be considered.
• Guards or protective devices designed to protect persons against the hazards
generated by moving parts involved in the process should be:
• Fixed guards;
• Interlocking movable guards;
• Protective devices;
• Or a combination of above
 INTERLOCKING MOVABLE GUARDS

• Interlocking movable guards should, as far as possible, remain attached to the

machinery when open.
• Interlocking movable guards should be associated with an interlocking device which:
• Prevents the start of hazardous machinery functions until the guards are closed.
• Gives a stop command whenever the guards are opened.
Machinery Guards
Risk of Being Trapped in Machinery

Risk of being trapped in machinery

Machinery should be designed, constructed or fitted with a means of
preventing a worker from being enclosed within it.
 ACCIDENTS

• Accidents leads to major consequences such as;

• Production stoppage
• Legal issues
• Psychological impact on other workers
• Drop in productivity and production output
• Inability to meet production and customer timelines
THANKS…..
 ENVIRONMENT HEALTH AND
SAFETY
“THINK SAFETY BEFORE YOU START”

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 Facility Safety Introduction
Emergency phone numbers:

o Emergency control Room – 2199

o Security : 0422-7161000
o Fire : 2199 / 07094424107
o Ambulance : 07094424108

Nearest fire extinguisher:

At every shop floor, marked appropriately
Nearest First Aid box :
Main gate & Inside the shop floor, marked appropriately

Assembly point:
Ground opposite to
1) All Gates 2) Auto parts division 3) MHI (H block)
4) LPDC 5) PPD 6) HPDC main gate

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 COVID-19 Safety precautions
▪ Maintain 6-feet social distancing

▪ Wash your hand frequently for 20 seconds

▪ Follow the Facility screening process

▪ Always wear mask which covers your nose

and mouth

▪ Read and follow the facility OCP and Govt.

COVID Care Guidelines issued from time to
time

▪ Report to OHC if you have

Symptoms of Fever, dry cough,
shortness of breath, etc.,

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 SAFETY RULE : PPE, JEWELRY POLICY AND
PERSONAL HYGIENE AND DISCIPLINE
Safety Rule : PPE, Jewelry Policy and Personal Hygiene and Discipline
Follow PPE Policy - Always Use Helmet, Rifle. Jacket, Safety
Goggle,
1
Safety Shoes at Shop floor. Use other PPEs based on job
requirement

Follow Jewelry Policy – Do not wear Finger rings, Wristwatch,

Bracelet at shop floor work. OR cover it properly. Belt buckle
2
shall be covered
properly

Use of loose cloths and free hairs are not permitted. Tie the hairs
3
properly.

4
3.Maintain your personal hygiene and follow COVID-19
Guidelines

5 Use Face Shield where social distancing is not possible at work.

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 EMERGENCY ESCAPE ROUTE PLAN

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 Emergency Response Plan
▪ Don’t Panic

▪ Push the emergency call button at nearest location

▪ Shutdown the surrounding equipment in a normal

manner if necessary depending on type of emergency

▪ Rescue the injured person if any?

▪ In case of fire extinguish the same using nearest fire

extinguisher (If trained) or inform the concerned

▪ Do not leave your work place unless you are advised to

do

▪ On receiving information please evacuate the work place

and assemble in SAFE ASSEMBLY POINT.

▪ Wait for further instructions and execute

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 Emergency Response Procedure
▪ During emergency situation, long siren will blow three times

▪ Walk fast to the nearest assembly point

▪ Do not run / Do not use lifts

▪ Request the guest to move along with your host and follow his instructions

▪ If you are unable to locate your guide, kindly contact the below numbers for
emergency:

Contact person Emergency numbers

Security +91-7094424107
Ambulance +91-7094424108
Safety department +91-7639544544

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 Emergency Response (Pictorial
Representation)
Use Fire extinguisher or
hose Reel To put-
off fire
Don’t Panic

Use Emergency exit ad evacuate to

Assembly Point
For roll call

Activate MCP
and fire alarm

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 What is Safety ?
“The condition of being protected from or unlikely to cause danger, risk or injury”

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 Why workplace safety is Important?
BHOPAL DISASTER:

The Bhopal disaster, also referred to as the Bhopal gas tragedy, was a gas leak incident on the night of 2–3
December 1984 at the Union Carbide India Limited (UCIL) pesticide plant in Bhopal, Madhya Pradesh, India.

Date: 2 December 1984 – 3

December 1984

Location: Bhopal, Madhya Pradesh.

India

Deaths: At least 3,787

Non-fatal injuries: At least 558,125

Cause: Methyl isocyanate leak from

Union Carbide India Limited plant

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 Heinrich’s Triangle

Lagging Indicator

Leading Indicator

* If we you are increasing your leading indicator, Automatically your lagging indicator will come down

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 Key Safety Terms

1. Hazard & Risk

2. Unsafe Act
Unsafe Act Accident Unsafe Condition

3. Unsafe condition

4. Near Miss Incident

❖ Near miss
5. First Aid injury
❖ First aid Injury

❖ Non reportable
6. Non Reportable accidents
❖ Reportable

7. Reportable accidents ❖ Fatal

8. Fatal accident

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 Hazard and Risk

Hazard : A hazard is any object, situation, or behavior that has

the potential to cause injury, ill health, or
damage to property or the environment.

Risk : A situation involving exposure to Danger. An

expression of possible loss in terms of
Severity x Probability

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 Unsafe Act
▪ Any human action that violates an accepted safe procedure
which could lead to an accident.

1 2 3

1 1

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 Unsafe Act

4 5

6 7

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 Unsafe Condition
▪ Physical hazards which exist in poorly organized or improperly planned
situations

1 2 3

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 Unsafe Condition

4
5

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 Near Miss Incident
▪ An incident in which no personal injury was sustained but where, given a slight shift
in time or position, injury easily could have occurred.

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 Unsafe condition, Unsafe act, Near miss
and Accident

1 2 3 4

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 SPOT THE HAZARD

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 NON REPORTABLE INCIDENT

First Aid Injuries

▪ Injury which can be treated with in the factory, Injured person can

continue with work immediately without lose of man hours .

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 REPORTABLE INCIDENT
Medical treatment cases
▪ Injury which can be treated with in or outside the factory.

▪ Injured person can continue work with in 48 hours

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 Lost time incident

▪ Injury which can be treated with in or outside the factory.

