Engine Maintenance Research Articles

ANALISA RISK PRIORITY NUMBER (RPN) TERHADAP KEANDALAN KOMPONEN MESIN THRESHER DENGAN MENGGUNAKAN METODE FMEA DI PT.XYZ

PT. XYZ is a palm oil factory (PKS) producing crude palm oil (CPO). PT. XYZ has not implemented an effective engine maintenance system. The maintenance system that has been implemented is corrective maintenance, which is making repairs when there is damage. In addition, it is also assisted with planned maintenance that is scheduled every week to clean production machines. Therefore it is necessary to identify machine components that are susceptible to damage (critical components) and it is necessary to take special care measures for critical machine components by implementing a predective maintenance schedule (Prevention). Simulation techniques, often known as Monte Carlo simulation, estimate reliability using sampling random scenario. Failure mode effect analisys (FMEA) is defined as a process used to determine the actions that should be taken to ensure that each physical item or a system can run properly according to the function desired by the user then based on data processing, replacement of the roller binding drum binding drum , angle iron welding, chain transmission component replacement, drum stopper bearing replacement. Replacement of the drum stopper bolt, replacement of the chain transmission part is very loose and the replacement of the iron is carried out in corrective maintenance (replacement of components after damage occurs). And the results at the lowest value on the thresher engine component are in the Loose Transmission Chain component, the repair rate is 0.5 hours and the number is 0.999737189. Based on the results of the analysis of numbers (availability), the highest number is found in Broken Elbow Iron with a repair rate of 3 hours and the number 0.999605833

Numerical and Experimental Assessment of the Effect of Residual Stresses on the Fatigue Strength of an Aircraft Blade.

The work presents the results of numerical fatigue analysis of a turbine engine compressor blade, taking into account the values of initial stresses resulting from surface treatment-shot-peening. The values of the residual stresses were estimated experimentally using X-ray diffraction. The paper specifies the values of the residual stresses on both sides of the blade and their reduction due to cutting through the blade-relaxation. The obtained values of the residual stresses were used as initial stresses in the numerical fatigue analysis of the damaged compressor blade, which was subjected to resonant vibrations of known amplitude. Numerical fatigue ε-N life analysis was based on several fatigue material models: Manson’s, Mitchell’s, Baumel-Seeger’s, Muralidharan-Manson’s, Ong’s, Roessle-Fatemi’s, and Median’s, and also on the three models of cyclic hardening: Manson’s, Xianxin’s, and Fatemi’s. Because of this approach, it was possible to determine the relationship between the selection of the fatigue material ε-N model and the cyclic hardening model on the results of the numerical fatigue analysis. Additionally, the calculated results were compared with the results of experimental research, which allowed for a substantive evaluation of the obtained results. These results are of great scientific and practical importance. The problem of determining the fatigue life of blades with defects operating under resonance vibrations is one of the original tasks in the field of fracture mechanics and experimental mechanics. The results obtained are of great importance in the aviation industry and can be used during engine maintenance and inspections to assess the suitability of blades with defects in terms of the needs of further work. This aspect of engineering maintenance is of great importance from the aircraft safety point of view.

Career Identification of Production Operators’ Position in Manufacture Industries

Graduating of Vocational High School in the manufacturing industry occupies job of production position. The demands of industrial needs are in the manufacturing sector. They want employees or labor that have told and professional competencies. Therefore, it is necessary to analyze and identify career in operator position. This study uses qualitative research. This research focuses on analysis of operator's position needs in the industry. Based on the results of the research, the work of production operators includes briefing, setting, operating, quality procedures, and engine maintenance. There are several competencies regarding the position of production operators, namely occupational health and safety, quality assurance, measuring instruments, hand tools, technical drawings, general machining, and special conditions. Production operators get salaries, which include grade-based salaries, and salary holidays. Susceptible salary obtained by production operator position gets a vulnerable salary based on the industrial area district minimum wage where he works.

