IMMPROVMENT OF SELF ALIGNMENT FOOTING SYSTEM FOR

MOTOR-PUMP ROTATING SHAFT

MAGED ABDULLAH AHMED ALKHANBASHI

MASTER OF MANUFACRUING ENGINEERING (QUALITY

SYSTEM ENGINEERING)

2019

IMPROVEMENT OF SELF ALIGNMENT FOOTING SYSTEM FOR PUMP-

MOTOR ROTATING SHAFT

MAGED ABDULLAH AHMED ALKHANBASHI

A report submitted in fulfilment of the requirements for the degree of Master of

Manufacturing Engineering (Quality System Engineering)

Faculty of Manufacturing Engineering

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

2019

DECLARATION

I declare that this report entitled “Improvement of self-alignment footing system for pump-

motor rotating shaft” is the result of my own research except as cited in the references. The

report has not been accepted for any degree and is not concurrently submitted in candidature

of any other degree.

Signature : ....................................

Name : Maged Abdullah Alkhanbashi

Date : ....................................

APPROVAL

I hereby declare that I have read this dissertation/report and in my opinion this

dissertation/report is sufficient in terms of scope and quality as a partial fulfillment of Master

of Manufacturing Engineering (Quality Engineering System).

Signature :……………………………………...

Supervisor Name: Dr. Mohammed Shahir

Date :………………………………………...

Dedication

To my beloved father and mother

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ABSTRACT

This project described the development of motorized shaft alignment system to be used in

motor-pump machineries. Shaft alignment is vital to ensure the equipment able to operate for

longer duration. It was well known that poor alignment causes the bearing failures, coupling

wear or failure, increase energy consumption, bearing housing damage and bent rotors or

crankshafts. In the past, misalignment issues were solved manually by using shims, however,

this method having problematic issue such as skill requirement and time consuming.

Alternatively, the shimless footing system were introduced to overcome this problem. This

project described the improvement of current shimless design by introducing motorized

system. It was notified the root causes of the previous design problems due to manufacturing

quality (t-slot and normal screw that used). A new motorize self-alignment system was

developed along with fabricate a new footing system. A new feature will be added to overcome

delay response time, backlash, not accurate positioning, and ease for maintenance. A linear

bearing and backlash free screw are the major component to solve the backlash problem,

reducing response time needed to settle down the misalignment correction, and become more

precise. The new design of block was fabricated with size of 100 mm x 200 mm x 100 mm.

The drawing of the prototype is done by using solidworks software. The block made of

aluminum and machined by CNC milling machine. Vibration sensor was added to measure the

response of misalignment. The PID controller will do correction by controlling shaft position

by mean of step motor drive. Finally, the test on the fabricated system will be done by using

test rig. As expected the project got improved in terms of response time with more accurate

position. The lowest record score 7 seconds to correct the misalignment in shaft speed 100

RPM, while it took 86 second for correction in shaft speed 1000 RPM.

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ABSTRAK

Projek ini menggambarkan perkembangan sistem penjajaran aci bermotor yang akan

digunakan di jentera pam motor. Penjajaran shaft sangat penting untuk memastikan peralatan

dapat beroperasi untuk tempoh yang lebih lama. Adalah diketahui bahawa penjajaran yang

buruk menyebabkan kegagalan galas, pakai gandingan atau kegagalan, meningkatkan

penggunaan tenaga, menyebabkan kerosakan perumahan dan rotor bengkok atau crankshafts.

Pada masa lalu, isu-isu misalignment telah diselesaikan secara manual dengan menggunakan

shims, bagaimanapun, kaedah ini mempunyai masalah bermasalah seperti keperluan

kemahiran dan memakan masa. Sebagai alternatif, sistem pijakan tak berkilau diperkenalkan

untuk mengatasi masalah ini. Projek ini menggambarkan peningkatan reka bentuk tanpa

sinaran semasa dengan memperkenalkan sistem bermotor. Ia telah diberitahu penyebab utama

masalah reka bentuk sebelumnya disebabkan oleh kualiti pembuatan (t-slot dan skru normal

yang digunakan). Sistem penjajaran diri bermotor baru telah dibangunkan bersama-sama