▪ Injured person can’t continue work within 48 hours

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 Fatal accident
▪ Injury which results in death is known as fatal accident

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 INCIDENT MANAGEMENT
▪ Incident Management system online tool created in ERP ( ERP MIS IMS
Transition Incident Notification new entry Incident Investigation CAPA )

▪ Incident Notification : When / Where / Who

▪ Incident description : What
▪ Incident Investigation : Why / How

• Basic causes
Unsafe acts and Unsafe conditions
• System causes
Personal factors and Job factors

▪ Corrective and Preventive action development & deployment

▪ Incident report closure

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 INCIDENT INVESTIGATION
WHY DO WE DO WHO WILL DO

▪ To find out cause of incidents and ▪ Employees with knowledge of work

to prevent similar accidents in the
future ▪ Safety officer

▪ To fulfill any legal requirements ▪ EHS committee

▪ To determine the cost of the ▪ Employees with experience in

incident investigation

▪ To determine the compliance with ▪ Outside expert

safety regulations
▪ Representative from local authority
▪ To determine the hazards that needs
to be corrected

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 CLASSIFICATION -- HAZARDS

PHYSICAL MECHANICAL ELECTRICAL CHEMICAL ERGONOMIC

Slippery Entanglement Loose cables Presence of Inadequate
Lying wires Unguarded fumes lighting
Exposed wires
Defective tools machinery Chemical spills Body posture
High voltage
Restricted access Inadequate Chemical splash Manual handling
Short circuit
controls Repetitive motion
Blind corners Lying cables Chemical contact
Moving objects

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 PPEs (Personal Protective Equipment)

Please follow
area specific
PPE Matrix

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 TYPES OF WORK PERMIT SYSTEM

▪ COLD WORK PERMIT

▪ HOT WORK PERMIT
▪ ELEVATED WORK PERMIT
▪ EXCUVATION WORK PERMIT
▪ CONFINED SPACE ENTRY WORK PERMIT

*In all Non routine activity LOTO to be followed for energy isolation

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 COLD WORK PPE’S

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 Height work - PPE’s

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 Confined space work - PPE’s

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 Excavation work - PPE’s

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 Guarding/ Fencing of Machinery

• Ensure emergency push buttons are working

• Ensure double hand switch is operating condition
• Ensure all the rotating's parts are guarded
• Ensure all the safety sensors and interlocks are working
• Ensure the guards physically good condition

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 CRANE SAFETY
0% - 25% OF ALL INDUSTRIAL ACCIDENTS ARE RELATED TO CRANES

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 Operator on Tea Break

🗴
🗴
✓ Load Hang on Crane

Load on ground with

chain stack

• Never leave the controls unattended while a load is

suspended. If it becomes necessary to leave the
controls, lower the load to the floor.

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 Never operate a hoist that has
been tagged with an “Out of
Order” or “Do Not Operate” tag,
or is your opinion, UNSAFE TO
OPERATE…

🗴
Load Hang on Crane

✓
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 🗴

🗴
Keep
300mm

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 NOTE ON FIRE AND EMERGENCY –
CLASSIFICATION OF FIRE
A TRASH WOOD PAPER C ELECTRICAL EQUIPMENT

• wood

• cloth

• paper • Energized
electrical
• rubber equipment
• many plastics

B LIQUIDS GREASE
• gasoline D COMBUSTIBLE
• oil • magnesium
• grease • sodium
• tar • potassium
•
•
oil-based paint
lacquer
D •
•
titanium
zirconium
• flammable • other flammable
gases METALS metals

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 FIGHTING THE FIRE

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 FIRE RESPONSE PLAN

• Know department emergency • Don’t attempt to fight unless:

procedures and evacuation routes. • Alarm is sounded.
• Know locations of extinguishers in • Fire is small and contained.
your area and how to use them. • You have safe egress route (can
be reached without exposure to
• Always sound the alarm regardless
fire).
of fire size.
• Available extinguishers are rated
• Avoid smoky conditions. for size and type of fire.
• Ensure area is evacuated. • If in doubt, evacuate!

2021 – All Rights Reserved

Craftsman Automation Limited
123/4, Sangothipalayam Road,
Arasur Post, Coimbatore – 641 407
Tamilnadu, India
info@craftsmanautomation.com
Kaizen
Define
Kaizen is a Japanese term meaning
change for the better or continuous
improvement.
It is a Japanese business philosophy
that concerns the processes that
continuously improve operations and
involve all employees
History
Kaizen was first practiced
in Japanese businesses after World
War II, influenced in part by
American business and quality-
management teachers, and most
notably as part of The Toyota Way.
It has since spread throughout the
world and has been applied to
environments outside business and
productivity
Objective
quality control

just-in-time delivery

standardized work

the use of efficient equipment

the elimination of waste

 Greater staff satisfaction
Improved customer satisfaction
Strengthened employee loyalty
Benefits Lower costs
Greater efficiency and productivity
Better problem solving
Principle
Known your customer

Let it flow

Go to Gemba

Empowering people

Be transparent
Tools

➢5S
➢PDCA
➢5W & 1H method
5W & 1H method
Improvement by
using Kaizen
The result: an Etios, Etios
Liva rolls off the assembly line
in Toyota's Plant No. 2 in Bidadi,
Karnataka, every 119 seconds,
An Innova or Fortuner in Plant
No. 1 every 162 seconds. In 16.5
hours of operation in a day, the
two plants produce a total of 744
vehicles.
KNOW YOUR MACHINE

