Machine Breaks Research Articles

Design and Analysis of an Automatic Shell Cracking Machine of Metohuayo (“Caryodendron orinocense Karst”) with a Capacity of 50 kg/h

This article presents the design and analysis of an automatic shell broken machine of seeds of Metohuayo (“Caryodendron orinocense Karst”) with a production capacity of 50 kg/h, considering manufacturing and maintenance of local facilities. Metohuayo is the fruit of a tree that grows in various jungle areas of Perú, and the Metohuayo oil is very requested because of its nutritional properties. Starting with these specifications, the design was developed according to the systematic approach established by the VDI-2221 standard, with seven basic steps to analyze the optimum design. Once the definitive project was reached and the commercial components were selected, finite element simulations were performed to analyze the strength of the shell broken system and to evaluate the strength and the dynamic response of the structural support of the machine components. Additionally, complementary experimental studies were performed, such as the analysis of the required force to break the shell or the measurement of their dimensions.

Microstructure and Mechanical Properties of the Wire Arc Additively Manufactured Sv-08G2S Steel

Wire arc additive manufacturing enables using almost any grade of metal for the additive production of parts with complex shapes and large sizes. As an increasingly growing number of materials are being used for WAAM, it is necessary to conduct systematic research on the properties of various metals and alloys. This article presents a study of the microstructure and mechanical properties of the wire arc additively manufactured Sv-08G2S steel. Once the wall-shaped sample was deposited, it was cooled in the air at room temperature. The sample for microstructure studies was cut across the central line of the deposited layers. In the sample, three sectors were conditionally distinguished: the lower sector, deposited on a cold substrate, has a ferrite structure with inclusions of lamellar perlite; the middle sector has a purely ferritic structure; the upper sector has a bainite structure. The microstructure study was followed by hardness measurements performed in all sectors of the sample. The hardness values confirmed the presence of different structures in all sectors, the hardest of which was the upper sector with a bainite structure. The last stage of the study was the tensile testing of the sample performed on a test breaking machine. The obtained values of the ultimate tensile strength and yield strength of additively deposited steel are within the range and even exceed the characteristics of wrought low-carbon steels. Therefore, the conducted research proved that the additive manufacturing of parts made of Sv-08G2S steel enables achieving the necessary quality and provides the mechanical properties required for structural steels.

A Manifesto for the Broken Machine

This article reveals how conservative and alt-right understandings of technology are inextricably tied to how these ideologies conceptualize gender, race, and other forms of social difference. Feminists, the gender nonconforming, queer, nonwhite, and the rest of the non-abiding are cast off as broken technologies that need to be replaced and discarded. Using a techno-feminist approach, this article argues that rather than seek justice through inclusion or improvements in representation, there is a feminist politics up for grabs in this patriarchal formulation of feminists as broken machines. The piece offers a manifesto for the “Broken Machine,” revealing how power operates with a machinelike quality and can therefore offer feminism the possibility to refuse via the disruptive logics of broken technologies.

Analysis Improvement Production Process Of Making Joint Care Air Filter Mitsubishi (Cjm) With Overall Equipment Effectiveness And Six Big Losses

The performance measurement studies have been performed the method of Overall Equipment Effectiveness. To know the losses that occur in the production process is carried out by the methods of analysis of the Six Big Losses. To find out the cause dominant done with fishbone diagrams, Nominal Group Technique and scatter diagram. The results will be the basis of recommendation improvements to decrease downtime and increase the value of the effectiveness of the company’s production machine by performing the calculation of OEE after repair. Objects are examined in this research is the engine Room Temperature Oven Curring for CJM air filter production process. The data used is data one year i.e. January 2017–December 2017 retrieved value Overall Equipemnt effectiveness. Value does not meet the ideal of OEE that is above 85%, machine down time occurs high in February 2017. The results of availability ratio between 66.29%-98.91% derived from the calculation of the loading time for the month of january of 314 hours and the factor cause downtime is machine break, trouble dies, material delay, delay forklifts and set up the operation, calculation time for the month of january 2017, this happens because the speed of production machines is not working optimally.