dengan mengarang sistem pijakan baru. Ciri baru akan ditambah untuk mengatasi masa

tindak balas kelewatan, tindak balas, kedudukan tidak tepat, dan kemudahan untuk

penyelenggaraan. Garis lurus linear dan backlash percuma adalah komponen utama untuk

menyelesaikan masalah tindak balas balik, mengurangkan masa tindak balas yang diperlukan

untuk menyelesaikan pembetulan misalignment, dan menjadi lebih tepat. Reka bentuk baru

blok dibuat dengan saiz 100 mm x 200 mm x 100 mm. Lukisan prototaip dilakukan dengan

menggunakan perisian solidworks. Blok yang diperbuat daripada aluminium dan dimesin oleh

mesin pengilangan CNC. Sensor getaran telah ditambah untuk mengukur tindak balas salah

jajaran. Pengawal PID akan melakukan pembetulan dengan mengawal kedudukan aci dengan

min memandu pemanduan. Akhir sekali, ujian pada sistem fabrikasi akan dilakukan dengan

menggunakan rig ujian. Seperti yang dijangka projek itu bertambah baik dari segi masa tindak

balas dengan kedudukan yang lebih tepat. Skor rekod paling rendah 7 saat untuk membetulkan

salah jajaran dalam kelajuan aci 100 RPM, sementara ia mengambil masa 86 saat untuk

pembetulan dalam kelajuan aci 1000 RPM.

iii

Acknowledgment

In preparing this report, I was in contact with many people, researchers, academicians and

practitioners. They have contributed towards my understanding and thought. In particular, I

wish to express my sincere appreciation to my main project supervisor, Dr.Mohd Shahir Bin

Kasim, for encouragement, guidance critics and friendship. I am also very thankful to the lab

technician En.Mohd Hanafiah for his help in fabrication and measuring guidance, advices and

motivation. Without their continued support and interest, this project would not have been

same as presented here.