CAL-BANGALORE-TPM
WHAT IS INSIDE YOUR CNC MACHINE ???
 PRIMARY ADDITIONAL -AXIS

ATC – TOOL MAGAZINE

APC – AUTOMATIC PALLET CHANGER

 SPINDLE UNIT

BALL SCREW ROD

ELCETRICAL PANEL

N P
( ) C

X Y
4

HYDRAULIC POWER PACK

Y W

J K
, A

S T L
= 0
B
[ ] SP

PAGE

1 7

OPERATORPANEL PANEL
COOLARS
SERVO MOTORS PENEUMATIC &LUB SYSTEM
HYDRAULIC POWER PACK

ELCETRICAL PANEL

N P
( ) C

X Y
Y W 4
J K
, A

PENEUMATIC &
S T L
= 0
B
[ ] SP

PAGE

LUBRICATION 1 7

SYSTEM

OPERATER PANEL PANEL

COOLARS
HYDRAULIC SYSTEM

ATC -& MAGAZINE CYLINDERS

TOOL CLAMPING

B-AXIS CLAMPING

APC OPERATION
CENTRAL GREASE LUBRICATION SYSTEM
MAGAZINE DRIVE AND ATC
X AXIS BALL SCREW AND GUIDE WAYS

Y AXIS BALL SCREW AND GUIDE WAYS

Z AXIS BALL SCREW AND GUIDE WAYS

APC GEAR
PNEUMATIC SYSTEM MAGAZINE DRIVE AND ATC DOOR

SPINDLE CONE AND FACE CLEANING

LOADING DOOR OPEN/CLOSE

B AXIS –PALLET AIR SEAT

SETTING STATION AIRSEAT

COOLANT SYSTEM

SPINDLE FACE COOLANT

SPINDLE THROUGH COOLANT

SHOWER COOLANT
CHIP CONVEYORS AND COOLANT SUPPLY
DRUM FILTER
SYSTEM

DRUM FILTER BACK

WASH SYSTEM
TELESCOPIC COVERS
EMERGENCY SWITCH LOCATION
 WHO WHAT WHEN HOW

CLEAN
AS PER
YOU LUBRICATE DAILY
CLIT
(OPERATOR) INSPECT WEEKLY CHECK SHEET
TIGHTEN
THANK YOU
Bearing - General
Load
Radial Load is defined as the maximum force that can be applied to the shaft in the radial direction (any direction
perpendicular to the motor shaft axis)
Axial or thrust load, are designed to withstand force in the same direction as the shaft
Types
Reduce rotational friction and support radial and axial loads.
➢ Ball Bearings (Deep grove ball bearing)
➢ Tapered Roller Bearings
➢ Ball Thrust Bearings
➢ Roller Thrust Bearing
Ball bearing
➢ These bearings can handle less weights.
➢ Ball bearings have a niche area in the field of bearings as they can handle both radial and thrust loads
Application
➢ Automotive Industry
➢ Home Appliances
➢ Paper-making Industry
➢ Toy Industries
Tapered Roller Bearings
➢ These bearings can handle huge loads in both axial and radial.
Application
➢ Car and vehicle wheel bearings
➢ Heavy duty applications, agriculture, construction and mining equipment
Ball Thrust Bearings
➢ Ball Thrust Bearings can handle thrust loads in low-speed, low-weight applications.
➢ The bearings are basically available in two configurations as follows:
• Single row thrust ball bearings
• Double row thrust ball bearings
Application
➢ Cycle handlebar
Roller Thrust Bearing
➢ Roller thrust bearings can handle larger amounts of thrust load
➢ There are two variants in the thrust roller bearings. They are
• Thrust Cylindrical Roller Bearing – Single Row
• Thrust Cylindrical Roller Bearing – Double Row

Application
➢ Found in car transmissions
Angular contact bearing
➢ In angular contact ball bearings, the forces are transmitted from one raceway to the other at a specific contact angle.
➢ Suitable for Axial & Radial load.

Application
Spindle
Comparison
Types Advantage Disadvantage Application
Bear both radial and axial Running accuracy is decrease gearboxes, pumps, electric
loads. and the running noise to motors, and clutches or
Angular ball bearing
It can work at higher speeds increase when excess load other high-speed
and High-precision applied. applications
low friction sensitive to shock loading Household Items: Bicycles,
minimum lubrication Noisy, when sudden load is Sewing Machines
Ball bearing
wear resistant applied Industries: Elevators,
easy replacement Assembly Lines
Tapered roller bearings will
It can support the thrust and hoisting equipment, rolling
Taper roller bearing not tolerate dynamic
radial load capacity mills and machines
misalignment
Screw Jacks
handle thrust loads in low- Cannot take horizontal end
Machine Tool Spindle Tail
Ball trust bearing speed, low-weight trust
Stock
applications. cannot operate at high speed

the mechanical efficiency is The noise is great.

Pulp and paper processing
high, The structure of the bearing
Roller trust bearing equipment
structure is compact, the seat is complex.
Marine propulsion
weight is light The cost is high
 Identification of bearing
Type Type Shield/ Seal/Others Bearing Code
Bearing Name Bearing Name
Code Code Brass Cage M
Self Aligning Ball Bearing 1 Needle Roller Bearing With Open Ends HK One Side Shielded Z
Both Sides Shielded ZZ
Spherical Roller Bearing 2 Needle Roller and Cage Thrust Assembly K One Side Sealed RS
Double Row Angular Contact Ball Both Side Sealed 2RS
3 CARB Toroidal Roller Bearings C
Bearing One Side Non-Contact Seal V
Four Point Contact Bearings QJ Both Sides Non-Contact
Double Row Ball Bearing 4 VV
Seal
Thrust Ball Bearing 5 Both Sides Contact Seal DDU
Series Code
Snap Ring and Groove NR
Extra Light 0 Bearing ID Code
Single Row Deep Groove Ball Bearing 6
Extra Light 10 00
1
Singular Row Angular Contact Bearing 7 Thrust 12 01
Light 2 15 02
Felt Seat Bearing 8 Medium 3 17 03
Heavy 4 After this, Bore size= Code x
Tapered Roller Bearing 32/T
Extra thin 8 5
Inch Bearing R Very thin 9

Cylindrical Roller Bearing N Clearance

C2 Clearance is less than international standards
Needle Roller Bearing NA
C3 Clearance is greater than the international standards
Double Row Roller Bearing NN
Needle Roller Bearing With Closed C4 Clearance is greater than C3
BK
Ends
Bearing life calculation
Bearing life calculation

Where:
L10 - Reliability rating of bearing (90)
C - Dynamic load
P - Actual load
N - RPM
e - 3.0 for ball bearings, 10/3 for roller bearings
Bearing life calculation

Where:
L10 - Reliability rating of bearing (90)
C - Dynamic load
P - Actual load
N - RPM
e - 3.0 for ball bearings, 10/3 for roller bearings
Bearing life calculation
Machine – Hartford VMC -131 (MHI – Bay4)
Bearing used in spindle – Angular contact ball bearing (7020 C4)
https://www.skf.com/in/products/super-precision-bearings/angular-contact-ball-bearings/productid-
7020%20CE%2FP4BVG275

Let,
C = 44.9kN
P = 3770N
N = 1350
Solution:
L10 = (44.9*103/3770)3 * (106/60*1350)
L10 = 20,842
Bearing life calculation
Machine – Hartford VMC -131 (MHI – Bay4)
Bearing used in spindle – Angular contact ball bearing (7020 C4)
https://www.skf.com/in/products/super-precision-bearings/angular-contact-ball-bearings/productid-
7020%20CE%2FP4BVG275

Let,
C = 44.9kN
P = 3770N
N = 1350
Solution:
L10 = (44.9*103/3770)3 * (106/60*1350)
L10 = 20,842

Avg span - 22,800 hrs

Bearing Re-lubrication calculation
Re-lubrication Amount of Grease (g) = 0.005 * Bearing Outside Diameter (mm) *
Total Bearing Width (mm)
Spindle motor design
Spindle speed

▪ Spindle motors will generally provide constant torque up

to the base speed, and constant horsepower after the base
speed
▪ The spindle speed and feed rate for a given cut must be
balanced for best work quality, tool life and spindle life.
▪ Larger-diameter tools require slower cutting speeds

Speed (RPM) = (Frequency in Hz x 120) / (# of motor

poles)
Chip load

• Chip load is a term used to describe the thickness of a chip removed by

one cutting edge of the tool.
• Chip load is sometimes referred to as “feed per tooth”.

Chip Load = Feed Rate ( Ipm ) ÷ ( Cutting Rpm X Number Of

Cutting Edges )
Spindle Air Seals and Labyrinth
Designs
Seal method

▪ High precision bearings are quite sensitive to external contamination.

Chips, dust, dirt, coolant, and other foreign material will contaminate
the bearing surfaces, resulting in pre-mature failure
▪ positive air over-pressure
▪ chimney effect
▪ Labyrinth seals
Drawbar
Drawbar
A drawbar or spindle drawbar is a clamping mechanism for toolholders on machine tools.

Belleville/disk
Retention knob
spring

Drawba
r

Drawbar clamp
Spring used in drawbar
➢ Belleville spring/washer
➢ Helical / coil spring
Why
Basic difference is their load versus deflection characteristics.
Belleville - very high loads with a small amount of deflection.
Coil springs - lighter loads and much higher deflection
Arrangement
Journey
Established in 1949, Solon Manufacturing Co. designs and manufactures Solon Belleville Springs,
disc springs (DIN EN 16983 & DIN EN 16984)
Material
h/t ratio

Let,
➢ t = thickness (m),
➢ h = deflection to flat (m),
➢ Do = outer diameter (m)
➢ Fflat = load at flat position (N)
Calculation
A Belleville spring is required to give a
constant force of 200 N ± 10 N over a
deflection of ± 0.3 mm. The spring must fit Constant deflection range – 55% to
within a 62 mm diameter hole. 145%

Solution δmin = 0.65 h = 0.65 × 1.114 = 0.724 mm.

