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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
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 978-83-63500-95-5 Copyright by Sekcja Wydawnictw Wydziału Zarządzania Politechniki Częstochowskiej Częstochowa 2014 Sekcja Wydawnictw Wydziału Zarządzania Politechniki Częstochowskiej, 42-200 Częstochowa, al. Armii Krajowej 36 B tel. 34 32 50 480, 32 50 859 e-mail: wyd.wz@zim.pcz.czest.pl Wydanie B5. Nakład 100 egz. 3
Table of Contents Introduction... 1. DIAGNOSTIC MONITORING OF ELEMENTS AND STRUCTURES OF THE SPECIAL PURPOSE VEHICLE.... 9 1.1. Introduction.......... 9 1.2. Analysis of the characteristic features of the selected special purpose vehicle..... 10 1.2.1. Analysis of the regulations relating to the vehicles for the transport of horses... 10 1.2.2. Structural elements, characteristic of the vehicles for the transport of horses...... 12 1.2.3. Areas of the object requiring diagnostic monitoring... 13 1.3. Proposals of exemplary solutions for diagnostic monitoring of elements and structure of the vehicle for the transport of horses..... 14 1.4. Summary..... 17 2. THE METHODOLOGY OF THE DESIGN OF THE DIAGNOSER OF BRAKING MECHANISMS USING MODELLING TECHNIQUES..... 19 2.1. Introduction.. 19 2.2. The methodology of the process of diagnosing the hydraulic circuit of the working brake in motor vehicles..... 20 2.3. Summary........ 32 3. RESEARCH ON VIBRATIONS OF FRICTION LININGS OF THE CAR BRAKING MECHANISM.... 33 3.1 Introduction.......... 33 3.2. Elements of traffic safety....... 34 3.3. Modeling the dynamics of vibrations of braking system... 36 3.4. New solution for the disc braking system... 41 3.5. Elements of the disc braking systems...... 42 3.6. Braking force test.... 43 3.7. Summary..... 45 4. ASSESSMENT OF TECHNICAL CONDITION OF THE CAR BRAKING MECHANISM IN THE PROCESS OF OPERATION........ 46 4.1. Introduction..... 46 4.2. Analysis of the vehicle braking process... 47 4.2.1. Real and theoretical braking distance. 48 4.2.2. Driver's reaction time.. 51 4.2.3. Dependence of the braking distance on changes in coefficient of adhesion.. 52 4.3. Stability analysis of the car movement.......... 54 4.4. Braking performance conditions...... 59 4.5. Maintenance of the braking system. 61 4.5.1. Brakes with hydraulic actuating mechanism.. 62 4.5.2. Brakes with air actuating mechanism. 69 4.6. Equipment for diagnosing and servicing. 70 4.7. Summary.. 75 7
5. OPERATION AND EVALUATION OF WORKING MECHANISMS OF RAILWAY VEHICLES....... 76 5.1. Introduction.... 76 5.2. Braking systems in rail vehicles.. 78 5.3. Diagnostic techniques in passenger wagons.... 82 5.4. Devices for diagnosing braking systems. 83 5.5. Vehicles with brake diagnosing system... 90 5.5.1. Prima II locomotive (Alstom). 90 5.5.2. Upgraded EN57 unit 92 5.5.3. St45 locomotive... 93 5.5.4. EMV vehicle by KONCAR. 95 5.5.5. ATR 220 rail vehicle..... 96 5.6. Summary.. 97 6. METHODS FOR DETECTING UNDESIRABLE OBJECTS ON THE CONVEYOR BELT.... 99 6.1. Introduction.. 99 6.2. The impact of difficult minerable deposits in the open pit mining.. 100 6.3. Methods applied in opencast mining... 100 6.4. Sorting system applied in the industry. 102 6.5. Summary.. 108 7. DIAGNOSIS OF TECHNICAL EFFICIENCY OF CONVEYOR BELTS. 109 7.1. Introduction....... 109 7.2. Supervision of safety at work at conveyors belts... 109 7.3. Analysis and reduction of risk. 111 7.4. Concept and structure of the conveyor belt monitoring system... 114 7.5. Developing own mechatronic stone detection system 116 7.6. Methods of eliminating undesirable objects from the conveyor belt.. 118 7.7. Summary.. 118 8. TECHNICAL METHODS ENSURING THE CORRECT OPERATION OF SILOS FOR BULK MATERIALS PRONE TO DEVELOPING BUILD-UPS AND BLOCKAGES..... 119 8.1. Introduction.. 119 8.2. Methods for cleaning silos from consolidated material 120 8.2.1. Methods using compressed air. 120 8.2.2. Method using magnetic field... 126 8.2.3. Method using sound waves. 127 8.2.4. Method using carbon dioxide.. 130 8.3. Control of material moving in a silo... 132 8.3.1. Measurement of levels of bulk materials in silos 132 8.3.2. Measurement of bulk materials flowing out of silos.. 136 8.4. System for flow blockage control... 137 8.5. Summary.. 139 5
9. SELECTION OF THE OPTIMUM TOOTH PROFILE FOR PLASTIC CYCLOIDAL GEARS... 140 9.1. Introduction..... 140 9.2. Geometry of the gear set in the G-rotor pump 141 9.3. Principle of the operation of cycloidal gears in the G-rotor hydraulic machine.... 143 9.4. The research program and selection of parameters for the numerical analysis 144 9.5. Calculation model of the G-rotor gear set 146 9.6. Numerical analysis results 148 9.7. Summary.. 151 10. DIAGNOSTICS OF THE TECHNICAL CONDITION OF HIGH-POWERED INDUSTRIAL MACHINERY... 154 10.1. Introduction.. 154 10.2. Diagnostics of mechanical vibrations.. 155 10.3. Inspection of the technical condition of electrical machines.. 155 10.4. Impact of mechanical vibrations on the man and the environment in the man - machinery environment system. 161 10.5. Summary.. 162 11. APPLICATION OF ACOUSTIC SIGNALS FOR DIAGNOSING THE CONVEYOR DRIVE UNIT IN THE BUCKET -WHEEL EXCAVATOR - CASE STUDY...... 164 11.1. Introduction... 164 11.2. Problem formulation.. 165 11.2.1. Noise hazard assessment.. 166 11.2.2. Results of the noise hazard assessment... 169 11.2.3. Diagnosis - technical condition assessment 170 11.2.4. Results of the technical condition assessment... 171 11.3 Summary.. 175 12. DIAGNOSTIC EVALUATION OF THE ELECTRIC DRIVE OF MINING MACHINERY AND EQUIPMENT... 176 12.1. Introduction.. 176 12.2. Research methodology.... 177 12.3. Analysis of the tests results.... 183 12.4. Summary... 184 CONCLUSIONS.. 185 REFERENCES. 187 LIST OF FIGURES.. 197 LIST OF TABLES.... 201 ABOUT THE AUTHORS.... 202