Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
machine
CONTENT
BHEL- AN Overview
Operation of a lathe
CNC machine
Introduction to PLC
I/O devices
BHEL AN OVERVIEW
BHEL is the largest engineering and manufacturing enterprise in India in the energy related infrastructure sector today. BHEL was established more than 40 years ago when its first plant was setup in Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India a dream which has been more than realized with a well recognized track record of performance it has been earning profits continuously since 1971-72. BHEL caters to core sectors of the Indian Economy viz., Power Generation's & Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defense, etc. The wide network of BHEL's 14 manufacturing division, four power Sector regional centres, over 150 project sites, eight service centres and 18 regional offices, enables the Company to promptly serve its customers and provide them with suitable products, systems and services efficiently and at competitive prices. BHEL has already attained ISO 9000 certification for quality management, and ISO 14001 certification for environment management.
POWER GENERATION
Power generation sector comprises thermal, gas, hydro and nuclear power plant business as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65% of the total installed capacity of 99,146 MW in the country, as against nil till 1969-70. BHEL has proven turnkey capabilities for executing power projects from concept to commissioning, it possesses the technology and capability to produce thermal sets with super critical parameters up to 1000 MW unit rating and gas turbine generator sets of up to 240 MW unit rating. Co-generation and combined-cycle plants have been introduced to achieve
higher plant efficiencies. to make efficient use of the high-ash-content coal available
in India, BHEL supplies circulating fluidized bed combustion boilers to both thermal and combined cycle power plants. The company manufactures 235 MW nuclear turbine generator sets and has commenced
production of 500 MW nuclear turbine generator sets. Custom made hydro sets of Francis, Pelton and Kapian types for different head discharge combination are also engineering and manufactured by BHEL. In all, orders for more than 700 utility sets of thermal, hydro, gas and nuclear have been placed on the Company as on date. The power plant equipment manufactured by BHEL is based on contemporary technology comparable to the best in the world and is also internationally competitive. The Company has proven expertise in Plant Performance Improvement through renovation modernisation and uprating of a variety of power plant equipment besides specialised know how of residual life assessment, health diagnostics and life extension of plants.
INDUSTRIES
BHEL is a major contributor of equipment and systems to industries, cement, sugar, fertilizer, refinances, petrochemicals, paper, oil and gas, metallurgical and other process industries. The range of system & equipment supplied includes: captive power plants, co-generation plants DG power plants, industrial steam turbines, industrial boilers and auxiliaries. Wate heat recovery
boilers, gas turbines, heat exchangers and pressure vessels, centrifugal compressors, electrical machines, pumps, valves, seamless steel tubes, electrostatic precipitators, fabric filters, reactors, fluidized bed combustion boilers, chemical recovery boilers and process controls. The Company is a major producer of large-size thruster devices. It also supplies digital distributed control systems for process industries, and control & instrumentation systems for power plant and industrial applications. BHEL is the only company in India with the capability to make simulators for power plants, defense and other applications. The Company has commenced manufacture of large desalination plants to help augment the supply of drinking water to people.
TELECOMMUNICATION
BHEL also caters to Telecommunication sector by way of small, medium and large switching systems.
RENEWABLE ENERGY
Technologies that can be offered by BHEL for exploiting non-conventional and renewable sources of energy include: wind electric generators, solar photovoltaic systems, solar lanterns and battery-powered road vehicles. The Company has taken up R&D efforts for development of multi-junction amorphous silicon solar cells and fuel based systems.
INTERNATIONAL OPERATIONS
BHEL has, over the years, established its references in around 60 countries of the world, ranging for the United States in the West to New Zealand in the Far East. These references encompass almost the entire product range of BHEL, covering turnkey power projects of thermal, hydro and gas-based types, substation projects, rehabilitation projects, besides a wide variety of products, like transformers, insulators, switchgears, heat exchangers, castings and forgings, valves, well-head equipment, centrifugal compressors, photo-voltaic equipment etc. Apart from over 1110MW of boiler capacity contributed in Malaysia, and execution of four prestigious power projects in Oman, Some of the other major successes achieved by the Company have been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan, Sri
Lanka, Iraq etc. The Company has been successful in meeting demanding customer's requirements in terms of complexity of the works as well as technological, quality and other requirements viz extended warrantees, associated O&M, financing packages etc. BHEL has proved its capability to undertake projects on fast-track basis. The company has been successful in meeting varying needs of the industry, be it captive power plants, utility power generation or for the oil sector requirements. Executing of Overseas projects has also provided BHEL the experience of working with world renowned Consulting Organisations and inspection Agencies. In addition to demonstrated capability to undertake turnkey projects on its own, BHEL possesses the requisite flexibility to interface and complement with International companies for large projects by supplying complementary equipment and meeting their production needs for intermediate as well as finished products. The success in the area of rehabilitation and life extension of power projects has established BHEL as a comparable alternative to the original equipment manufactures (OEMs) for such plants.
