Search results for: flotation machines

Authors: S. Apprich, F. Wulle, A. Lechler, A. Pott, A. Verl

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Large-scale machine tools for the manufacturing of large work pieces, e.g. blades, casings or gears for wind turbines, feature pose-dependent dynamic behavior. Small structural damping coefficients lead to long decay times for structural vibrations that have negative impacts on the production process. Typically, these vibrations are handled by increasing the stiffness of the structure by adding mass. This is counterproductive to the needs of sustainable manufacturing as it leads to higher resource consumption both in material and in energy. Recent research activities have led to higher resource efficiency by radical mass reduction that is based on controlintegrated active vibration avoidance and damping methods. These control methods depend on information describing the dynamic behavior of the controlled machine tools in order to tune the avoidance or reduction method parameters according to the current state of the machine. This paper presents the appearance, consequences and challenges of the pose-dependent dynamic behavior of lightweight large-scale machine tool structures in production. It starts with the theoretical introduction of the challenges of lightweight machine tool structures resulting from reduced stiffness. The statement of the pose-dependent dynamic behavior is corroborated by the results of the experimental modal analysis of a lightweight test structure. Afterwards, the consequences of the pose-dependent dynamic behavior of lightweight machine tool structures for the use of active control and vibration reduction methods are explained. Based on the state of the art of pose-dependent dynamic machine tool models and the modal investigation of an FE-model of the lightweight test structure, the criteria for a pose-dependent model for use in vibration reduction are derived. The description of the approach for a general posedependent model of the dynamic behavior of large lightweight machine tools that provides the necessary input to the aforementioned vibration avoidance and reduction methods to properly tackle machine vibrations is the outlook of the paper.

Keywords: Dynamic behavior, lightweight, machine tool, pose-dependency.

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Authors: M. Hossain, A. Abdkader, C. Cherif, A. Berger, M. Sparing, R. Hühne, L. Schultz, K. Nielsch

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Due to the best quality of yarn and the flexibility of the machine, the ring spinning process is the most widely used spinning method for short staple yarn production. However, the productivity of these machines is still much lower in comparison to other spinning systems such as rotor or air-jet spinning process. The main reason for this limitation lies on the twisting mechanism of the ring spinning process. In the ring/traveler twisting system, each rotation of the traveler along with the ring inserts twist in the yarn. The rotation of the traveler at higher speed includes strong frictional forces, which in turn generates heat. Different ring/traveler systems concerning with its geometries, material combinations and coatings have already been implemented to solve the frictional problem. However, such developments can neither completely solve the frictional problem nor increase the productivity. The friction free superconducting magnetic bearing (SMB) system can be a right alternative replacing the existing ring/traveler system. The unique concept of SMB bearings is that they possess a self-stabilizing behavior, i.e. they remain fully passive without any necessity for expensive position sensing and control. Within the framework of a research project funded by German research foundation (DFG), suitable concepts of the SMB-system have been designed, developed, and integrated as a twisting device of ring spinning replacing the existing ring/traveler system. With the help of the developed mathematical model and experimental investigation, the physical limitations of this innovative twisting device in the spinning process have been determined. The interaction among the parameters of the spinning process and the superconducting twisting element has been further evaluated, which derives the concrete information regarding the new spinning process. Moreover, the influence of the implemented SMB twisting system on the yarn quality has been analyzed with respect to different process parameters. The presented work reveals the enormous potential of the innovative twisting mechanism, so that the productivity of the ring spinning process especially in case of thermoplastic materials can be at least doubled for the first time in a hundred years. The SMB ring spinning tester has also been presented in the international fair “International Textile Machinery Association (ITMA) 2015”.

Keywords: Ring spinning, superconducting magnetic bearing, yarn properties, productivity.