Rescheduling of unrelated parallel machines with job-dependent setup times under forecasted machine breakdown

ABSTRACT We address a rescheduling problem of unrelated parallel machines with job-dependent setup times where a machine breakdown is known in advance. Typical rescheduling methods usually re-assign or re-sequence jobs from a given schedule after machines break down. Recently, machine breakdowns can be forecasted with high accuracy before their actual occurrences from IoT sensors or artificial intelligence methods. We therefore define a new rescheduling problem in which jobs are re-assigned before machine breakdowns occur, and propose a mathematical programming model with three objective measures, makespan, stability and penalty cost. We then develop a simulated annealing (SA) algorithm combined with a fuzzy logic controller for adjusting the parameters in SA. We demonstrate the performance of the proposed algorithm with extensive experiments.

Corrosion state of oil cracking reactors as the main factor of fire and explosion safety during their operation

The corrosion and mechanical properties of the oil catalytic cracking reactor vessel made of stainless steel Y1-T (1X18N9T) after its operation for more than 60 years have been determined. The chemical composition of the reactor metal meets the requirements of GOST and involves the isolation of non-metallic inclusions of manganese sulfide in its structure, which cause the development of pitting, and chromium carbides, which are responsible for the propensity to intergranular corrosion. After long-term operation, the mechanical characteristics of the metal (tensile strength σb, yield strength σt, elongation δ, relative contraction Ψ), determined using cylindrical samples at a temperature of 20 °C (GOST 1497-84) and at an operating temperature of 465 °C (GOST 9651), on the breaking machine TC 110M-50, correspond to the standard values. Metallographic studies carried out using an optical microscope “Axio Observer Z1m « at magnifications of X25, X75, x125, X200, X250, X400, X500, x1000, X2000 showed that long – term operation of the metal at a temperature of 375…425 °C with periodic overheating up to 550…650 °C leads to the release of excess phases, namely, chromium carbides and titanium carbonitrides. The metal grain boundaries are enriched with Cr23C6 carbides, which cause a loss of resistance against intergranular corrosion. Corrosion pitting and weakened metal grain boundaries are promoters of the occurrence of corrosion cracks. The most dangerous areas of large-size equipment are welded joints and zones of thermal influence. A mandatory condition for fire and explosionproof operation of the refinery is periodic diagnostics of the corrosion state of the equipment in order to identify and timely eliminate potentially dangerous areas, the probability of which breaching with subsequent spillage and fire of oil and petroleum products is the highest.

Application of powder from alloy of brass L63, in the composition of elastomeric composite, for increasing the tension sensitivity coefficient

The range of rubber-cord products used in industry is quite wide. Their design includes determination of parameters during calculation and subsequent tests confirming their reliability, operability and properties. It is equally important to assess the stress-strain state (VAT) of a structure during operation, which allows to understand the accident rate, make a timely decision, collect statistics for effective development of new structures and improvement of old ones. The VAT control methods offered today have a number of drawbacks: the short service life of measuring and sensing elements, their introduction of errors in the operation of the structure, and often the inability to measure, for example, when working in aggressive media. The aim of the work is to evaluate the possibility of using brass powder L63, obtained by high-speed processing, in the elastomeric composite. To achieve the set goal it is necessary to solve the following problems: to make samples from the mixture with the addition of powder L63 and without it; to compare the samples from the received mixtures on the strain-sensitivity coefficient; to compare the samples from the specified mixtures in the process of mechanical loading on the breaking machine with simultaneous registration of electrical resistance. The results: Studies were conducted on the possibility of using ultra-dispersive powder L63 to improve the electrical properties of rubber. It has allowed to increase the coefficient of strain-sensitivity in 5-7 (in comparison with classical electroconductive rubbers), keeping their mechanical properties. Sensitive elements made of such a rubber mixture will give an opportunity to create “smart” composites, as well as to control the stress-strain state. Based on the results of these studies, the Act of Implementation has been issued.