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TABLE OF CONTENTS

PAGE

DECLARATION

DEDICATION

ABSTRACT i

ABSTRAK ii

ACKNOWLEDGEMENTS iii

TABLE OF CONTENTS iv

LIST OF TABLES vii

LIST OF FIGURES ix

LIST OF ABBREVIATIONS xi

CHAPTER

1. INTRODUCTION 1

1.1 Background of Study 1

1.2 Problem Statements 2

1.3 Research Objective 2

1.4 Scope of Work 3

2. LITERATURE REVIEW 4

2.1 Introduction 4

2.2 Shaft Alignment 4

2.3 Shaft Misalignment 5

2.4 Type of Misalignment

2.4.1 Parallel Misalignment

2.4.2 Angular Misalignment

6

6

6

2.5 Cause of Misalignment 7

v

2.6 Effect of Misalignment 7

2.7 Current Method of Correction Misalignment 8

2.7.1 Traditional Method 8

2.7.1.1 Dial Indicator 8

2.7.1.1.1 Rim Face Method 9

2.7.1.1.2 Reverse Indicator Method 10

2.7.1.2 Laser Alignment 10

2.7.2 Current Method of Correction 12

2.7.2.1 Shim 12

2.7.2.2 Shimless Alignment 13

2.8 Alignment Tolerance 14

2.9 Linear Bearing 15

2.10 Backlash Free Screw 16

2.11 Control System 17

2.11.1 Controller System 18

2.11.2 PID Controller 18

3. METHODOLOGY 19

3.1 Research Methodology 19

3.2 Flow Chart 19

3.3 Gant Chart

3.4 Selection Required Criteria and Specification

3.4.1 Determination of the criteria for concept selection list

21

21

21

3.5 Concept Generation 21

3.5.1 Pugh concept selection method

3.5.2 Prepare the selection matrix

3.5.2.1 Rating the concept

3.5.2.2 Ranking the concept

3.5.3 Concept Scoring

3.5.3.1 Prepared of selection matrix

3.5.3.2 Rating the concept

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vi

3.5.3.3 Ranking the concept

3.5.3.4 Select one or more concept

3.6 Fabrication of The Product

3.6.1 Technical Drawing

3.6.2 Material

3.6.3 Fabrication Process

3.7 Tuning Testing of Self-Alignment

3.7.1 Shaft RPM Measuring

3.8 PID Controller System

3.8.1 Components

3.8.2 Coding System

3.9 Shaft-Alignment Footing System Comparison

3.10 Testing

3.10.1 Test Rig

3.10.2 Vibration Meter

3.10.3 Experimental setup

4. RESULT AND DISCUSSION

4.1 Determine List of Criteria for Concept Generation and Selection

4.2 Conceptual Design

4.3 Concepts Selection Method

4.3.1 Concept screening phase

4.3.2 Concept scoring

4.3.3 Discussion of concept selection method

4.4 Vibration Testing

4.5 Response Time Testing

4.6.4 PID Controller Graph

4.6 Comparing the performance in Both systems

4.7 Vibration Validation

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vii

5. CONCLUSION AND RECOMMENDATION

5.1 Conclusion

5.2 Recommendation

REFERENCES

APPENDIXS

57

57

58

59

63

viii

LIST OF TABLES

TABLE TITLE PAGE

2.1 Shaft alignment tolerances (Offset) 14

2.2 Shaft alignment tolerances (Angular) 14

3.1 Selection matrix for concept screening 22

3.2 Relative performance 23

3.3 Selection matrix of concept scoring 24

3.4 Relative performance 25

3.5 Description of each parts 27

3.6 Vibration Severity per ISO 10816 34

3.7 Speed of the Shaft 34

3.8 Calculation of Step Motor Displacement 42

4.1 List of criteria 47

4.2 Conceptual design 48

4.3 Screening concept 50

4.4 Concept scoring 51

4.5 Data of vibration meter reading (after correction) 50

4.6 The response time data corresponding to the shaft speed 52

4.7 Comparison in performance between both systems 54

ix

LIST OF FIGURES

FIGURE TITLE PAGE

2.1 Required Alignment for a Shaft 5

2.2 Parallel Misalignment 6

2.3 Angular Misalignment 7

2.4 Dial Indicator 9

2.5 Rim and Face Indicator Setup 9

2.6 Reverse Dial Indicator Method 10

2.7 The Overview of Laser Alignment 11

2.8 Scheme of a Laser Measuring System 11

2.9 Exhibits a Precut Stainless Steel Shim 12

2.10 Shimless Aligner 13

2.11 Alignment Tolerance Chart 15

2.12 (a) Linear Bearing (b) Linear Bearing with t-slot guide 16

2.13 Backlash Free Screw 17

2.14 Process Under Control 17

2.15 PID Controller 18

3.1 Project Flow Chart 20

3.2 Exploded View of the Footing System Parts 26

3.3 Dimension of the self-alignment footing system 28

3.4 variable elevation of the system 29

3.5 Footing System fabricated by Aluminum 29

3.6 5-axis CNC Milling machine 30

3.7 Flow chart of fabrication 31

3.8

Final prototype

32

x

3.9

3.10

3.11

3.12

3.13

3.14

3.15

3.16

3.17

3.18

3.19

4.1

4.2

4.3

4.4

Graph of ISO 7919 Mechanical vibration severity

Tachometer device

PID Controller system diagram

Accelerometer Sensor with Controller

System components (a) Motor drive (b) Stepper motor

Automated system of PID controller

Footing system (a) Motor drive (b) Stepper motor

Test Rig

Vibration Meter

System Installation

Machine controller

Graph Correction of vibration against shaft speed

Graph of response time against shaft speed

Graph of PID automated system for 600 RPM of shaft speed

Validation of product

33

35

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xi

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Gant Chart of MPII 63

xii

LIST OF ABBREVIATIONS

CNC Computer Numerical Control

MM Millimeter

PID Proportional-Integral-Derivative

MPII Master Project 2

UTeM Universiti Teknikal Malaysia Melaka

RPM Revolutions Per Minute

IOT Internet of Things

1

CHAPTER 1

INTRODUCTION

This particular chapter will describe shaft alignment in rotary machinery. This chapter

covers the background of the study, objectives of study, problem statement, scope of the project

and chapter overviews.