BHEL has introduced, in the recent past, several state-of-the-art products developed in-house: low-NQx oil / gas burners, circulating fluidized bed combustion boilers, high-efficiency Pelton hydro turbines, petroleum depot automation systems, 36 kV gas-insulated sub-stations, etc. The Company has also transferred a few technologies developed in-house to other Indian companies for commercialisation. Some of the on-going development & demonstration projects include: Smant wall blowing system for cleaning boiler soot deposits, and micro-controller based governor for diesel-electric locomotives. The company is also engaged in research in futuristic areas, such as application of super conducting materials in power generations and industry, and fuel cells for distributed, environment-friendly power generation.
TRANSPORTATION
In the transportation filed, product range covers: AC locomotives, AC/DC dual-voltage locomotives, diesel-electric shunting locomotives, traction motors and transformers, traction elections and controls for AC, DC and dual voltage EMUs, diesel-electric multiple units, diesel power car and diesel electric locomotives, battery-powered vehicles. A high percentage of the trains operated by Indian Railways are equipped with traction equipment and controls manufactured and supplied by BHEL.
GENERAL
Block-III manufactures Steam Turbines, Hydro Turbines, Gas Turbines and Turbines Blades. Special Toolings for all products are also manufactured in the Tool Room located in the same block. Equipment layout plan is a per Drawing appended in Section III. Details of facilities are given in Section II.
1.2
The Block consists of four Bays, namely, Bay-I and II of size 36x378 metres and 36x400 metres respectively and Bay-III and IV of size 24x402 metres and 24x381 metres respectively. The Block is equipped with the facilities of EOT Cranes, compressed air, Steam, Overspeed Balancing Tunnel, indicating stands for steam turbine, rotors, one Test stand for testing 210 MW steam turbines Russian Design, one Test Stand for Hydro Turbine Guide Apparatus and two separate Test Stands for the testing of Governing Assemblies of Steam and Hydro Turbines.
1.3
All the parts are conserved, painted and packed before dispatch.
2.0
2.1
(a)
(b)
(c)
Guide Vanes and Shaft Machining Section This section is equipped with
Heavy duty Lathe machines upto 16 metres bed, CNC turning machines, Horizontal Boring Machine, Heavy planer, Deep Drilling Machine, Boring Machines, marking Table, Marking Machines and Assembly Beds. Turbine shafts, Guide Vanes, Journals and Rotors of Spherical and Disc Valves are machined here. Rotors of Steam Turbines are also machined in this section.
(d)
Assembly Section In this section, assembly and testing of Guide Apparatus, Disc
Valve, Spherical Valves, Servo motor shaft and combined Boring of coupling holes are
done.
(e)
Preservation and Packing Section Final preservation and packing of all the
Hydro Turbine components / assemblies is done here.
(f)
(g)
2.2
STEAM TURBINES
as follows:
The facilities and parts manufactured in the various sections of Steam Turbine manufacture are
(a)
Turbine casing Machining Section It is equipped with large size Planer, Drilling,
Horizontal Boring, Vertical Boring, CNC Horizontal and Vertical Boring machines etc. Fabrication work like casings, Pedestals etc. are received from Fabrication Block-II.
(b)
Rotor Machining Section It is equipped with large size machining tools like
Turning Lathe, CNC Lathes, Horizontal Boring Machines, special purpose Fir tree Groove Milling Machine etc. Some rotor forgings are imported from Russia and Germany and some are indigenously manufactured at CFFP, BHEL, Hardwar.
(c)
Rotor Assembly Section This is equipped with Indicating Stand, Small size
Grinding, Milling, Drilling, machines, Press and other devices for fitting Rotors and Discs. Machined Rotor, Discs and Blades are assembled here. Balancing and over speeding of Rotor is done on the dynamic balancing machine.
(d)
Taper Turning:
This is similar to turning. Apart from turning, tool path cuts the axis of rotation of tool at a particular angle. This motion of tool is achieved through combined motions of carriage assembly and cross slide.
Facing Operation
Facing is the process of removing metal from the end of a workpiece to produce a flat surface. Most often, the workpiece is cylindrical, but using a 4-jaw chuck you can face rectangular or odd-shaped work to form cubes and other non-cylindrical shapes. When a lathe cutting tool removes metal it applies considerable tangential (i.e. lateral or sideways) force to the workpiece. To safely perform a facing operation the end of the workpiece must be positioned close to the jaws of the chuck. The workpiece should not extend more than 23 times its diameter from the chuck jaws unless a steady rest is used to support the free end.
