DIAGNOSIS OF WORKING MECHANISMS IN MACHINERY AND EQUIPMENT

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2 Czestochowa University of Technology Faculty of Management DIAGNOSIS OF WORKING MECHANISMS IN MACHINERY AND EQUIPMENT MODELLING DESIGNING ASSESSMENT OF THE CONDITION MONOGRAPH SCIENTIFIC EDITOR Adam IDZIKOWSKI Czestochowa 2014

3 Reviewers: Prof. dr hab. inż. Zbigniew Kłos Prof. dr hab. inż. Franciszek Przystupa Scientific editor Dr inż. Adam Idzikowski Technical editor Agnieszka Grabara Cover design Marcin Pilarski Authors: Adam IDZIKOWSKI, Joanna CYGANIUK chapter 2 Agnieszka PUSTUŁKA chapter 7 Agnieszka PUSTUŁKA, Adam IDZIKOWSKI chapter 6 Bogdan ŻÓŁTOWSKI, Mariusz ŻÓŁTOWSKI chapter 4 Bogdan ŻÓŁTOWSKI, Mariusz ŻÓŁTOWSKI chapter 5 Bogdan ŻÓŁTOWSKI, Piotr STANOWSKI, Mariusz ŻÓŁTOWSKI chapter 3 Joanna CYGANIUK, Adam IDZIKOWSKI chapter 8 Krzysztof BIERNACKI chapter 9 Marek SOKOLSKI chapter 11 Patrycja GAJDA chapter 10 Piotr SOKOLSKI chapter 12 Piotr STRYCZEK chapter 1 ISBN Copyright by Sekcja Wydawnictw Wydziału Zarządzania Politechniki Częstochowskiej Częstochowa 2014 Sekcja Wydawnictw Wydziału Zarządzania Politechniki Częstochowskiej, Częstochowa, al. Armii Krajowej 36 B tel , wyd.wz@zim.pcz.czest.pl Wydanie B5. Nakład 100 egz. 3

4 Table of Contents Introduction DIAGNOSTIC MONITORING OF ELEMENTS AND STRUCTURES OF THE SPECIAL PURPOSE VEHICLE Introduction Analysis of the characteristic features of the selected special purpose vehicle Analysis of the regulations relating to the vehicles for the transport of horses Structural elements, characteristic of the vehicles for the transport of horses Areas of the object requiring diagnostic monitoring Proposals of exemplary solutions for diagnostic monitoring of elements and structure of the vehicle for the transport of horses Summary THE METHODOLOGY OF THE DESIGN OF THE DIAGNOSER OF BRAKING MECHANISMS USING MODELLING TECHNIQUES Introduction The methodology of the process of diagnosing the hydraulic circuit of the working brake in motor vehicles Summary RESEARCH ON VIBRATIONS OF FRICTION LININGS OF THE CAR BRAKING MECHANISM Introduction Elements of traffic safety Modeling the dynamics of vibrations of braking system New solution for the disc braking system Elements of the disc braking systems Braking force test Summary ASSESSMENT OF TECHNICAL CONDITION OF THE CAR BRAKING MECHANISM IN THE PROCESS OF OPERATION Introduction Analysis of the vehicle braking process Real and theoretical braking distance Driver's reaction time Dependence of the braking distance on changes in coefficient of adhesion Stability analysis of the car movement Braking performance conditions Maintenance of the braking system Brakes with hydraulic actuating mechanism Brakes with air actuating mechanism Equipment for diagnosing and servicing Summary

5 5. OPERATION AND EVALUATION OF WORKING MECHANISMS OF RAILWAY VEHICLES Introduction Braking systems in rail vehicles Diagnostic techniques in passenger wagons Devices for diagnosing braking systems Vehicles with brake diagnosing system Prima II locomotive (Alstom) Upgraded EN57 unit St45 locomotive EMV vehicle by KONCAR ATR 220 rail vehicle Summary METHODS FOR DETECTING UNDESIRABLE OBJECTS ON THE CONVEYOR BELT Introduction The impact of difficult minerable deposits in the open pit mining Methods applied in opencast mining Sorting system applied in the industry Summary DIAGNOSIS OF TECHNICAL EFFICIENCY OF CONVEYOR BELTS Introduction Supervision of safety at work at conveyors belts Analysis and reduction of risk Concept and structure of the conveyor belt monitoring system Developing own mechatronic stone detection system Methods of eliminating undesirable objects from the conveyor belt Summary TECHNICAL METHODS ENSURING THE CORRECT OPERATION OF SILOS FOR BULK MATERIALS PRONE TO DEVELOPING BUILD-UPS AND BLOCKAGES Introduction Methods for cleaning silos from consolidated material Methods using compressed air Method using magnetic field Method using sound waves Method using carbon dioxide Control of material moving in a silo Measurement of levels of bulk materials in silos Measurement of bulk materials flowing out of silos System for flow blockage control Summary

6 9. SELECTION OF THE OPTIMUM TOOTH PROFILE FOR PLASTIC CYCLOIDAL GEARS Introduction Geometry of the gear set in the G-rotor pump Principle of the operation of cycloidal gears in the G-rotor hydraulic machine The research program and selection of parameters for the numerical analysis Calculation model of the G-rotor gear set Numerical analysis results Summary DIAGNOSTICS OF THE TECHNICAL CONDITION OF HIGH-POWERED INDUSTRIAL MACHINERY Introduction Diagnostics of mechanical vibrations Inspection of the technical condition of electrical machines Impact of mechanical vibrations on the man and the environment in the man - machinery environment system Summary APPLICATION OF ACOUSTIC SIGNALS FOR DIAGNOSING THE CONVEYOR DRIVE UNIT IN THE BUCKET -WHEEL EXCAVATOR - CASE STUDY Introduction Problem formulation Noise hazard assessment Results of the noise hazard assessment Diagnosis - technical condition assessment Results of the technical condition assessment Summary DIAGNOSTIC EVALUATION OF THE ELECTRIC DRIVE OF MINING MACHINERY AND EQUIPMENT Introduction Research methodology Analysis of the tests results Summary CONCLUSIONS REFERENCES. 187 LIST OF FIGURES LIST OF TABLES ABOUT THE AUTHORS