1.1 Background of Study

Nowadays, our daily life is surrounded by rotating dynamic machinery. After unbalance,

misalignment is accepted as the second most commonly observed disturbance source in rotor

systems (Patel and Darpe, 2009). Negligence of machine alignment is consuming 30% of the

machine’s downtime (Hariharan and Srinivasan, 2011). Misalignment happens when

centerlines of the motor and the driven device shafts are not positioned in the same axis.

Misalignment problem may cause up to 70% of the vibration problems observed in rotating

machines (Luis et al., 2014) Misalignment of rotating shaft generate, noise, coupling,

exaggerated vibrations, bearing temperature increases, and premature bearing, or shaft failure.

Poorly aligned shafts may cause serval machine problems: studies have shown that

misalignment of the shaft is the cause for around half of machine breakdowns. Thus, proper

shaft alignment affecting the smooth, effectiveness transportation of generating power to the

driven equipment via the motor. Attaining a correct shaft alignment when installing rotating

mechanical systems is essential apart.

2

1.2 Problem Statement

Misalignment is considered one of the main common problem in the machinery

industry. Over the years, a lot of researches have been done just to understand the rotor

dynamics phenomena. Shaft alignment is considered one of the most common form of

alignment performed on rotating machines(Lin et al., 2010). The alignment of the shaft by

using shim are difficult because of a pre-cut shim has its standard size, tolerances, and time

consuming, moreover it’s not accurate method to align the shaft due to the skills needed to

perform the alignment process. Therefore, using shimless footing system is implemented in

this project. There are two issues to be rectified. On the mechanical part, the quality of shimless

footing system was inadequate to do alignment task. The T-slot dependent in sliding motion

and ordinary screw were the major contribution to the backlash issue. It was proposed by this

project to improve new design for high accuracy sliding rack to replace current T-slot to

enhance the response time, along with backlash free screw for settling down the backlash issue.

Second issue is the controller itself which to introduce smart system (PID) that accommodate

with mechanical parts. Some controller need to be fine-tuned so that the system can performed

as desired.

1.3 Research Objective

The objectives are as follows:

i. To design an improve motorize self-alignment system by using PID controller.

ii. To fabricate a system with smooth tuning and could reduce vibration during the

shaft alignment process.

iii. To check the performance in terms of response time, and accuracy for motorize

self-alignment system.

3

1.4 Scope of Work

This project is to study and analyses the current design of shimless footing

system. This report explains in details the design and development of self-alignment

horizontal (Z axis) and vertical (Y axis) for rotating motor-pump shaft. The correction

done by this device only limited to 3 mm. The scope for the project as follows

It was proposed by this project to introduce high accuracy sliding rack to replace

current T-slot.

The common screw to control motion to be replaced with the backlash free type lead

screw.

The self-alignment footing product that made of aluminum is fabricated using

machining processes to form the final product.

The motorize system is then implemented and integrated with PID controller to

validate the performance during rotating shaft machinery.

4

CHAPTER 2

LITERATURE REVIEW

This chapter will explain about the literature review from the research regarding of shaft

misalignment, type of misalignment, causes and effects of misalignment, methods of alignment,

and methods of misalignment, PID controller system and the components involved in shaft

alignment.

2.1 Introduction

This session of the study will investigate more in the effect of misalignment on the

vibration and noise emission of the rotating speed machinery. This chapter reviews and

explains about the previous studies that have been done. Literature review examines

respectively to the source and describes to justify the statement with proof of research or study

in related field.

2.2 Shaft Alignment

Shaft is defined as a rotating machine element used to transfer the power from one part

to another. Shafts place members like gears or pulleys in their specific positions, torque will

transmit along with members when it is connecting together. Shaft alignment is the process

where two machines are positioned in collinear such that the power transferred from one shaft

to another (A Practical Guide to Shaft Alignment. 4th edn, 2002).

Shaft alignment is a coupling machine shaft-to-shaft alignment consisting of driver and

driven machine. The driver machine, such as electric motors, turbine or reciprocating machine,

has been designed to provide the driven machine with a coupling to rotate mechanical power.