OPTIMIZATION OF WORKSHOP FACILITIES IN VOCATIONAL SCHOOL TO SERVE THE PRACTICUM OF LIGHT VEHICLE ENGINE MAINTENANCE

This research is motivated by the lack of optimal practical infrastructure in vocational schools on the subject of light vehicle engine maintenance. This study aims to optimize the practice facilities at SMK PU Negeri Bandung. The method used in this research is a quantitative descriptive method with instruments of observation, interviews and documentation, then the collected data is processed statistically. The results showed that the light vehicle technique had the smallest ratio between the area of the room and the number of students among other skill competencies. The level of availability of infrastructure for an engine work area of 96 m², an electrical work area of 48 m², a chassis work area of 64 m², an instructor's room work area of 48 m² and an overall workshop area of 256 m² so that if categorized as standard workshop infrastructure at SMK PU Negeri Bandung 25% less than the standard BSNP and Permendiknas RI No. 40 of 2008. Therefore, optimization is done by making a practice schedule to increase the arrangement and use of practical infrastructure to 80%.

IMPLEMENTATION OF ONLINE LEARNING IN LIGHT VEHICLE MACHINE MAINTENANCE SUBJECTS

This study aims to determine the implementation of e-learning-based learning on the light vehicle engine maintenance lesson, through the planning aspect which includes planning supervision, implementation, and learning evaluation. This study uses quantitative descriptive method. This study took a sample of 4 light vehicle engine maintenance teachers, 32 students, and the principal. The findings of this study showed that the lesson planning which carried out by the teachers was included as good category, the implementation of e-learning-based learning was included as quite good category, the learning evaluation was included as good category, and the planning supervision that is carried out by the principal was included as very good category.

ANALISIS TROUBLESHOOTING ENGINE SEPEDA MOTOR YAMAHA VIXION

Motorcycle engine performance must always be maintained in the best condition. To maintain engine performance can be done with regular maintenance. The troubleshooting step is a reference in performing engine maintenance and repair. This study aims to perform troubleshooting analysis on the Yamaha Vixion engine. The method in this study is the removal, inspection, and reassembly of existing components based on the Yamaha Vixion manual or service manual. The results of the inspection and measurement are compared with the standards in the Yamaha Vixion manual or service manual. This method is used to determine the troubleshooting analysis on the Yamaha Vixion engine. In the component inspection step, the component measurement results are compared with the standard. The result of measuring components that exceed their standard limits or intervals means that the component has been damaged, worn, and or is not suitable for use. Therefore, components that are outside the limits or standard intervals must be repaired or if they cannot be repaired then replaced with new components. Based on the results of existing research, it can be concluded that troubleshooting is a series of systematic activities that include observing symptoms, diagnosing damage, conducting inspections and measurements on systems and components, identifying damage based on the results of inspections and measurements, and determining corrective steps if repairs must be made.

Conceptual design and structural analysis of a Ground Support Equipment for handling and maintenance of Turboshaft engines

This paper describes the application of computational modeling and computer-aided design (CAD) for the conceptual design and structural analysis of the maintenance process of Klimov TV3-117 engines at an approved Maintenance, Repair and Overhaul (MRO) facility in Colombia. The main issue is that these engines are difficult to roll and manipulate due to their weight, which ranges between 250 and 350 kg, which causes time and cost overruns for the operator, and delays in the scheduled maintenance times. The solution proposed by this study is the conceptualization and structural feasibility of a prototype of ground support equipment for handling and maintenance of Turboshaft engines, implementation of which could save up to 100 person-hours, which translates into about USD 10,000, since the current process requires four specialists and two inspectors, whereas the modified process would only require one of each

Hazardous and toxic waste standard design for temporary storage for oil and gas

One of the main activities in the oil and gas industry is the maintenance of diesel engines. There is a special process called preventive maintenance with regular oil changes. The process of changing oil is done regularly which results in B3 waste in the form of waste oil. Considering these aspects, the purpose of this research is to identify the temporary storage of petroleum waste for oil and gas based on the literature and the design of the B3 Temporary Waste Storage (TPS). The method used is descriptive qualitative methodology. The data refers to government regulations that have been made in order to create a safe, solicitous and orderly life. The results of these calculations are used as a reference in the design of the TPS, where the maximum waste capacity for the B3 Solid Waste Warehouse is 4.000 tons and for the B3 Liquid Waste Warehouse is 4.000 liters, and the building area of the B3 waste TPS is 108 m2. The layout design for new B3 waste is done based on suitability of characteristics B3 waste with a suitable building design (may combined in placing packaging waste).