δmax = 1.35 h = 1.35 × 1.114 = 1.504 mm.

https://www.sciencedirect.com/topics/eng
ineering/belleville-spring

t = 0.788mm
h/t = 1.414
h = 1.414 t
h = 1.414 × 0.788
h = 1.114 mm.
Tool holder
Tool holder
Taper calculation

Taper ratio Taper angle

K = D-d/L Tan θ = D-d/2L

θ = tan-1 (D-d/2L)
Were ,
Were ,
K = Taper Ratio
D = Larger diameter of the taper D = Larger diameter of the taper
d = Smaller diameter of the taper d = Smaller diameter of the taper
L = Length of the taper L = Length of the taper
 Types of tool holder
➢ MT – (Morse tapper)
➢ BT – (JIS)
➢ Sk – (DIN)
➢ HSK – (Hollow shank holders)
➢ CAT – (Customized Mount Tool)
 Morse Taper
➢ The Morse Taper was invented in 1864 by Stephen A. Morse
➢ ISO as ISO 296 and the DIN as DIN 228-1
➢ The taper angle of the Morse taper size is typically 1.49 degrees (around 3 degrees included).
➢ Application : lathes and drill presses to mount tooling
BT Taper
➢ BT is the norm of 7/24 taper from Japan, It started from the norm MAS403 in 1969.
➢ BT standard for ISO7388-2:2007 & MAS403 -BT
➢ Mostly used in high-speed machines.
➢ taper angle 8˚17.50”
SK Taper
➢ SK series is as per standard (DIN 69871) DIN ISO 7388-1
➢ Taper angle 8˚17.50”
➢ Application – Mostly suitable for Milling operation with spindle speed of 12000 RPM
 Hollow Shank Holder
➢ The taper on all HSK shanks is 10:1
➢ HSK shank standard is also known as ISO 12164, DIN 69893, DIN 29893-1, and DIN 69063-1
➢ Application - high-speed machining (HSM)
 Hollow Shank Holder
Advantage
➢ They are lighter and balanced with the highest precision
➢ the radial stiffness of HSK tool holders up to five times greater than the value for CAT, SK, or BT.
The HSK shank acts as a fuse during collisions.
 Customized Mount Tool
CAT tool holders accept both Imperial and Metric-sized tools.
CAT tapered tool holders are like BT tapered tool holders (flange style and thickness)
CAT standard is also ISO 7388-1, DIN 69871, NFE 62540, ANSI B5.50
Application – CNC lathe
 Taper ratio
Taper ratio is based on ‘X’ unit of dia is reduced per ‘Y’ unit of axial length.

7/24 or 7:24 taper

These holders have a cone that tapers at 3.5 " (88.9mm) per foot and are often called 7/24 tapers (7 " of taper per 24 " of
axial length).
Reference: https://www.ctemag.com/news/articles/understanding-tapered-spindle-connections
https://www.quora.com/search?q=7%2F24%20taper
Comparison chart
Tool holder type BT SK CAT HSK
Standard ISO7388-2:2007 & DIN ISO 7388-1 ISO 7388-1, DIN 69871, NFE ISO 12164, DIN 69893,
MAS403 –BT (JIS) 62540, ANSI B5.50 29893-1, 69063-1

Taper angle 7/24 10:1

Flange thickness 20, 25, 30, 35 mm 15.9 mm 15.9 mm 20 to 29 mm
Flange angle 60
Tapper M12, M16, M24 M16, M24 -
Application High speed machining High speed milling (12000 CNC Lathe High speed machining
operation RPM) operation
BY changing collet nut, it is
Radial stiffness is 5 time
easy to change variety of
Merits Great balance & Stable Tensile strength is higher greater than others.
tools
Less weight, act has fuse

De-merits Stiffness is low - Stiffness is low -

Holding External holding Internal holding
Comparison chart

9
8
7

Runout in µm
6
5
4
3
2
1
0
No. of time ATC motion
Contact with taper only Similtaneous contact with taper and flange
BT30
Let,
D = 31.75 / d = 17.63 / L = 48.4

Calculation:
Tan ɵ = D-d/2L
ɵ = tan-1 (D-d/2L)
ɵ = tan-1 ((31.75 – 17.63) / 2(48.4))
ɵ - tan-1 (14.13 / 96.8)
ɵ = tan-1 (0.1459)
ɵ = 8.30˚
Spindle housing
Cartridge system
The spindle shaft and motor must be held in a housing
Many high-speed spindle designs utilize a cartridge type housing, as this is the simplest to service, and the tolerances
The primary function of housing is to locate bearing housing, lubrication, air seal, cooling water or oil,
Bearing life calculation

50000

35000

20000

7000
2000

600 950 1350 1900 2500

Revolution per minute
Linear motion elements
Define
➢A lead screw is sometimes
referred to as a “power screw”
or a “translation screw”.
➢They are used within motion
control devices to transform
rotary or turning movements
into linear movements.
How Does a Lead
Screw Work?
A lead screw works in one of two
ways:
➢ The shaft is stationary, and the power
is supplied to the nut
➢ The shaft rotates and transfers power
to the nut.
Types of Lead Screw Threads
Square Thread
This 0° thread angle prevents any radial pressure
on components and reduces friction between
them.
Advantage:
➢ They have a much higher intrinsic
efficiency.
➢ Due to the lack of a thread angle, there is
no radial pressure,
Disadvantage:
➢ Sq. threads are difficult to manufacture
➢ The thread thickness at core
ACME Thread
The acme thread is a trapezoid-shaped thread with a
thread angle of 29°. It is based on the imperial standard
but is accepted throughout the world.
The trapezoidal thread follows the metric standard and
has a thread angle of 30°. The exact specifications for
trapezoidal threads can be found under DIN 103.
Advantage:
➢ Increased clamping area
➢ Manufacturability
Disadvantage:
➢ Reduced Shaft Diameter & Strength
Butterss
thread
The buttress thread is a triangular-shaped thread that
is used when force needs to be transmitted in one
direction only. It has a 7° inclination on the load
flank and a 45° inclination on the trailing flank.
Advantage:
➢ Increased clamping speed
➢ High thread strength in one direction
Disadvantage:
➢ Only designed to be loaded in one direction
Development
Ball Screw
History
Ball screws date all the way
back to the late 19th century,
when an engineer placed ball
bearings inside the nut threads
to reduce friction
Advantage

Manageable Backlash
Achieve greater accuracy
With proper lubrication, wear rate is too low
Gothic Arc Profile.
This is the most common groove profile. It is made by two intersecting
arcs. With this profile, the ball has two contact points on the screw shaft
and two contact points on the nut.
Semi-Circular Arc Profile.
This groove profile has the shape of a semicircle. With this profile, the
ball has one contact point on the screw shaft and one contact point on
the nut.
Basic configuration of ball screw and Lead screw

BALL SCREW LEAD SCREW

Components of the Ball Screw
Types of Ball screws

• Internal Ball Recirculation

• a) Deflector-Type Ball Screws.
• b) End Cap-Type Ball Screws.

