I.

INTRODUCTION

Industrial machinery and processes are composed of various noise sources such as rotors,
stators, gears, fans, vibrating panels, turbulent fluid flow, impact processes, electrical
machines, internal combustion engines etc. The mechanisms of noise generation depend on
the particularly noisy operations and equipment including crushing, riveting, blasting
(quarries and mines), shake-out (foundries), punch presses, drop forges, drilling, lathes,
pneumatic equipment (e.g. jack hammers, chipping hammers, etc.), tumbling barrels, plasma
jets, cutting torches, sandblasting, electric furnaces, boiler making, machine tools for forming,
dividing and metal cutting, such as punching, pressing and shearing, lathes, milling machines
and grinders, as well as textile machines, beverage filling machines and print machines,
pumps and compressors, drive units, hand-guided machines, self-propelled working machines,
in-plant conveying systems and transport vehicles. On top of this there are the information
technology devices which are being encountered more and more in all areas.

Noise is therefore a common occupational hazard in a large number of workplaces such as

the iron and steel industry, foundries, saw mills, textile mills, airports and aircraft
maintenance shops, crushing mills, among many others. In many countries, noise-induced
hearing loss is one of the most prevalent occupational diseases.

The avoidance or minimization of health hazards in the working process by the

appropriate design of working equipment and processes, in other words by prevention, is very
important for assuring that there is a high level of safety, health and consumer protection. This
noise control principle is manifested in the definition and declaration of noise characteristics
for products or machines and the description of achievable values by the standards.

II. LITERATURE REVIEW

a) RELATED LITERATURE 1: Industrial Noise Sources

The sound pressure level generated depends on the type of the noise source, distance from
the source to the receiver and the nature of the working environment. For a given machine,
the sound pressure levels depend on the part of the total mechanical or electrical energy that is
transformed into acoustical energy.

Sound fields in the workplace are usually complex, due to the participation of many
sources: propagation through air (air-borne noise), propagation through solids (structure-
borne noise), diffraction at the machinery boundaries, reflection from the floor, wall, ceiling
and machinery surface, absorption on the surfaces, etc. Therefore any noise control measure
should be carried out after a source ranking study, using identification and quantification
techniques. The basic mechanism of noise generation can be due to mechanical noise, fluid
noise and/or electromagnetic noise.

The driving force for economic development is mainly the endeavor to produce consumer
goods ever more cost-effectively. From the point of view of the machine manufacturer, this
generally means offering products with a low space, material, energy and production time
requirement (smaller, lighter, more economical and more productive). At the same time
account is being taken increasingly of resource conservation and environmental friendliness,
although the rise in noise levels which frequently goes along with increased output and
productivity is often overlooked. Personnel are then exposed to higher noise levels than
before, despite noise-reducing measures taken in the machine's design. This is because the
noise emission rises non-linearly because of higher rotary and travelling speeds in machine
parts.

For example, for every doubling of the rotary speed the noise emission for rotating print
machines rises by about 7 dB, for warp knitting looms 12 dB, for diesel engines 9 dB, for
petrol engines 15 dB and for fans is between 18 to 24 dB. For the purpose of comparison: the
doubling of sound power produces an increase in emission of 3 dB only.

But even previously quiet procedures are often replaced by loud ones for reasons of cost,
e.g. stress-free vibration instead of annealing for welded parts. In some cases new
technologies also result in higher emissions; for example, with the use of phase-sequence-
controlled electrical

drives, the excitation spectrum shifts further to high frequencies, which results in a greater
sound radiation from large machine surfaces. This means that some new noise problems are
closely related to the use of modern technologies.
. Mechanical Noise
A solid vibrating surface, driven or in contact with a prime mover or linkage, radiates sound
power (W in Watts) proportional to the vibrating area S and the mean square vibrating
velocity

< v 2>, given by;

W ρcS ( ν ) 2σ rad
where
ρ-is the air density (kg/m3),
c- is the speed of sound (m/s) and
σ rad -is the radiation efficiency (see Gerges 1992).