An experimental study of a novel liquid carbon dioxide rock-breaking technology

Safely and high-efficiently breaking rock is of practical significance. In some engineering, explosive blasting may be restricted for its side effects. Traditional non-explosive methods like demolition agent and rock breaking machine are generally time-consuming. Therefore, this study proposes a novel liquid carbon dioxide rock-breaking technology and designs the relative device. The effectiveness, safety and high-efficiency of the proposed technology are investigated by shock pressure test, vibration site test and field rock breaking experiment. The experimental results show that the duration of the monitoring shock pressure is around 1500 μs. The shock pressure signal of liquid carbon dioxide tube breaking in free condition contains four stages, namely, increasing exponentially, decreasing oscillatory, stabilization, and negative pressure stage. As pressure sensor is set at 850 mm from the test tube radially, the shock pressure monitored increases to the maximum value of 115.7 kPa within 6 μs. During the liquid carbon dioxide rock breaking, the vertical component of the peak particle velocity of vibration is 173 mm/s, 85 mm/s and 35 mm/s along distance at 1.5 m, 2.5 m and 3.5 m from the tube, respectively. The Fourier power spectra results show that about 85% energy distributes at 6–60 Hz. The vibration caused by the novel technology can meet the requirement of mainstream blasting safety criteria better than that of explosive blasting. Finally, the technology is successfully applied in rock excavation at a metro station construction site. The proposed liquid carbon dioxide rock-breaking technology is preliminarily demonstrated to be safer than explosive blasting and more efficient than traditional non-explosive techniques.

A Novel Negative-Sequence Current Injection Method for Reducing LVPMM Electromagnetic Thrust Ripple Considering Static Longitudinal End Effect

The thrust force ripple of a linear motor includes positioning force and electromagnetic thrust ripple. Compared to the conventional rotary motor, linear vernier permanent magnet machines (LVPMM) break at both ends, leading to three-phase asymmetry. This article focuses on the elimination of the electromagnetic thrust ripple caused by the special structure of the LVPMM, and an asymmetrical current control strategy using in power grids is introduced to the drive system. However, unlike power grids working at a fixed frequency, the drive system of the LVPMM needs variable speed operations, and some improvements are made to the original method. High bandwidth of current loop is guaranteed, and the stability of the control system is achieved with the proposed method. Experimental results obtained are presented. It verifies that the asymmetrical current control strategy reduces electromagnetic thrust ripple by more than 67%.

Machine Cell Formation for Dynamic Part Population Considering Part Operation Tradeoff and Worker Assignment Using Simulated Annealing based Genetic Algorithm

In this study, an integrated mathematical model for the cell formation problem is proposed considering the dynamic production environment. The proposed model yields, manufacturing cells, part families and worker's assignment simultaneously by allowing a cubic search space of 'machine-part-worker' in the CMS. The resources are aggregated into manufacturing cells based on the optimal process route among the user specified multiple routes. The model interprets flexibility in the processing of subsets of a part operation sequence in the different production mode (internal production/subcontracting part operation). It is a tangible advantage during unavailability of worker and unexpected machine break down occurring in the real world. The proposed cell formation problem has been solved by using a simulated annealing-based genetic algorithm (SAGA). The algorithm imparts synergy effect to improve intensification, diversification in the cubic search space and increases the possibility of achieving near-optimum solutions. To evaluate the computational performance of the proposed approach the algorithm is tested on a number of randomly generated instances. The results substantiate the efficiency of the proposed approach by minimising overall cost. [Received: 17 August 2018; Accepted: 28 July 2019]

Вплив типу в'язального обладнання на показники втрати міцності поліетиленових та параарамідних ниток після в'язання