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Authors: Sidharth Talan, Devendra Kumar Yadav, Yuvraj Singh Rajput, Subhajit Bhattacharjee

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Mining industry is known for its appetite to spend sizeable capital on mine equipment. However, in the current scenario, the mining industry is challenged by daunting factors of non-uniform geological conditions, uneven ore grade, uncontrollable and volatile mineral commodity prices and the ever increasing quest to optimize the capital and operational costs. Thus, the role of equipment reliability and maintenance planning inherits a significant role in augmenting the equipment availability for the operation and in turn boosting the mine productivity. This paper presents the Risk Based Maintenance (RBM) planning conducted on mine loading equipment namely Load Haul Dumpers (LHDs) at Vedanta Resources Ltd subsidiary Hindustan Zinc Limited operated Sindesar Khurd Mines, an underground zinc and lead mine situated in Dariba, Rajasthan, India. The mining equipment at the location is maintained by the Original Equipment Manufacturers (OEMs) namely Sandvik and Atlas Copco, who carry out the maintenance and inspection operations for the equipment. Based on the downtime data extracted for the equipment fleet over the period of 6 months spanning from 1^st January 2017 until 30^th June 2017, it was revealed that significant contribution of three downtime issues related to namely Engine, Hydraulics, and Transmission to be common among all the loading equipment fleet and substantiated by Pareto Analysis. Further scrutiny through Bubble Matrix Analysis of the given factors revealed the major influence of selective factors namely Overheating, No Load Taken (NTL) issues, Gear Changing issues and Hose Puncture and leakage issues. Utilizing the equipment wise analysis of all the downtime factors obtained, spares consumed, and the alarm logs extracted from the machines, technical design changes in the equipment and pre shift critical alarms checklist were proposed for the equipment maintenance. The given analysis is beneficial to allow OEMs or mine management to focus on the critical issues hampering the reliability of mine equipment and design necessary maintenance strategies to mitigate them.

Keywords: Bubble matrix analysis, LHDs, OEMs, pareto chart analysis, spares consumption matrix, critical alarms checklist.

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Authors: Malte Brettel, Niklas Friederichsen, Michael Keller, Marius Rosenberg

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The German manufacturing industry has to withstand an increasing global competition on product quality and production costs. As labor costs are high, several industries have suffered severely under the relocation of production facilities towards aspiring countries, which have managed to close the productivity and quality gap substantially. Established manufacturing companies have recognized that customers are not willing to pay large price premiums for incremental quality improvements. As a consequence, many companies from the German manufacturing industry adjust their production focusing on customized products and fast time to market. Leveraging the advantages of novel production strategies such as Agile Manufacturing and Mass Customization, manufacturing companies transform into integrated networks, in which companies unite their core competencies. Hereby, virtualization of the process- and supply-chain ensures smooth inter-company operations providing real-time access to relevant product and production information for all participating entities. Boundaries of companies deteriorate, as autonomous systems exchange data, gained by embedded systems throughout the entire value chain. By including Cyber-Physical-Systems, advanced communication between machines is tantamount to their dialogue with humans. The increasing utilization of information and communication technology allows digital engineering of products and production processes alike. Modular simulation and modeling techniques allow decentralized units to flexibly alter products and thereby enable rapid product innovation. The present article describes the developments of Industry 4.0 within the literature and reviews the associated research streams. Hereby, we analyze eight scientific journals with regards to the following research fields: Individualized production, end-to-end engineering in a virtual process chain and production networks. We employ cluster analysis to assign sub-topics into the respective research field. To assess the practical implications, we conducted face-to-face interviews with managers from the industry as well as from the consulting business using a structured interview guideline. The results reveal reasons for the adaption and refusal of Industry 4.0 practices from a managerial point of view. Our findings contribute to the upcoming research stream of Industry 4.0 and support decision-makers to assess their need for transformation towards Industry 4.0 practices. 

Keywords: Industry 4.0., Mass Customization, Production networks, Virtual Process-Chain.