Therefore care must be taken to reduce the vibrating area and/or reduce the vibration
velocity. Reducing the vibrating area can be carried out by separating a large area into small
areas, using a flexible joint. Reduction of the vibration velocity can be carried out by using
damping materials at resonance frequencies and/or blocking the induced forced vibration. A
reduction of the excitation forces and consequently of the vibration velocity response by a
factor of two can provide a possible sound power reduction of up to 6 dB assuming that the
other parameters are kept constant. Typical examples of solid vibration sources are: eccentric
loaded rotating machines, panel and machine cover vibration which can radiate sound like a
loudspeaker, and impact induced resonant free vibration of a surface.
Fluid Noise
Air turbulence and vortices generate noise, especially at high air flow velocities. Turbulence
can be generated by a moving or rotating solid object, such as the blade tip of a ventilator fan,
by changing high pressure discharge fluid to low (or atmospheric) pressure, such as a cleaning
air jet or by introducing an obstacle into a high speed fluid flow.

The aerodynamic sound power generated by turbulent flow is proportional to the 6th to 8th
power of the flow velocity (W ∼ U6 to 8), which means that a doubling of the flow velocity (U)
increases the sound power (W) by a factor of 64 to 254 or 18 to 24 dB respectively. Table 5.3
shows the effects of doubling of the typical velocity together with other primary mechanisms.
Therefore care must be taken to reduce flow velocity, reduce turbulence flow by using
diffusers and either remove obstacles or streamline them. The next few examples show the
applications of these fundamental concepts to machinery noise reductions.

b) RELATED LITERATURE 2: Attenuation Of Vibration In Boring Tool Using Spring

Controlled Impact Damper

Now-a-days, the challenge of modern machining industries are mainly focused on the
achievement of high quality, dimensional accuracy of work piece, surface finish, high
production rate, less wear on the cutting tools, economy of machining in terms of cost saving
and increase in cutting performance with reduced environmental impact. During machining,
the result of productivity and quality is limited due to poor dynamic stiffness that tends to
initiate self-excited vibration which can be minimized by using lobbing effect for stable
cutting. In boring tool, vibration is developed as a result of the dynamic interaction between
the structures and the cutting process. The wavy surface left by vibrations is removed in the
next pass in a dynamic cutting process. The wavy surface and the vibrating tool result in
modulated chip thickness, which causes periodically varying cutting forces to excite the
machine and work piece structures. The presence of tool vibration can leads to poor surface
finish, excessive tool wear and production of high irritating noise. During machining process
tool vibration can be reduced by providing damper to tool holder. In the past many types of
dampers have been used to reduce tool vibration in metal cutting. Among various dampers,
impact damper, viscous damper, magnetorheological and frictional damper are considered to
be effective. The impact damper is inexpensive compared to other dampers, simple in design
and provide effective damping performance over a range of frequencies and accelerations.

c) RELATED LITERATURE 3: Electrical Noise And Mitigation

Introduction

In this chapter, we will learn about noise in electrical circuits, the reasons for their
generation, types of noise and mitigation. We will cover shielding as a means of noise control
and the role played by grounding and how properly designed grounding can reduce noise. We
will learn about zero signal reference grids for noise-prone installations. We will briefly deal
with the subject of harmonics and how they affect power and electronic equipment and about
ways of controlling them.

Definition of electrical noise and measures for noise reduction:

Noise, or interference, can be defined as undesirable electrical signals, which distort or
interfere with an original (or desired) signal. Noise could be transient (temporary) or constant.
Unpredictable transient noise is caused, for example, by lightning. Constant noise can be due
to the predictable 50 or 60 Hz AC 'hum' from power circuits or harmonic multiples of power
frequency close to the data communications cable. This unpredictability makes the design of a
data communications system quite challenging.

Noise can be generated from within the system itself (internal noise) or from an outside
source (external noise). Examples of these types of noise are:

Internal noise

 Thermal noise (due to electron movement within the electrical circuits)

 Imperfections (in the electrical design).

External noise

 Natural origins (electrostatic interference and electrical storms)

 Electromagnetic interference (EMI) - from currents in cables
 Radio frequency interference (RFI) - from radio systems radiating signals
 Cross talk (from other cables separated by a small distance).