Knurling
Knurling is not a cutting operation. Knurling is achieved using knurling tool. This tool has two wheels with slashed lines on it. This tool is pressed against rotating job to get knurled part. Knurling is achieved using plastic deformation of job material.
Drilling
Drilling at the lathe machine is achieved in bit different way than other lathe operations. Drilling tool is held in the tail stock and fed into job using handle on tailstock.
Threading
For threading operations to be done accurately, tool must be fed into job with constant speed. This constant motion is achieved by attaching carriage assembly with lead screw. Lead screw is connected to the driving mechanism through gear trains. So, for particular rpm of job there is constant rpm of lead screw. Threading is of two types viz. External Threading, Internal Threading.
a. External Threading
External threading is done by V shaped tool. It is easier than internal threading.
b. Internal Threading
Internal threading is also done by V shaped tool. But in this case tool is mounted on thin bar which can be able to go into bore of the workpiece where threading is to be done. Shaping tool for this operation is work of skilled worker.
Chamfering
Chamfering is slash cutting of the edges of the workpiece. It can be called as very small taper turning but still taper turning needs a lot more accuracy and skill than chamfering. Also, both have very different sets of uses.
Grooving
Grooving is generally needed to be done before external threading. In this, grooving tool is fed perpendicular to axis of rotation of job.
Parting
Parting is like that of grooving. Parting is done for cutting of job into part.
INTRODUCTION OF CNC
Development of computer numerically controlled (CNC) machines is an outstanding contribution to the manufacturing industries. It has made possible the automation of the machining process with flexibility to handle small to medium batch of quantities in part production. Initially, the CNC technology was applied on basic metal cutting machine like lathes, milling machines, etc. Later, to increase the flexibility of the machines in handling a variety of components and to finish them in a single setup on the same machine, CNC machines capable of performing multiple operations were developed. To start with, this concept was applied to develop a CNC machining centre for machining prismatic components combining operations like
milling, drilling, boring and taping. Further, the concept of multi-operations was also extended for machining cylindrical components, which led to the development of turning centers.
The CNC systems are constructed with a NC unit integrated with a programmable logic controller (PLC) and some times with an additional external PLC (non-integrated). The NC controls the spindle movement and the speeds and feeds in machining. It calculates the traversing path of the axes as defined by the inputs. The PLC controls the peripheral actuating elements of the machine such as solenoids, relay coils, etc. Working together, the NC and PLC enable the machine tool to operate automatically. Positioning and part accuracy depend on the CNC system's computer control algorithms, the system resolution and the basic mechanical machine accuracy. Control algorithm may cause errors while computing, which will reflect during contouring, but they are very negligible. Though this does not cause point to point positioning error, but when mechanical machine inaccuracy are present, it will result in poorer part accuracy. This chapter gives an overview of the configuration of the CNC system, interfacing and introduction to PLC programming.
N C
Velocity Feedback
Tape Reader Tape Punch Other Devices
Tacho Generator
Lead Screw
Proximity switches Limit switches Relay coils Pressure switches Float switches
Servo-Control Unit
The decoded position and velocity control signals, generated by the CPU for the axis movement forms the input to the servo-control unit. This unit in turn generates suitable signals as command values. The servo-drive unit converts the command values, which are interfaced with the axis and the spindle motors The servo-control unit receives the position feedback signals for actual movement of the machine tool axes from the feedback devices (like linear scales, rotary encoders, resolves, etc.). The velocity feedback is generally obtained through tacho generators. The feedback signals are
passed on to the CPU for further processing. Thus the servo-control unit performs the data communication between the machine tool and the CPU. As explained earlier, the actual movements of the slides on the machine tool is achieved through servo drives. The amount of movement and the rate of movement are controlled by the CNC system depending upon the type of feedback system used, i.e. closed-loop or open-loop system
Closed-loop System
The closed-loop system is characterized by the presence of feedback. In this system, the CNC system send out commands for movement and the result is continuously monitored by the system through various feedback devices. There are generally two types of feedback to a CNC system -position feedback and velocity feedback.