• External Ball Recirculation.

• Return Pipe-Type Ball screws.
 Internal ball return System

This design is used for applications that require fine leads. It has a compact size, which is
.
suitable for small clearance assemblies.
Internal ball return System

End caps are mounted to guide the balls through a tunnel within the ball nut‘s internal; this
directs them back to their starting point.
External ball return System

The balls pass through an external tube that is protruding from the ball nut‘s wall. The return tube
directs the balls back to their starting point. Fingers are fixed on the endings of the return tube to
guide the balls in entering and leaving the return tube. The length of the return tube is supported by
a tube holding bracket. The return tube assembly is easy to install and dismantle.
What is Preloading?

• Preloading is the application of axial force on

the balls and the grooves of the screw shaft and
the nut to make them compact.
• The purposes of preloading are to increase the
rigidity and to eliminate the backlash of the ball
screw assembly.
• Backlash is the lost motion caused by the
clearance between the ball and the nut and
screw tracks.
Ball screw Preloading types

• Spacer Preloading.
• Spring Preloading
• Offset Lead Preloading.
• Oversized Ball Preloading.
Spacer Preloading

spacer preloading, a spacer is inserted between two ball nuts to achieve the
desired preload. The spacer applies force on the adjacent sides of two ball nuts;
this force is transmitted to the nut and the grooves. This method is used for setting
a large preload.
Spring Preloading

spring preloading, a spring is placed between two ball nuts that transmit the
preload. Tensional forces are applied on two adjacent sides of the ball nuts due to
the spring force.
Offset Preloading

During machining, to create the grooves, an offset is created in the lead, which is in
the middle of a recirculation circuit. Since there are no spacers or springs required, it
is more compact than double nut mechanisms. However, this preload mechanism
creates longer leads, which reduce the load capacity of the ball screw.
 Over sized ball Preloading

Preload is applied by assembling larger ball bearings. The oversized balls produce a
more compact structure by increasing the contact area of the balls to the grooves.
However, this mechanism produces the smallest preload and is suitable in
applications where precision is not that crucial.
It is important to optimize the preload value in ball screws and maintain it during the
operation.
A large preload requires more torque and can cause excessive heat generation.
Pretension
Material and Heat Treatment
Ball screw types
Grounded ball screw

Ground screw threads are fabricated by an abrasion process.

Grounded ball screw manufacturing
Rolled type ball screw manufacturing

Rolled screw threads are fabricated by a cold work deformation process.

Rolled type ball screw manufacturing

Rolled ball screw threads are created by pushing

each uncut bar stock blank through rotating
tool dies in a single operation.
Application of Ball screws

• Machine tools, Robots and precision assembly equipment’s

• Aircraft and Missiles to move control surfaces
• Food processing equipment's
• Semi conductor manufacturing equipment.
• Automobile power steering to translate rotary motion to axial
motion of steering rack.
Disadvantage of ball screw

Depending upon their lead angle, ball screws can be back-driven due to their
low internal friction.
THANK YOU!!!

Engineering Service Department

 Spindle
Rotating axis of machine
Types
• Belt-Driven Spindle
machine spindle can rotate up to 15,000 RPM
• Gear-Driven Spindle
machine spindle can rotate up to 10,000 RPM
• Integral Motor Spindle
internal motor that can reach a maximum speed of 60,000 RPM
Uses of Spindle
▪ Provide constant power in a certain speed range to ensure sufficient cutting force.
▪ Positioning: make the spindle stop at a certain position accurately used for tool changing, boring tool withdrawing and
special work requirement.
▪ If there are multiple spindles in a system, two spindles can operate synchronously.
▪ Turn the spindle into a servo axis.
Spindle selection

Spindle Style:
• Belt Driven or Integral Motor-Spindle
Spindle Bearings:
• Type, Quantity, Mounting, and Lubrication
Method
Spindle Motor:
• Belt-Type, Motor-Spindle, Capacity, Size
Spindle Shaft:
• Including Tool Retention Drawbar and
Tooling System Used
Spindle Housing:
• Size, Mounting Style, Capacity
Spindle Drawbar
Spindle style
Belt drive

▪ A belt-driven high-speed spindle is quite

similar in design to a conventional speed
spindle design, with some noticeable
differences.
▪ A typical belt-driven spindle assembly
consists of the spindle shaft, held with a
bearing system and supported by the
spindle housing.
▪ The spindle shaft incorporates the tooling
system, including the tool taper, drawbar
mechanism and tool release system.
Belt drive - Advantage

▪ Reasonable Cost
▪ High Power and Torque Possible

Belt drive – Limitation

▪ Maximum Speed is Limited
▪ Belts Utilize Bearing Load Capacity
Integrated drive

▪ The integral motor-spindle does not rely

upon an external motor to provide torque
and power.
Spindle Bearing
Condition of bearing

▪ Bearing Loads, Axial and Radial

▪ Vibration Levels
▪ Quality and Quantity of Lubrication
▪ Maximum Speed
▪ Average Bearing Temperature
▪ Bearing life is typically expressed as L10 life
Bearing
One of the most critical components of any high-speed spindle design is the bearing system.
Our design requirements state that the spindle must provide high rotational speed, transfer torque and power to the cutting
tool, and be capable of reasonable loading and life.
Angular contact Vs Tapper roller bearing

Angular contact bearing

▪ Angular contact bearings are most used today in very high-
speed spindle designs.
▪ This provide the precision, load carrying capacity and speed
required for metal cutting spindles.
▪ They are designed to provide both axial and radial load carrying
capacity
Tapper roller bearing
▪ Tapered roller bearings are used, due to their higher load
capacity and greater stiffness over ball bearings.
▪ However, tapered roller bearings do not allow the high speeds
required by many spindles
Angular contact bearing
Angular contact angle available angle is 12˚, 15˚ &
25˚. – Lower angle support high radial load &
Higher angle support high axial load.
Angular contact ball bearings preloading
Light - allow maximum speed and less stiffness
Medium
Heavy - allows less speed, but higher stiffness
F/F or X preloading
Bearing pair is capable of withstanding both axial
and radial loading.
B/B or O preloading
Provide a good accuracy and rigidity.
Tandem preloading
Increase moment loading capacity and spindle
performance
Bearing life calculation
Rotary Union
Define

Rotary manifold, swivel joint, rotating joint, rotary coupling, fluid swivel or fluid rotary union (FRU)
A rotary union functions by connecting a stationary input (supply) to a rotating part, allowing a moving
connection to be preserved and permitting the flow of media (liquids, solids and gases).
PRIMARY COMPONENTS
FLUID SEALING & TRANSFER

Rotary unions (swivel joints) may integrate multiple independent flow channels (passages) for the
sealing and transfer of different types of fluid media simultaneously.
OPERATING PARAMETERS
Application
 ESD-PPD
KNOWLEDGE SHARING PRESENTATION ON

PNEUMATICS

© Copyright Makino 2020

 CONTENTS

❑ INTRODUCTION TO PNEUMATICS.