Evaluation of Learning Cycle 4E-RE to Improve Chemistry Learning of Vocational High School Students

This study aimed to examine the effect of the Learning Cycle 4E-RE on the vocational school students’ chemistry learning outcomes in light vehicle engine maintenance subject. The research subjects were 164 Vocational High School (SMK) students majoring in Technology and Engineering, the Automotive Engineering expertise program, consisting of 100 students in the experimental group and 64 students in the control group. The research instrument was a learning outcome test with 30 multiple-choice items with reliability of Kuder-Richardson ρ (KR 20) = 0.837. This study used a quasi-experimental pre / posttest control group design. The mean similarity of the experimental class and the control class was tested from the pretest results using t-test statistical analysis. The research hypothesis was tested using the ANCOVA test with a significance level of 5% (0.05). The results showed that there were differences in the learning outcomes of students who were taught with the Learning Cycle 4E-RE strategy with students who were taught with verification/conventional teaching. Student learning outcomes in the experimental class were higher than those in the control class. The implication of this research is that contextual learning strategies such as the Learning Cycle 4E-RE are suitable for vocational students to improve their learning outcomes. For further research, reflection activities in a learning strategy need to be tested again using different learning strategies and chemistry topics.

The dimension indicator of the vibration signal for diagnosing gas turbine engines support bearings

This paper showcases the results of a study on the correlation dimension of the vibration signal in cases of the destruction of aviation engines support bearings. The relevance of the study is determined by the search for promising solutions to improve the maintenance of aircraft engines. It is established that the correlation dimension of the vibration signal of working and defective bearings are contrast with a significance level of 0.002. The scientific significance of the research lies in the statistical substantiation of the application of the vibration signal dimension in gas turbine engines diagnosis systems.

Digital twin–driven aero-engine intelligent predictive maintenance

Aero-engine is one of the most important components of an aircraft. The development of maintenance has undergone the transition from “post-event maintenance” and “preventive maintenance” to “predictive maintenance”, and the future development direction is precise maintenance, which aims to achieve the collaborative optimization goal of ensuring operational safety and reducing operating costs. To improve the effect of predictive engine maintenance, the aero-engine predictive maintenance framework driven by digital twin (DT) is studied, and the implicit digital twin (IDT) model is mined. The validity of the model is verified by the consistency evaluation of virtual and real data assets. Combining the data-driven with LSTM model of deep learning method and taking an aero-engine as an example can show that the method is effective. Experimental results show that when the data set used for model training is 80%, the model prediction has high accuracy, and the RMSE predicted by aero-engine RUL is 13.12, which is better than other experimental schemes.

EVALUASI PELAKSANAAN PEMBELAJARAN PEMELIHARAAN MESIN SEPEDA MOTOR KELAS XI DENGAN MODEL CIPP (CONTEXT, INPUT, PROCESS, PRODUCT) DI SMK NEGERI NGARGOYOSO

<p><em>The purpose of this research is to evaluate the implementation of motorcycle engine maintenance learning at Ngargoyoso Vocational High School. The evaluation in this study uses the CIPP model (context, input, process, product). The location of this research is in Ngargoyoso Vocational High School on learning to maintain class XI motorcycle engines with research subjects as teachers of maintenance for motorbike engines in class XI, students of class XI, and facilities. The technique of collecting data used a questionnaire that was distributed to class XI TSM A, XI TSM B, and XI TSM C and the teacher of motorcycle engine maintenance. Interview with one of the teachers, and document the final value of maintaining a XI class motorcycle engine. The validity used in this study is content validity where validation is carried out by experts. The trial of the research instrument was conducted in class XI of TSM D Ngargoyoso State Vocational School by testing the validity of using SPSS. Analysis of scores using the average to be assessed based on the assessment criteria. The results of the study show: (1) evaluation of the context (context) which includes the background of the program has been classified as good; (2) evaluation of input (input) is classified as good, input aspects include: human resources, curriculum, learning resources, and infrastructure; (3) evaluation of the process (process) which includes the process of implementing learning in classrooms and workshops is classified as good, but the aspects of the learning media used are quite sufficient so that they need to be improved. (4) Evaluation of product (product), which is the final grade of students classified as good.</em></p>