This article presents the results of a study of the effect of type of knitting equipment on the loss of strength of high molecular weight polyethylene (PE) and para-aramid (PA) filaments after knitting, as well as when combined in the process of knitting with a metal monofilament. Samples of knitted fabrics are made by interlacing the cooling surface on two types of flat-knitting equipment of the 8th class: the flat-type machine PVRK and the glove machine PA-8-33 (RA). In the process of knitting, the length of the thread in the loop remained the same (l = 8.9mm). In accordance with the existing methodology, the value of the breaking load and the elongation of the yarns before and after knitting on the KaoTieh KT-7010AZ breaking machine was established. To estimate the loss of thread strength after knitting, the use factor of strength, which is the ratio of the strength of the thread after and before knitting, was used. As a result of the experiment, it is found that the coefficient of PA strength of the yarn of knitwear samples without introduction into the metal monofilament structure, in comparison with PE, increases regardless of the type of knitting equipment. When introduced into the structure of a metal monofilament, regardless of the type of knitting equipment, the coefficient of PA strength of the filament compared to the PE increases. Thus, the PE filaments, when processing them into the structure of knitwear, weave loosening, to a greater extent, lose their strength, which is explained by the peculiarities of the original polymer. PE filaments are more sensitive to elongation at power loads and destruction of individual fibers due to interaction with the metal monofilament. This causes a greater loss of strength in the knitting process of the PE thread itself, which by its structure is a multifilament non-twisted thread. The characteristics of the loss of strength of high-molecular-weight polyethylene and para-aramid threads obtained in the structure of the knit fabric knit fabric, obtained in the course of the researches, give the opportunity to form the specified properties of knitwear in the final product. Keywords : tensile load, tensile elongation, strength factor, loss of strength, high strength raw material, high molecular weight polyethylene filament, para-aramid filament, metallic monofilament.

Застосування двопівперіодного підсилюючого випрямляча напруги без діодів на операційних підсилювачах у автоматизованій системі випробувань на розривній машині

The article discusses the problem of transformation of measuring signal of differential transformer converter of universal testing machines for further processing by microprocessor controller. In order to automate the testing process, it is necessary to collect, process and transmit the measured data to an automated workplace using a microprocessor controller. Due to the fact that usually the secondary windings of the differential transformer converters produce an alternating voltage of very small magnitude, such a measurement signal cannot be processed with the help of modern microprocessor controllers without conversion. Since the analog-to-digital converter of the microprocessor controller cannot operate with alternating voltage, it becomes necessary to rectify and amplify the measuring signal. For low voltages (less than 0.6 V), the use of conventional resistor-diode rectifiers becomes impossible and there is a need for other methods of rectifying alternating current. It is proposed to use full-wave active rectifiers without diodes on operational amplifiers for conversion of the measuring signal of differential transformer converters, the main disadvantages of diode rectifiers and advantages of rectifiers on operational amplifiers are considered. The biggest advantage of a rectifier proposed for use in an automated testing system is the ability to simultaneously rectify and amplify the measurement signal with the required precision, allowing it to be processed by most modern microprocessor controllers. For the first time, an automated testing system on a tensile machine was developed using an active full-wave voltage rectifier on operational amplifiers without the use of diodes. The circuit shown in the article makes it possible to convert the signal of a differential transformer converter for further processing using the Arduino microcontroller platform. An amplifying active full-wave voltage rectifier without diodes on operational amplifiers can be used to modernize testing or measurement equipment containing a differential transformer transducer of a measuring signal. The developed electrical circuit of the rectifier was applied to automate the process of testing on the breaking machine of model P-0.5. Keywords: differential transformer converter, operational amplifier, rectifier, measuring signal converter, tensile testing machine, automated test system.

Obtención de un aglomerado para material de construcción a partir de un adhesivo obtenido de viruta de wet blue del proceso del curtido de pieles.