DIFERENT CNC MACHINES USED AT BHEL FOR MILLING, TURNING, FACING, BORING, DRILLING AND OTHER MANUFACTURING TECHNIQUES OF THEIR PRODUTS. 1) CNC MILLING MACHINES
Item Description Model Supplier CNC Control System Table Traverse : : : : : : CNC Horz. Milling M/c (6 Nos.) BFH-15 BATLIBOI, INDIA SINUMERIK 810 M 1500 x 400 mm X=1170 mm Y=420 mm Z=420 mm
Spindle Speed Power Rating Max. Load Capacity Weight of the m/c
: : : :
2) CNC HORIZONTAL BORERS: Item Description Model Supplier CNC Control System Spindle Dia. Table Max. Load on Table Travers Ram traverse Swing Over Bed Spindle Speed Power Rating Weight of the Job Weight of the m/c : : : : : : : : : : : : : : CNC Horz. Borer RAPID 6C WOTN, GERMANY FANUC 12M 200mm 4000 x 4000 mm 100 T X=20000, Y=5000, X=1400mm W = 1000 mm 2400 mm 0 125 RPM 92 KW 110 TON 124 TON
: :
Champion 32 /10, 300 SINUMERIC 850 M 320 KN 10.3 mm 1500 mm 9650 mm 1-25 M/min 60 M/min 135 KW
Broaching capacity (pulling force) : Broaching slide stroke Broaching slide width : :
Max tool length (continuous /row) : Broaching Speed (cutting stroke) : Broaching Speed (return stroke) Drive power rating : :
4)
CNC VERTICAL BORERS Item Description Model Supplier CNC Control System Table dia Turning dia Turning Height Spindle Speed No. of Ram Power Rating Max. Load Capacity Machine Weight : : : : : : : : : : : : CNC Vertical Borer TMD 40 / 50 OSAKA MACHINES, JAPAN FANUC 6TB, 3TC 4000 mm 5000 mm 4200 mm 0.23-30 RPM 2 75 KW 70T 100 T : 2200 mm
5)
CNC LATHES Items Description Model Supplier CNC Control System Centre Distance Swing Over Carriage Swing Over Bed Spindle Speed Power Rating : : : : : : : : : CNC Centre Lathe D-1800 NYF HOESCH MFD, GERMANY SINUMERIK 3T 8000 mm 1800 mm 2400 mm 0 125 RPM 92 KW
internal portions of the I/O structures, and not the field devices. A wide variety of voltages, current capacities and types of I/O modules are available.
I/O Devices Input Devices PROXIMITY SWITCH-- A proximity switch is a sensor that can detect objects without
making physical contact. In order to effectively sense such objects, the switch must be in close proximity to the object.
PUSH BUTTON--
KEY OPERATED SWITCH-- A key switch is a switch that can be activated only by
a key. Key switches are usually used in situations where access needs to be restricted to the switch's functions.
FLOW SWITCH--
or pipe. The flow switch symbol has a flag or paddle shape that represents either an air flow switch or a liquid flow switch.
FLOAT SWITCH-- A type of switch that controls the action of a pump as it relates to the
level of liquid in a tank. The float switch symbol has a circle connected to a line that represents a ball float
LATCHING SWITCH-- A latching switch is a switch that maintains its state after being
activated. A push-to-make, push-to-break switch would therefore be a latching switch - each time you actuate it, whichever state the switch is left in will persist until the switch is actuated again.
NON LATCHING SWITCH-- A non-latching switch returns to the original state after
being pressed
Output Devices RELAY-- A relay is an electrically operated switch. Many relays use an electromagnet to
operate a switching mechanism mechanically, but other operating principles are also used. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal.
SOLENOID-- A solenoid is a coil wound into a tightly packed helix. In physics, the term
solenoid refers to a long, thin loop of wire, often wrapped around a metallic core, which produces a magnetic field when an electric current is passed through it. Solenoids are important because they can create controlled magnetic fields and can be used as electromagnets.
PLC Programming
The principle of operation of a PLC is determined essentially by the PLC program memory, processor, inputs and outputs. The program that determines PLC operation is stored in the internal PLC program memory. The PLC operates cyclically, i.e. when a complete program has been scanned, it starts again at the beginning of the program. At the beginning of each cycle, the processor examines the signal status at all inputs as well as the external timers and counters and are stored in a process image input (PII). During subsequent program scanning, the processor the accesses this process image. To execute the program, the processor fetches one statement after another from the programming memory and executes it. The results are constantly stored in the process image output (PIO) during the cycle. At the end of a scanning cycle, i.e. program completion, the processor transfers the contents of the process image output to the output modules and to the external timers and counters. The processor then begins a new program scan. STEP 5 programming language is used for writing user programs for SIMATIC S5 programmable controllers. The program can be written and entered into the programmable controller as in:
Statement list (STL), Fig.A (a) Control system flowchart (CSF), Fig.A (b) Ladder diagram (LAD), Fig.A (c) I 2.3 Statement list STL A I A I O I = Q A I 2.3 4.1 3.2 1.6 2.3 Statement (a) I 4.1 I 3.2 A N D O R (b) Control system flow chart CSF
Q 1.6
Operatio n
A I
2.3 2. 3
Operand Paramet er
I 3.2