An early fault diagnosis method of common-rail injector based on improved CYCBD and hierarchical fluctuation dispersion entropy

Early fault diagnosis of common rail injectors is essential to reduce diesel engine testing and maintenance costs. Therefore, this paper proposes a new common rail injector early fault diagnosis method, which combines the Maximum Second-order Cyclostationary Blind Deconvolution (CYCBD) optimized by the Seagull Optimization Algorithm (SOA) and Hierarchical Fluctuation Dispersion Entropy (HFDE). First, we use SOA adaptively to seek the optimal filter length of CYCBD and use the optimal CYCBD to filter the fuel pressure signal of the high-pressure fuel pipe. Then, in order to make up for the shortcomings of Multi-scale Fluctuation Dispersion Entropy (MFDE) ignoring high-frequency component information, this paper proposes HFDE to extract the fault characteristics after filtering. Finally, we input the fault characteristics into Least Squares Support Vector Machines (LSSVM) for classification and recognition. Through the analysis of experimental data, the method proposed in this paper can effectively identify the early failure state of the common rail injector. Compared with the existing methods, the proposed method has a higher fault recognition rate.

Sistem Pakar Untuk Mendeteksi Kerusakan Pada Diesel Pump Dengan Metode Forward Chaining Berbasis Web

Frequent fires can occur in or like buildings of buildings or high rise buildings. The losses incurred by the fire disaster are enormous. Care and maintenance standards for diesel engine pumps must be observed. All technicians must have expertise in the maintenance and maintenance of the diesel pump engine. Such expertise can be obtained from official training conducted by the education center, reading guidelines for dealing with diesel pump engine damage obtained from diesel pump manufacturing plants and additional knowledge gained from learning while attending education and training. In this study the researchers set "Symptoms of Damage to the diesel engine of the Fire Pump" as a variable. The expert system application detects web-based diesel pump damage with a forward chaining method that has been made, after conducting an expert analysis test then testing the user's response to this expert system application, the test is carried out by consulting using this expert system application. Expert systems are components and elements that are combined into one to achieve certain goals. The system design is done after analyzing the diesel pump damage data and designing a web-based expert system. Chaining forward method is a method of inference that makes sense from a problem to a solution. Damage to the diesel pump by using the forward chaining method provides the right solution of the problem at hand. Based on these suggestions it can be concluded that an expert system detects damage to a web-based diesel pump that has been made can help all users in analyzing the problem based on consultation

Análise, processamento e prognose de falhas em motores de combustão (otto) através de vibração: aplicação de sistemas imunológicos artificiais

Este trabalho demonstra a aplicação dos sistemas imunológicos artificiais (AIS) de seleção negativa na prognose e detecção de falhas nas misturas de combustíveis. A motivação deste estudo está relacionada à manutenção de motores de combustão ciclo OTTO, cuja propriedade difere das análises físico-químicas de laboratórios especializados. Este trabalho foi dividido em fases distintas, sendo elas, a execução do experimento considerando um motor de motocicleta; a coleta de sinal e formação do banco de dados considerando o combustível de posto (500ml); o combustível de posto (500ml) com 100ml de etanol de posto; o combustível de posto (500ml) com 200ml de etanol de posto. O resultado encontrado dos diferentes sinais, após a aplicação do AIS, demonstrou com sucesso o grupamento e classificação dos sinais dos bancos de dados.

Calculation and Analysis of Overall Equipment Effektiveness (OEE) Method and Six Big Losses toward the Production of Corter Manchines in Oni Jaya Motor

One of the factors that influence the smoothness in the Production Process is the condition of the equipment or machine. Frequent jams or even the engine may stop suddenly making the readiness and reliability of the machine is not optimal, causing production losses and quality degradation. For this reason, engine maintenance becomes a very important thing to consider in order to maintain the ongoing level of productivity. Oni Jaya Motor is a company engaged in manufacturing that produces motorcycle spare parts. This company is inseparable from problems related to the effectiveness of equipment or machinery. One of the causes of disruption to the production process is due to the lack of maintenance management on the machine. To overcome this, one of the methods used to measure engine effectiveness is the Overall Equipment Effectiveness (OEE) method. Where is known the value of OEE can provide information in evaluating maintenance activities so as to minimize the occurrence of lost production and decreased quality. The results of calculations with the OEE method on Oni Jaya motorcycles are carried out on the Corter Machine and take place from January 2018 to December 2018 with the highest OEE value of 81.0%, while the lowest OEE value of 77.1%. Based on the results of data processing and identification of the six big losses, the most influential losses on the machine are set up and adjustment of 29.8%, Reduced Speed Loss of 25.6% and Breakdown Loss of 21.3%.