5

The driven machine like a generator, a ventilator or a pump that generated power (Wowk,

2002).

The driver was transmitting power to the driven motor by connecting the two shafts to

each other. Both shafts ‘centerlines must remain in one straight line as they are coupled

together and rotate under their standard operating conditions. The main goal of shaft alignment

is to expand the operating life span of the dynamic rotating machine.(Al-Hussain and

Redmond, 2002).

The perfect alignment of the shaft will reduce the excessive axial and radial forces on

the bearings in order to protect the rotor's longer life and stability under its standard operating

conditions and reduce the amount of shaft bending due to the transfer of power from one

connection to another (Tsiafis et al., 2015). Figure 2.1 show the perfect alignment.

Figure 2.1: Required Alignment for a Shaft

2.3 Shaft Misalignment

Shaft misalignment is the deviation of the relative shaft position from the rotational

axis measured at the power transmission points during normal operation (Baer et al., 2013).

Failure to align shaft is liable for 50 percent of machine downtime and machine damage cost.

Implementing proper shaft alignment can prevent a large number of damage to machinery and

reduce downtime that causes loss to company and production. The alignment required is done

by adjusting the machine correctly by moving its feet (Gairola, 2004). The main reason for

alignment during rotation is to obtain coaxial centerlines. Company and machine downtime

cost increase dramatically if the shaft or belt on rotating components not matching, causes seals

and coupling damage (Luedeking, 2012c). Any misalignment between the centers of the

shaft’s rotation can cause vibration and additional loads that can result in premature wear,

6

catastrophic failure of the bearings, seals, the coupling itself and other machine components

when the shaft of tow rotating machine is coupled directly by fixable coupling (Bloch, 2004).

2.4 Type of Misalignment

Failure to align shaft is liable for 50% of machine downtime and machine damage cost.

Implementing proper shaft alignment can prevent a large number of damage to machinery and

reduce downtime that causes loss to company and production. There are two types of

misalignment parallel misalignment and angular misalignment (Huang, Zhou and Yang, 2011).

2.4.1 Parallel Misalignment

Offset or parallel misalignment occurs at the gap between two shafts centerlines.

Parallel misalignment can occur in horizontal and vertical direction. Offset that present in the

horizontal plane in which the movement will be left or right, and vertical plane that positioned

at different level up and down (Huang, 2005). Figure 2.2 shows the parallel misalignment

between the driver shaft and driven machine.

Figure 2.2: Parallel Misalignment (Mark et al., 2008)

2.4.2 Angular Misalignment

The angular misalignment is occurring when the shaft motor is set in an angle to the

driven machine (not parallel). This type of misalignment may cause serious damage of the

driven equipment and the motor shaft due to the difference in slope. Figure 2.3 shows an

angular or face misalignment.

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Figure 2.3: Angular or face misalignment (Mark et al., 2008)

2.5 Causes of Misalignment

There are many causes contributing to shaft misalignment. One of them is the procedure

of alignment. An alignment procedure is not complete or the wrong alignment procedure can

cause misalignment of human error. Foundations or also known as base plates may settle down

to a lower position. This can lead to setting misalignment. Even if the equipment is realigned,

misalignment can occur again if no action is taken on the machine base plates (Leso et al.,

2011).

Other than that, coupling defect that originated from manufacturing due to distorted

coupling. This misalignment usually occurs on new equipment or when the coupling is the

breakdown. Moreover, thermal growth or expansion is due to mechanical changes in the shaft

centerline location (Bourgault, 2004).

These changes are caused by process forces such as pressure, airflow and others.

However, temperature changes are the most notable aspect that result to misalignment

(Jang&Khonsri,2015). Different material expands when heated at different rates. It is necessary

to consider about thermal growth when equipment normally operates above ambient

temperature (Hermanson, 2013).

2.6 Effect of Misalignment

In dynamic rotating machinery, misalignment can be detected in several aspects that

include excessive vibration, wear patterns, extreme bearing temperatures and noise. Several

techniques are integrated into a system’s preventive maintenance program (Bhattacharya &

Yu, 2012). Inspections usually take place when the damage is occurring.