❑ WHY WE USE PNEUMATIC SYSTEM.

❑ COMPONENTS AND BLOCK DIAGRAM OF PNEUMATIC SYSTEM.

❑ SYMBOLS OF VARIOUS PNEUMATIC COMPONENTS.

❑ CIRCUIT DIAGRAM OF PNEUMATIC.

❑ ADVANTAGE OF PNEUMATIC SYSTEM.

 INTRODUCTION TO PNEUMATICS.

▪ Pneumatic system is a system that

uses compressed air for carry out the
desired task.

▪ A pneumatic system is a system that

uses compressed air to do work, it
capture air , transport
around a circuit and accomplish
desired task with the generated energy.

▪ These are present both auto and

manually.
 WHY WE USE PNEUMATIC
SYSTEM?

1. Generally Used with smaller load as pneumatic

system.
2. Produce less force than hydraulic system.
3. Compressing the air is easy.
4. Pneumatic can absorb excess shock.
5. Flow much more quickly and easily through pipe .
COMPONENTS AND BLOCK DIAGRAM OF PNEUMATIC SYSTEM.
VARIOUS PNEUMATIC OF COMPONENTS SYMBOLS
CIRCUIT DIAGRAM OF PNEUMATIC SYSTEM
 ADVANTAGES OF PNEUMATIC SYSTEM

• Infinite Availability of the source.

• Clean and safe.

• The transfer of power and the speed is very easy to set.

• Can be stored and utilized.

• Low component cost and light weight.

Typical screw compressor
• Can be continuous run for long time.
Good Day!

© Copyright Makino 2020

Hydraulic power Pack
Elements of Hyd power pack
https://youtu.be/lXG5cZx8Vaw
Encoder
Define

Encoders convert motion to an electrical signal that can be read by some type of control device in a
motion control system, such as a counter or PLC.
The encoder sends a feedback signal that can be used to determine position, count, speed, or direction
Types based on Axis
➢Rotary
➢Linear
➢Angular
Types based on
operating principle
➢Mechanical
➢Magnetic
➢Capacitive
➢Optical
Mechanical
Encoder

This method detects the

rotational position with a
variable resistor whose
electrical resistance changes
in proportion to the rotation
angle.
Such a mechanical encoder
is generally called a
potentiometer
Magnetic
Encoder
This method uses a magnetic
sensor to measure changes in
the magnetic field distribution
created by a permanent magnet
attached to the motor shaft.
Then the motor rotates, the
magnetic field distribution of
the permanent magnet also
changes, so if you detect it with
a magnetic sensor, you can
determine the rotational
position of the motor shaft.
Capacitive
Encoder
Capacitive encoders are a
relatively new sensing
technology for encoder
design. The operating
principle relies on the
detection of a change in
capacitance using a high-
frequency reference signa
Optical Encoder

Optical encoders are the most

accurate of all the sensing
methods. A rotary optical encoder
consists of a light source such as
an LED and a rotating disk that is
patterned with a series of opaque
lines and alternating translucent
slots
Types of Position

➢Absolute
➢Incremental
Thank You
Coolant circulation pumps
What is coolant circulation pump?

These pump are used in CNC machines to circulate coolant at certain

flow and pressure to facilitate cooling, washing & chip extraction as
well
 Types of coolant pumps?

1. Centrifugal pump (In-line, Submersible)

2. Multi stage centrifugal pump ( Submersible, In-line)
3. Screw pump ( Submersible, In-line)
4. Piston pump – In-Line
Centrifugal pump?

A centrifugal pump is a machine that uses rotation to impart velocity to a liquid and then
converts that velocity into flow
In-line multi stage centrifugal pump

This is similar to centrifugal, multiple impeller are stacked together

to deliver more volume & Pressure requirements
In-line multi stage centrifugal pump – Part identification
Screw pumps:

Screw pump uses screw elements to push coolant instead of impellers in centrifugal pump
INTRODUCTION:

What Is Reciprocating piston Pump?

• A reciprocating pump is a class of positive-displacement pumps that includes the piston pump, plunger pump, and
diaphragm pump
• Well maintained, reciprocating pumps can last for decades, used where small flow & high pressure is needed.
• Because a reciprocating pump uses a piston or plunger for pumping purposes, therefore, it is also known as a piston pump
 Working of a piston pump:

Suction stroke Pressure or Delivery stroke

Piston Pump – Variants

•Single Acting Piston Pump – Having liquid chamber on only one side of the piston and valve arrangement
on that side only.
•Double Acting Piston Pump – Both sides of the piston have a liquid chamber and a valve arrangement.
•Duplex Pump – There are two piston-cylinders assemblies.
Typical specifications:
Reciprocating Pump Application
•Oil drilling, refineries, production, disposal, injections.
•Vehicle cleaning.
•Sewer line cleaning.
•High-pressure pumps for the RO system (Reverse osmosis)
•Hydro testing of tanks, vessels, etc.
•Firefighting system.
•Wastewater treatment system.

Advantages Of Reciprocating Pump

•Reciprocating pump can deliver the required flow rate very precisely.
•It gives a continuous rate of discharge.
•It can deliver fluid at very high pressure.
•No priming is needed in the reciprocating pump.
•Efficiency of a reciprocating pump is 10% to 20% greater than the efficiency of a Centrifugal Pump.

Disadvantages Of Reciprocating Pump

•The pump is very costly (Capital cost is high).
•Viscous liquids are difficult to pump using a reciprocating pump.
•The maintenance cost of the pump is very high as there is a large number of parts.
•The flow rate is less.
Thanks !
Motor
Define
An electric motor is an electrical
machine that converts electrical
energy into mechanical energy.
 Power Factor
Power factor (PF) is the ratio of
working power, measured in kilowatts
(kW), to apparent power, measured in
kilovolt amperes (kVA).
Working power (kW)
Power factor = ---------------------------
Apparent power (KVA)
Linear motor

➢Linear motors operate with an

AC power supply and servo
controller, which are often the
same as those used for rotary VS = 2t fs m/sec
servo motors Were,
Vs - velocity of linear travel
➢The rate of change of the
current controls the velocity of Fs - Frequency in Hz
the movement, and the t - Pitch distance of poles
amperage of the current
determines the force generated
Synchronous motor

➢A synchronous electric motor

is an AC electric motor in
which, at steady state, the
rotation of the shaft is
synchronized with the
frequency of the supply
current
Synchronous
Reluctance motor
➢The core idea of a SynRM
motor is that the rotor has no
windings or magnets, just
electric steel plates stacked
together to form a rotor
package.
Principle
➢The forces are established that
tend to cause iron poles
carrying a magnetic flux to
align with each
Synchronous
Hysteresis motor
➢Hysteresis-reluctance motor
is a hybrid salient pole rotor
synchronous motor, the rotor
of which is made of hard
magnetic material with a large
residual magnetization
Principle
 Induction motor
➢An induction motor or asynchronous
motor is an AC electric motor in
which the electric current in
the rotor needed to produce torque is
obtained by electromagnetic
induction from the magnetic field of
the stator winding