From a general point of view, there must be three contributing factors before an electrical
noise problem can exist. These are:

1. A source of electrical noise

2. A mechanism coupling the source to the affected circuit
3. A circuit conveying the sensitive communication signals.

Typical sources of noise are devices, which produce quick changes (spikes) in voltage or
current or harmonics, such as:

 Large electrical motors being switched on

 Fluorescent lighting tubes
 Solid-state converters or drive systems
 Lightning strikes
 High-voltage surges due to electrical faults
 Welding equipment.

Figure 8.1 shows a typical noise waveform and how it looks when superimposed on the power
source voltage waveform.
Figure 8.1 Noise signal (top) and noise over AC power (bottom)

Electrical systems are prone to such noise due to various reasons. As discussed in the
previous chapter, lightning and switching surges are two of these. These surges produce high
but very short duration of distortions of the voltage wave. Another common example is
'notching', which appears in circuits using silicon-controlled rectifiers (power thyristors). The
switching of these devices causes sharp inverted spikes during commutation (transfer of
conduction from one phase arm to the next). Figure 8.2 shows the typical waveform with this
type of disturbance.

Figure 8.2 Waveform distorted by notching

Harmonics in supply system is yet another form of disturbance. This subject will be reviewed
in detail later in the chapter. A typical waveform with harmonic components is shown in
Figure 8.3.
Figure 8.3 Waveform distorted by harmonics

Switching of large loads in power circuits to which automatic data processing (ADP)
loads are connected can also cause disturbances. Similarly, faults in power systems can cause
voltage disturbances. All these distortions and disturbances can find their way to sensitive
electronic equipment through the power supply mains connection and cause problems.

Apart from these directly communicated disturbances, sparks and arcing generated in
power-switching devices and high-frequency harmonic current components can produce
electromagnetic interference (EMI) in signal circuits, which will require to be properly
shielded or screened to avoid interference. Figure 8.4 shows diagrammatically the reasons for
noise from the equipment within a facility.

Figure 8.4 Noise emanating from electrical systems within a facility

The following general principles are applicable for reducing the effects of electrical noise:

 Physical segregation of noise sources from noise-sensitive equipment

 Electrical segregation
 Harmonic current control
 Avoiding ground loops which are a major cause of noise propagation (including
measures such as zero signal reference grid, explained later in this chapter)
 Shielding/screening of noise sources and noise-susceptible equipment including use of
shielded/twisted pair conductors.
 III. METHODOLOGY

Noise attenuation is achieved by decreasing the intensity or volume of sound in a

controlled environment. There are many noise reduction strategies that can be employed in
industrial settings. One of the most effective and logical approaches to noise attenuation are to
install systems that minimize noise from the start, using control techniques such as:

 Damping – A method of reducing noise levels from chutes, hoppers, machine guards,

conveyors, panels and more

 Selecting efficient equipment – Selecting fans, compressors, PD blowers and engines that

operate efficiently contribute significantly to noise attenuation

 Adjusting Fan Speed – Fan noise is in direct correlation with fan speed, so simple adjustments

can produce significant results

 Controlling high pressure steam, natural gas and other vent noises

 Reducing noise from process exhaust stacks with attenuation

 Acoustically treating roof exhausters and ventilating equipment

 Closing openings in enclosures and barrier walls required for utilities

Methods Of Noise Control

The combat of noise is a problem of work and is represented by the assembly consisting in noise
sources, the propagation medium of the acoustic energy and noise receptors.

The methods of noise control are :

- methods of noise control at source;

- methods of noise control on the pathways;
- methods of noise control at receiver.
Combating at source, on transmission path from source to receiver constitute the active protection and
the reducing noise on the transmission paths or at receiver is the passive protection.

The methods of reducing noise at source are the most efficiency of assuming that since the design
phase of a system or a car to consider solutions to obtain their quiet operation.

2.1. Methods of noise control at source

The main solutions to combat noise source consists of fitting noise source (machinery, equipment) on
vibroinsulator elements. This measure ensures noise attenuation, mainly for low-frequency component
of the acoustic oscillation, between 75 ÷ 1200 Hz.

If is necessary to reduce noise in a specific point, between it and the noise source is interposed a
soundproofing screen. By placing such a screen to obtain noise attenuation for almost the entire range
of frequencies, higher attenuation occurring at frequencies above 2400 Hz. Location screen should be
such as to not disturb the process and to allow machine operation and access to the control elements.