La industria del curtido de pieles produce una cantidad grande de aguas residuales y desperdicios sólidos que contienen una cantidad significativa de cromo, la viruta de wet blue es un material particulado sólido microcolagenosas impregnado con grasa y aceite sintético de cromo y agentes curtientes. El objetivo del estudio fue investigar la producción de un aglomerado a partir de un adhesivo obtenido de la viruta de wet blue producida mediante hidrólisis alcalinaa 60°C de temperatura, 0.4N de NaOH y 4 hrs. para la neutralización. Para la obtención del aglomerado se utilizó 2 Kg de aserrín de 1mm de madera de ébano el que secó a 105 °C por 4 horas, posteriormente se realizó un mezclado manual en dos proporciones; 125 gr de adhesivo y 250 gr de aserrín (0.5/1), y una segunda proporción de 250gr de adhesivo y 250 gr de aserrín (1/1), las mezclas se realizaron por 20 minutos a temperatura ambiente, el prensado fue al frio a 100kg/ cm2, en moldes de acero inoxidable para evitar que se pegue el aglomerado, las muestras permanecieron en la prensa por 2 hrs., terminado el prensado las muestras fueron expuestas al medio ambiente en un lugar con incidencia solar, donde permanecieron en el molde por las siguientes 48 hrs. Al culminar este tiempo las muestras se retiraron del molde para ser expuestas al sol por 5 días, el aglomerado obtenido fue sometido a pruebas mecánicas tales como la resistencia a la compresión en una máquina de ruptura universal de acuerdo a la norma DIN 68763 para “tableros planos de partículas para uso en conceptos de construcción de edificios, requisitos, pruebas e inspección”, también fueron sometidos a la prueba de conductividad térmica de acuerdo a la norma ASTM C-177 en un gradiente térmico emitido por una plancha de 1200 watts, midiendo la temperatura pasante cada 5 minutos, y la Prueba de densidad aparente de acuerdo a la norma DIN 68763. Los resultados mostraron en las pruebas de conductividad térmica que la mezcla 1/1 (250gr de adhesivo y 250 gr de aserrín),presentó menor promedio que la norma ASTM C-177 (0.28W/m.K) con un promedio de 0.22 W/m.K, además esta mezcla presentó mayor resistencia a la compresión que la norma DIN 68763 (175Kgf/m2) con un promedio de 291.57 Kgf/m2, demostrando ser un aglomerado muy resistente para construcción y representando una solución ecoamigable para la disposición final de la viruta wet blue, del proceso del curtido de pieles.

Parallel and Distributed Powerset Generation Using Big Data Processing

ABSTRACTData mining algorithms are more important today as it allows stakeholders to get a 360-degree view of their customers. Recently, powerset has become the basic core for many algorithms and techniques in different data mining domains as it provides optimal solutions for many problems in data mining. Nevertheless, it is challenging to be used in several instances because the complexity of powerset grows exponentially with the number of sets. Constructing powerset from huge datasets on a single machine causes an out-of-memory exception. So, from a business perspective in mega data projects, the enterprise companies need to invest a lot of money to build high-performance system infrastructure of powerset. Also, enterprise companies have to invest more money to build a standby system to keep the system alive if the high-performance machines break down. Furthermore, the existing powerset techniques are designed for structured data and not useful in intensive processing using in-memory unstructured data store. Thus, this paper tackles most problems that hinder deploying powerset algorithm toward Big Data and presents a series of pruning techniques that can greatly improve construction efficiency of powerset generation. The approach allows enterprise companies to explore huge data volumes and gain business insights into near-real-time and save the cost of infrastructure.

Models of Longitudinal Collision of Bars with Nonparallel Faces

A model of the longitudinal collision of bars having nonparallel impact faces proposed by V. B. Sokolinsky, in which the contact characteristic is described by a quadratic dependence, is considered. Longitudinal stresses in bars correspond to experimental data only at the angles of impact faces being offset less than 0.5°. At angles greater than 1°, the discrepancy between the theoretical and experimental results reaches 20%. The obtained values of the moment at faces of the bars do not correspond to the experiment. A model is proposed, where stress distribution along the radius of the contact surface of bars obeys a linear law. The dependence of contact forces and the moment at faces of bars on the angle of impact faces offset and their local contact deformations is obtained. The changes in longitudinal stresses with time are determined in bars. This model gives the results closer to the experiment in comparison with V. B. Sokolinsky’s model and can be used to estimate the maximum allowable angles of the impact faces offset when designing and operating percussion systems of drilling and breaking machines.

Модернизация упаковки для молока с заменой алюминиевой фольги металлизированным полиэтиленом

В статье рассматривается перспективное направление исследований в области производства комбинированных упаковочных полимерных материалов, используемых для упаковки молока и молочной продукции, состоящих из полиэтилена низкой плотности и бумаги, модернизации комбинированного материала на основе фольги металлизированным полиэтиленом, направленная на улучшение адгезионного взаимодействия между бумагой и полиэтиленом. Металлизированные пленки экономичнее алюминиевой фольги и имеют целый ряд технологических преимуществ: уменьшение массы пленочного материала, исключение повреждений металлического слоя при изгибах материала. Показано, что замена фольги на металлизированный полиэтилен при относительно небольших затратах повысит качество готового изделия. Для изучения комбинированных материалов с металлизированным слоем использовались следующие методы. Сравнительную характеристику полученных материалов проводили световой микроскопией. Для количественной оценки прочности сварного соединения, получаемого методом тепловой сварки, использовали прибор для определения прочности сварного шва РМ-50. Определение массы материала на 1 м2 проводили методом согласно ТУ 5456-198-00419785-99. Выяснили, что металлизированные пленки имеют наименьшее количество дефектов по сравнению с фольгированным материалом, что обеспечивает улучшение свойств пленок: проницаемости к свету, воде и кислороду, увеличению прочности, а так же уменьшение плотности.