Types
➢Squirrel Cage
➢Wound type
 Self exited motor
➢Shunt-wound DC motor
➢Series wound DC motor
➢Compound wound DC motor
 Shunt-wound DC motor
The field winding in a shunt-wound
motor is linked parallel to the armature.
Due to the constant speed and medium
starting torque, the shunt DC motors are
usually used in industrial applications
as machine tools, winding or unwinding
machines.
 Series wound DC motor
In the series-wound DC motor, the field
winding is connected in series to the
armature winding and the entire
armature current passes through it. A
series DC motor has a strong starting
torque and is frequently used to start
high-inertia loads like trains, elevators,
and hoists.
 Compound wound DC motor
The compound wound DC motor is
the compound or the mixture of shunt
and the series field winding. This type
of DC motor is used when high-speed
torque and good speed regulation both
are needed
 Separately Excited DC Motor
In separately excited DC motors,
the supply is given to the field and
armature windings separately. The main
feature of this type of DC motor is that
the current through the armature
doesn’t flow through the field windings
because the field winding is energized
by a separate DC source
 Permanent magnet DC Motor
The permanent magnet DC
Motors includes armature winding but
not necessarily field windings. These
DC motors are constructed in such a
way that the radially magnetized
permanent magnets are positioned on
the inner periphery of the stator core to
produce the field winding.
The rotor uses a standard DC
armature with commutator segments
and brushes.
 Servo motor
A servo motor is a rotary actuator that
allows for precise control of angular
position. It consists of a motor coupled
to a sensor for position feedback. It also
requires a servo drive to complete the
system. The drive uses the feedback
sensor to precisely control the rotary
position of the motor.
Knowledge sharing presentation On

“Photoelectric Sensor’
Contents:

• Introduction - Types of photoelectric sensor

• Types of reflections & Examples
• Difference between Retro & Diffuse reflective sensor
• Data Sheet & Ordering Info.
• Block Diagram.
• Amplifier.
• Modulator/Pulse Generator.
• Synchronous Detector.
• Photo Detector.
• Level Sensor.
• Applications & Limitations.
Introduction:

A photoelectric sensor is a device used to determine the distance, absence, or presence of an

object by using a light transmitter, often IR, and a photoelectric receiver.

There Are Three Types Of Photoelectric Sensor Are Available.

Through beam photo electric sensor

The Through-beam photoelectric Sensor is transmitter and emitter are in separate housings. Light
emitted from the transmitter is aimed directly at the receiver.

When an object breaks the beam of light between the emitter and receiver, the receiver’s output
changes state.
Types of reflections:
Mirror reflection

Retro : Backwards Object

Diffuse :Become spread widely in all directions.

Diffuse reflective sensor

Retroreflective sensor
Retro reflective photo electric sensor

A Retro-reflective sensor is a type of photoelectric sensor, which uses the interruption of a reflected light beam to
detect objects
 Difference Between Diffuse And Retroreflective Sensors

Retro : Backwards
Diffuse :Become spread widely in all directions.

Retro Reflective Diffuse Reflective

Normal condition
Detection condition
 Block Diagram.

Amplifier:-
An amplifier, electronic amplifier or (informally) amp is an electronic device that can increase the power of a signal (a time-varying voltage or current).
Modulator/Pulse Generator:-
This stage generates a signal to rapidly turn the LED on and off.
Pulse Generator the power source for an artificial pacemaker.
Synchronous Detector:-
A Synchronous Detector is a device that recovers information from a modulated signal by mixing the signal.
Photo Detector:- They transform optical signals into electrical signals.
Level Sensor:- It is the Comparing The 2 Signals.
Data sheet & Specifications.

Disadvantage of Diffuse-reflective Sensors

•The most important disadvantage of using a diffuse sensor is that it has the shortest detection range compared
to other types because it depends on the shape, size, and color of the object; it may not reflect light well to the
sensor receiver.
•Error in the detection of colors that are too white or too black
•Less accuracy and reliability
 PRECISION MEASUREMENT

A. STEEL RULES
• Also called rulers or scales.
• Range in length from 1 - to - 48 inches.
• Most common is spring tempered 6-inch.

1. Fractional-Inch Rule
• Divided in fractions of an inch. Such as 1/2, 1/4, 1/8, 1/16 or smaller.
• Bottom number indicates number of spaces within an inch.

Fractional-Inch rule in 8ths and 16ths.

 2. Review of Reducing Fractions
• Reducing does not change the value of a fraction.
• Divide numerator (top number) and denominator (bottom number)
by same number.

Reduce 2/8
2 2=1
2/8 = 1/4
8 2=4

Reduce 16/32

a. 16 2=8 b. 8 2=4 c. 4 2=2 d. 2 2=1

32 2 = 16 16 2=8 8 2=4 4 2=2

16/32 = 1/2
 Reducing Fractions Exercise
Solve these problems. Show all work.

a. In 1 1 ⁄2 there are ______________

24 16ths.
b. In 1 ⁄2 there are _______________
8 16ths.
c. In 3 ⁄4 there are _____________
6 8ths.
d. In 1 4 ⁄16 there are _______________
10 8ths.
e. In 24 ⁄ 32 there are _______________
3 4ths.
f. In 2 1 ⁄2 there are _______________
40 16ths.
g. 12 ⁄16 reduced to its lowest terms is _______________.
3/4
h. 28 ⁄ 32 reduced to its lowest terms is _______________.
7/8
i. 48 ⁄ 64 reduced to its lowest terms is _______________.
3/4
j. 96 ⁄64 reduced to its lowest terms is _______________.
1-1/2
k. 19 ⁄32 reduced to its lowest terms is _______________.
19/32
l. In 1 40 ⁄64 there are _______________
26 16ths.
m. In 1 ⁄8 there are _______________
8 64ths.
n. In 1 5 ⁄16 there are _______________
42 32nds.
o. In 3 ⁄4 there are __________________
12 16ths.
p. 1
15 ⁄8 reduced to its lowest terms is __________.
-7/8

CHECK YOUR ANSWERS !

 Rule Reading Exercise

3/8
a. __________ 7/16
e. __________ 7/16
i. __________ 1-5/8
m. __________

11/16
b. __________ 5/16
f. __________ 5/16
j. __________ 1-3/8
n. __________

3/4
c. __________ 13/16
g. __________ 1/8
k. __________ 3- 1/16
o. __________

1-1/4
d. __________ 3/8
h. __________ 3/4
l. __________ 3 - 3/8
p. __________

CHECK YOUR ANSWERS !

3. Decimal-Inch Rule
• Measures closer than fractional-inch rule.
• “100” at end of rule means 1 inch divided into 100 parts.
• Each division = 1/100 of an inch.
• Can be divided into 50ths and 10ths.

.10 .20 .30 .40

 Reading the Decimal-Inch Rule Exercise

Complete the readings called for by placing your answers in

the spaces provided.

.32
a. __________ d. __________2.06
g.__________ 1.5

.94
b. __________ e. __________ .3h. __________ 2.0

1.56
c. __________ f. __________ .9

CHECK YOUR ANSWERS !