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Authors: Mehmet Altınöz

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This study focuses on bureau management technologies and information systems in developing countries. Developing countries use such systems which facilitate executive and organizational functions through the utilization of bureau management technologies and provide the executive staff with necessary information. The concepts of data and information differ from each other in developing countries, and thus the concepts of data processing and information processing are different. Symbols represent ideas, objects, figures, letters and numbers. Data processing system is an integrated system which deals with the processing of the data related to the internal and external environment of the organization in order to make decisions, create plans and develop strategies; it goes without saying that this system is composed of both human beings and machines. Information is obtained through the acquisition and the processing of data. On the other hand, data are raw communicative messages. Within this framework, data processing equals to producing plausible information out of raw data. Organizations in developing countries need to obtain information relevant to them because rapid changes in the organizational arena require rapid access to accurate information. The most significant role of the directors and managers who work in the organizational arena is to make decisions. Making a correct decision is possible only when the directors and managers are equipped with sound ideas and appropriate information. Therefore, acquisition, organization and distribution of information gain significance. Today-s organizations make use of computer-assisted “Management Information Systems" in order to obtain and distribute information. Decision Support System which is closely related to practice is an information system that facilitates the director-s task of making decisions. Decision Support System integrates human intelligence, information technology and software in order to solve the complex problems. With the support of the computer technology and software systems, Decision Support System produces information relevant to the decision to be made by the director and provides the executive staff with supportive ideas about the decision. Artificial Intelligence programs which transfer the studies and experiences of the people to the computer are called expert systems. An expert system stores expert information in a limited area and can solve problems by deriving rational consequences. Bureau management technologies and information systems in developing countries create a kind of information society and information economy which make those countries have their places in the global socio-economic structure and which enable them to play a reasonable and fruitful role; therefore it is of crucial importance to make use of information and management technologies in order to work together with innovative and enterprising individuals and it is also significant to create “scientific policies" based on information and technology in the fields of economy, politics, law and culture.

Keywords: Bureau Management, Information Systems.

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Authors: Wolfram Irsa, Lorenz Boruch

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Innovative solutions in additive manufacturing applying material extrusion for functional parts necessitates innovative filaments with persistent quality. Uniform homogeneity and consistent dispersion of particles embedded in filaments generally require multiple cycles of extrusion or well-prepared primal matter by injection molding, kneader machines, or mixing equipment. These technologies commit to dedicated equipment that are rarely at disposal in production laboratories unfamiliar with research in polymer materials. This stands in contrast to laboratories which investigate on complex material topics and technology science to leverage on the potential of 3-D printing. Consequently, scientific studies in labs are often constrained to compositions and concentrations of fillers offered from the market. Therefore, we present a prototypal laboratory methodology scalable to tailored primal matter for extruding ceramic composite filaments with fused filament fabrication (FFF) technology. A desktop single-screw extruder serves as core device for the experiments. Custom-made filament encapsulates the ceramic fillers and serves with polylactide (PLA), which is a thermoplastic polyester, as primal matter and is processed in the melting area of the extruder preserving the defined concentration of the fillers. Validated results demonstrate that this approach enables continuously produced and uniform composite filaments with consistent homogeneity. It is 3-D printable with controllable dimensions, which is a prerequisite for any scalable application. Additionally, digital microscopy confirms steady dispersion of the ceramic particles in the composite filament. This permits a 2D reconstruction of the planar distribution of the embedded ceramic particles in the PLA matrices. The innovation of the introduced method lies in the smart simplicity of preparing the composite primal matter. It circumvents the inconvenience of numerous extrusion operations and expensive laboratory equipment. Nevertheless, it delivers consistent filaments of controlled, predictable, and reproducible filler concentration, which is the prerequisite for any industrial application. The introduced prototypal laboratory methodology seems capable for other polymer matrices and suitable to further utilitarian particle types, beyond and above of ceramic fillers. This inaugurates a roadmap for supplementary laboratory development of peculiar composite filaments, providing value for industries and societies. This low-threshold entry of sophisticated preparation of composite filaments - enabling businesses creating their own dedicated filaments - will support the mutual efforts for establishing 3D printing to new functional devices.

Keywords: Additive manufacturing, ceramic composites, complex filament, industrial application.

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