Macroergonomics Conceptual Assessment of a Local SME in Banda Aceh using Causal Loop Diagram (CLD) and System Archetype: a Case Study in Banda Aceh

Macroergonomics is a sociotechnical approach that sees the relationship between one element and another in optimizing a work system. MP is one of Small Medium Enterprse (SME) that produces perfume in Banda Aceh, it often experiences work system problems such as uncomfortable physical environment, a small workstation, tentative work schedule and a work demand, broken machine and lack of skilled human. In order to reduce the problems found in this SME, macroergonomics approach is implemented to improve the work system by selecting important elements based on macroergonomics factor and elements. The result consists of 15 elements are the most influential element and analyzed to find the relationship of one variable to another by using system thinking or the Causal Loop Diagram (CLD). The result are success to the successful and fix that fail system archetype were obtained from the final CLD and interview. The result shows that, SME must spent macroergonomics investment by giving a training to the employees therefore they can understand and capable in manufacturing technology and tools, and decrease the number of evaluation, from twice a day becomes once a day and once a week for meeting.

A Study on the Breaking and Winnowing Machine for Cocoa Beans at Small Industrial Scale in Vietnam

In the chocolate or cocoa powder processing process, the roasted cocoa beans have to pass to the breaking and winnowing step to obtain the nibs. The quality of chocolate or cocoa powder depends strongly on the amount of shell that is not separated and still mixing on the nibs. Recently, most of the cocoa bean breaking machines are based on the principle of grinding. This leads to some disadvantages as (1) the shells might be not separated from the cocoa kernel after the shattering that results in low efficiency of the cleaning process (<96%); and (2) the nibs are also crushed so much to become smaller so that they are easy to moving out together with the shell in the winnowing step due to the similar density. As a result, the ratio of nibs loss during the cleaning process is very high as around 11.3%. Therefore, the shattering and cleaning process has strongly affected the economic efficiency of cocoa production. One of the new methods for cocoa breaking and winnowing in order to increase the cleanness level and to reduce the nibs loss rate has been developed and studied. The cocoa seeds breaking based on the centrifugal mechanism in combination with the pneumatic cleaning have been conducted to manufacturing breaking and winnowing machine with a capacity of about 80 kg/hour. The experimental results indicate that the efficiency of the cleaning process rises to more than 99% and the ratio of nibs loss reduces to 1.6% only which leads to increase the economic efficiency of the cocoa processing process.

UTILISATION OF IOT AND SENSING FOR MACHINE TOOLS

Strong requirements for automation in the production processes using machine tools have been increasing due to lack of high-skilled machining engineers. Automation used to be utilised in mass production, but it is also necessary in medium- to low-volume production recently. Next requirements will be monitoring or sensing functions to make the following possible: prompt service when the machine stops; detection of abnormality before the machine breaks down; and compensation of thermal displacement to ensure machining accuracy. These now need to be performed automatically in place of operators so that abnormality can be detected during machining operation. In this paper core technologies to support automation system will be discussed which are operation monitoring, predictive maintenance, sensing interface and thermal displacement compensation as a sensing application.

A hybrid algorithm to solve the stochastic flow shop scheduling problems with machine break down

A flow shop scheduling problem with uncertain processing times and machine break down is considered in this paper. The objective is to minimise the maximum completion time (makespan). As the problem is non-deterministic polynomial-time hard (NP-hard), a hybrid algorithm (HA) is proposed to solve the problem. The firefly algorithm (FA) is hybridised with the variable neighbourhood search (VNS) algorithm in the proposed HA. Extensive computational experiments are carried out with random problem instances to validate the performance of the proposed algorithm.