B. USING STEEL RULES
• Don’t use end as reference point, except with “knee”..
• If no “knee”, use 1 inch mark as reference.

Use scale
edge.
1. Care of The Rule
• Don’t use as screwdriver.
• Keep away from moving machinery.
• Don’t lay other tools on the rule (destroys markings).
• Wipe often with oily cloth (prevents rust).
• Clean with fine steel wool.
• Store rule by itself.
• Don’t damage ends or edges.
• Use correct rule for job.
• Coat rule with wax or rust preventative for long storage time.
B. HOOKED RULES

Common Uses
 D. HELPER MEASURING TOOLS
• Generally a spring caliper.
• Has no scale - cannot be used by itself.
• Common examples are “Inside and Outside” calipers.

“Outside”

“Inside”
E. ADJUSTABLE JAW CALIPERS
• Moveable jaws.
• Takes measurement directly from part.

1. Dial Calipers
• Dial indicator mounted on moveable jaw.
Common Uses of Dial Calipers
 2. Digital Calipers
• Latest advancement.
• Measurement converted to digital readout.
• Similar to conventional calipers.
• Scale can be calibrated in both inches and centimeters.

• More rugged.
• More accurate.
• Better repeatability.
• Easier to handle & read.

Follow guidelines for proper use.

F. DIAL MICROMETERS

1. Outside Micrometers
• Measures accurately to (.001).
• Vernier micrometers measure to (.0001).
2. Standard Micrometers
• Spindle rotates in fixed nut - (40 threads per inch).
• One complete turn of spindle = 1/40 (.025) inches.

Micrometer Graduations
 Micrometer Reading

1. Line “1” visible, plus two other lines:

“1” = .100
+ 2 @ .025 = .050
.150

2. Index line coincides with 12 on thimble:

12 x .001 = .012

.100 – Line marked “1”

.050 – 2 extra vertical lines
.012 – Thimble reading
.162 – Total reading
How Micrometers are Read
 Micrometer Reading Exercise

.125 .250

.235 .312

.082 .468

.375 .187

.625 .718

CHECK YOUR ANSWERS !

 Micrometer Reading Exercise

.033 .175

.625 .325

.103 .500

.022 .187

.293 .435

CHECK YOUR ANSWERS !

3. Metric Micrometers
• Measure in hundredths of a millimeter (0.01 mm)
• One complete turn of thimble = 1/2 mm.
• Sleeve marked in “millimeters” below the line.
• Marked in half-millimeters above line.
• Thimble marked in 50 divisions.
- Each division = 1/50 of a 1/2 millimeter or 1/100 (.01)mm.

Step 1. Note whole millimeter mark on sleeve.

Step 2. Note whether a half-mm mark is showing between whole
millimeter mark and thimble.
Step 3. Read thimble for hundredths reading.
Step 4. Add readings.
 Metric Micrometer Reading

Whole millimeter marks 10 x 1 mm = 10.00 mm

Half millimeter marks 1 x .50 mm = .50 mm
Thimble Reading 16 x .01 mm = .16 mm
Reading 10.66 mm
Metric Micrometer Reading Exercise

5.82 mm 8.16 mm

4.12 mm 5.50 mm

16.25 mm 6.05 mm

22.11 mm 9.95 mm

3.55 mm 20.57 mm

CHECK YOUR ANSWERS !

4. Micrometer Adjustments
• Removing Play
- Back off the thimble.
- Insert a C-spanner into slot or hole of adjusting nut.
- Turn adjusting nut clockwise until play between threads
is eliminated.
4. Micrometer Adjustments
• Adjusting Accuracy
- Clean measuring faces and check for damage.
- Closes faces.
- Turn sleeve until index line on sleeve matches zero (0)
line on thimble.

- Recheck accuracy by opening and closing faces. Rating

should be zero (0).
5. Care of the Micrometer
• Close faces carefully to avoid damage.
• Keep micrometer clean. Wipe with oily cloth. Oil threads.
• Not too much pressure.
• Clean face of anvil and spindle before use.
• Check for accuracy. Close faces - should read zero (0).
• Don’t lay unit where it could fall.
• Don’t twirl micrometer to open or close a great distance.
• Clean and oil for long term storage. Place in box.
 6. Inside Micrometers
• For internal measurements larger than 1-1/2 inch
• Consists of:
- Micrometer head - Range of 1/2 to 1 inch.
- Extension rods- different lengths inserted in head.
- 1/2 inch spacing collar.

Review and follow steps for using inside micrometer.

Uses of Inside Micrometers
G. DIGITAL MICROMETERS
• Modern Version - Results Displayed Electronically
• Delicate instrument - handle with care.

1. How to Read Digital Micrometers

a. Before taking reading, do the following:

- Turn display on.
- Press button to activate desired scale.
- Slowly close micrometer until ratchet engages.
- Zero micrometer by pressing Origin or Set button.

b. For thickness reading:

- Open micrometer.
- Insert sample.
- Slowly close micrometer until ratchet engages.
- Read thickness on digital display.
2. Proper Care of Digital Micrometers

• When finished, open slightly.

• Never store with spindle closed
• Turn instrument off and store in protective case.
H. GAUGE BLOCKS
• Rectangular blocks - hardened and ground alloy steel.
• Measuring surfaces lapped and polished - accurate to within
a few millionths of an inch.
• Size of block stamped one surface.
Wringing Gage Blocks Together
I. SQUARES
• Used for laying out, checking, and setting up work.
• Beam and blade form a right angle.
• Good quality squares are hardened.

1. Solid and Adjustable Squares.

• Not accurate enough for precision work or inspection.
2. Combination Squares.

• Checking inside and outside squareness.

• Drawing lines parallel to edges of work piece.
• Measuring depth.
• Finding centers of round work pieces.
• Checking 450 angles.
Uses of Combination Squares.
3. Using Solid Steel Squares.
• Remove all burrs from work surface. Wipe clean.
• Wipe square clean.
• Face source of light.
• Hold work with one hand. Grasp square with other.
• Place inside of square against finished surface.
• Lower blade to surface of work.
• All light should be excluded.
4. Beveled Edge Squares.
• Used for inspection.
• Edges are beveled and hardened.
• Better contact with surface. More accurate.
5. Cylindrical Squares.
• Made in 4”, 6” and 12” lengths.
• Used as master squares to check other squares.
• Thick-walled, alloy steel cylinder (hardened, ground, and lapped).

STEPS:
• Place in contact with work.
• Turn until no light is seen between.
• Uppermost curved line shows squareness.
Zero
 Concept of “Maintenance Activity” resembles to TQM ( Such as
employ empowerment, management commitment, long term goal
setting etc)
Responsibility to all
Define Maintenance is one of the key aspects of any organization.
TPM breaks non-profit activity.
Avoid unexpected interrupts to the production & avoid unscheduled
maintenance.
History
The parent of TPM is TQM. TQM
was evolved after the quality
concerns the Japan had after the
Second World War
Seiichi Nakajima
Implementation
Pillars of To avoid the loss of equipment, talent, raw materials,
and energy, the whole team must share this vision. The
team must be proactive, willing to try new methods,
TPM and eager to sit around the table to work out problems.
Follow