Automated Defect Detection and Decision-Support in Gas Turbine Blade Inspection

Background—In the field of aviation, maintenance and inspections of engines are vitally important in ensuring the safe functionality of fault-free aircrafts. There is value in exploring automated defect detection systems that can assist in this process. Existing effort has mostly been directed at artificial intelligence, specifically neural networks. However, that approach is critically dependent on large datasets, which can be problematic to obtain. For more specialised cases where data are sparse, the image processing techniques have potential, but this is poorly represented in the literature. Aim—This research sought to develop methods (a) to automatically detect defects on the edges of engine blades (nicks, dents and tears) and (b) to support the decision-making of the inspector when providing a recommended maintenance action based on the engine manual. Findings—For a small sample test size of 60 blades, the combined system was able to detect and locate the defects with an accuracy of 83%. It quantified morphological features of defect size and location. False positive and false negative rates were 46% and 17% respectively based on ground truth. Originality—The work shows that image-processing approaches have potential value as a method for detecting defects in small data sets. The work also identifies which viewing perspectives are more favourable for automated detection, namely, those that are perpendicular to the blade surface.

An Instantaneous Engine Speed Estimation Method Using Multiple Matching Synchrosqueezing Transform

Instantaneous rotational speed measurement of the engine is crucial in routine inspection and maintenance of an automobile engine. Since the contact measurement of rotational speed is not always available, the vibration measurement has been used for noncontact rotational speed estimation methods. Unfortunately, the accuracy of the noncontact estimation methods by analyzing engine vibration frequency is not satisfactory due to the influence of noise and the strong nonstationary characteristic of the vibration signal. To overcome these problems, based on the multiple matching synchrosqueezing transform (MSST) (MMSST, improved MSST with multiple squeeze operations), a novel noncontact method is proposed to accurately estimate the instantaneous rotational speed of automobile engine in this paper. Firstly, a MMSST is proposed to process the vibration signal to obtain a concentrated time‐frequency (TF) representation. Secondly, the instantaneous frequency (IF) detection algorithm is employed to extract the fundamental frequency from the TF result. Finally, the rotational speed of the engine is calculated according to the relationship between the fundamental frequency and rotational speed. Results from numerical simulations and test on real engine have proven that the proposed method can obtain much higher frequency resolution and more precise IF estimation of the engine vibration signal and more accurate rotational speed estimation result compared with the MSST method. Furthermore, the proposed method is verified to have a stronger noise robustness and can provide satisfactory estimation results for engine vibration signal containing nonlinear frequency‐modulated components.

Use of Technological Diagnosis in Rail Vehicle Engines Maintenance

Abstract The paper aims to classify the maintenance of internal combustion engines in 812 series diesel multiple units, to analyse operating failures, and to identify methods and procedures for determining their current mechanical condition. The paper specifies the required procedures and methods for maintenance starting from the development of the DMU (diesel multiple units) 812 series to the present. It also focuses on understanding how diagnosis and control sensors are attached in individual cable harnesses. A protocol for diagnosing combustion engine defects is proposed in the final part of the paper. A part of the paper is a proposed list of codes for individual faults to facilitate the work. Another method proposed within this paper is the definition and attachment of individual sensor connections on the engine in the EDC (Electronic Diesel Control) M(S) 5 cable harness. Faults leading to engine stop are identified.

Improving the efficiency of maintenance of heavy-duty engines

The paper deals with the issue of improving the efficiency of heavy-duty engines by restoring worn parts. The influence of the reserve of spare parts on the reliability of the engines is determined. It is proposed to carry out maintenance on centralized bases that serve several auto enterprises. Established: the method of replacing worn elements will reduce the number of engine overhauls.