Presentation1

Presentation1

• 2.
  Problem statement : There is a problem in braking system, because of which the machine is not filling the brake oil.
• 3.
  Possible reasons : 1.Torque not ok. 2. Leakage problem. 3. Problem in TMC. 4. Brake hose dust accumulation. 5. Brake oil reservoir not connected properly. 6. Brake drum quality not assured.
• 4.
  Problem analysis : After a thorough analysis of the braking system, the major cause out of the mentioned reasons was found to be torque not ok. Or in other terms ‘missed torque’  As human intervention is found more in this case, there is possibility that the worker might have missed to torque all the nuts, as there are 28 nuts that need to be torque, with a pre-set value of 18 Nm.
• 5.
   As mentioned,the major persuading reason for the failure in the braking system is, torque not ok problem.  So there needs to be an counter measure taken to avoid this problem and help increase the production.  Other causes are also addressed and the solution is found within the plant itself.
• 6.
  Solution : MEASUREMENT OFTORQUE USING ‘STRAIN GAUGE’.  THE SETUP:  Torque Indicator is a strain gauge signal conditioner and amplifier used to measure Torque due to load applied on the Torque Cell.  The strain gauge is bonded on the Specimen and is connected in the form of Whetstones Bridge. A pan and weights up to 1Kg with fulcrum arm of 1m length is provided to load the Torque Cell. Torque measuring setup is a complete system which can be used to conduct measurement of load applied on the Torque cell. The Torque indicator is provided with zero balancing facility through adjustable potentiometer. The system operates on 230V Ac supply.
• 7.
  Specifications of torqueindicator  TORQUE INDICATOR  DISPLAY RANGE : 3.5 digit RED LED display of 200 mV FSD to read up to +/-1999 counts.  ACCURACY : +/-0.5% of FSD  RESOLUTION : +/- 0.01 Kg-MS  BRIDGE EXCITATION : 10V DC  CALIBRATION : Directly loading sensor at 1meter arm length 1.00 Kg-m  POWER : 230 V +/- 10% at 50Hz. with perfect grounding.
• 8.
  Some of thereasons for not opting the Solution :  Although strain gauge torque transducers provide high accuracy  It is not Applicable because of- 1. Their high cost. 2. Bulkiness. 3. require high maintenance levels.  making them unsuitable for mass integration into manufacturing systems.
• 9.
  Alternative : The TorqstarTorque Sensor  The new Torqstar sensors meet the challenges for sensors to be used in manufacturing environments and can now be designed directly into production equipment.  They cost up to 60% less than comparable strain gauge methods. The accuracy of the new transducers is within 0.5% of full scale comparing favorably with strain gauge units costing almost five times as much, and they offer a compact size and rugged construction.
• 11.
  About the sensor: The sensor is made up of two main components: 1. A stainless steel shaft , dimensioned for the appropriate torque, 2. And a second metal ring , which fits tightly on the shaft. Although the ring appears to be normal steel, it is actually a special titanium-nickel material which has the property of being magneto-elastic.
• 12.
  WHAT ARE MAGNETO-ELASTIC MATERIALS.? Magneto-elastic materials are commonly known as pseudo magnets. When at rest, they produce no external magnetic fields, but as soon as their form experiences a change in shape through applied stress, their magnetic characteristics change to give a field whose strength is directly proportional to the applied stress.
• 13.
  Reason for notusing the sensor : 1. The main reason is that the sensor is wireless and is monitored by transducer, so for any wireless application within industry there must be approval by the government which will take around 6 month for its approval.  Hence even though the Torqstar torque sensor is compact , low cost and ready to use material it cannot be used as for now.