To achieve a higher attenuation of noise, where practical conditions permit, the equipment shall be
provided with an acoustic enclosure, resulting a attenuation for all over the frequency range.

If special conditions are needed to soundproofing, equipment can be mounted in a double enclosure
while the equipment and acoustic enclosure are mounted on vibroinsulator. By these measures the
level of noise at frequency components above 600 Hz falls below 40 dB, and minimum attenuation is
22 dB achieved at frequencies of 150 Hz.

Ways to combat noise at source are:

< the use a machine that emits a low noise level;

< avoiding the impact of metal on metal;
< the noise attenuation or the isolation of components who vibrating ;
< attaching of silencers;
< perform the preventive maintenance because the parts wear may increase noise levels;
< decoupling technical equipment of the physical medium of work;
< modification of equipment and technologies;
< avoidance of sudden vibration.

2.1.1. Attenuation systems - silencers

The use of silencers fall in the control methods of noise at source, being an effective and commonly
used to attenuate the effects of aerodynamic type of noise :

- the active silencers have the operating principle who is based on eliminate of the sound wave
by a simultaneous transmission of acoustic waves identical to the same energy but in phase
opposition with the initial wave. The energy sum of those waves is zero. If anti-noise product
is not exactly the mirror image of the noise generated by the source, then there is not an
overall reduction of noise, but a decrease in noise level. This type of attenuator made an
 attenuation of about 20-30 dB. If on this type of attenuator were attached the absorbent panels
are obtained the active cellular, lamellar, circular or baffle soundproofing attenuators [5, 6];
- absorption attenuators are used to reduce noise whose spectrum is continuous. These take the
form of a channel lined with absorbent material. On the absorbent material it is put perforated
sheet to prevent its disintegration at high speed equipment working. Depending on the chosen
diameter and type of perforations these have a resonator effect. They can increase the
attenuation for low frequency waves and to decrease for high frequency waves. The noise
reduction is done by dissipation of energy on pressure oscillations at friction of the pipe wall
and at the passing of gas through a sleeve made of absorbent material. Types of absorption
silencers are: attenuator low, attenuator "honeycomb", dampers with lamellae, circular
attenuator with interior bulb, attenuator with the pressure chamber, silencer with baffle [6, 11];
- the reactive attenuators helps at dissipation of acoustic energy by forming a "acoustic wave
stopper" that prevents passage of the sound at some frequencies due to the influence of mass
and elasticity of air in the attenuator cells [5, 13, 15]. Such a damper consists of a series of
cavities and ducts mounted so that the discontinuities they create, to reduce the level noise.
The researches in the field confirmed that in practical terms is not recommended the use of
more than two rooms identical. The mounting of tube of coupling between rooms of attenuator
is desirable to make in inside.

2.2. Ways to combat noise on the propagation pathways

The absorption of noise produced at the working place (workshop, hall, etc.) can be achieved by:

- soundproofing techniques;
- soundproofing treatment of the walls, by covering with absorbent materials such as:

• porous materials (polyurethane foam with open pores, mineral foam, rigid mineral
foam and expanded - foam of clay);
• fibrous material (glass wool);

• closed-cell materials (expanded polystyrene).

At the acoustic insulation to an enclosure, which is realized by interposing an acoustic barrier to the
propagation of sound, it can adopt the following solutions :

- acoustic enclosure for the noise source;

- layout between the noise source and employees an acoustic screens;
- protecting employees through isolation booths or acoustic stalls;
- soundproofing for the rooms noisy;
- isolation of procedures which involve noise emissions;
- the positioning of the machine tools and equipment so that the area in which working the
human operator to be the least noisy.

One of the most used methods to reduce noise on the pathways is the complete closure of noise
sources in an acoustic enclosure. The noise can be propagated in outside in the following ways :

- through the enclosure walls – the air noise;

- through leakages or the technology openings - the air noise;
- through enclosure structure - structural noise;
- through components of the machine - structural noise.

2.2.1. Methods to reduce the noise with the soundproofing materials

The characteristic of the soundproofing materials is that have a porous structure (wool, felt, plywood -
wood fiber-porous) so that the pores communicate with each other through channels or openings in the
material. One such material, under the sound field incidence has air molecules in motion, because of
the acoustic energy of the incident field sound. Depending of the air viscosity between the air particles
and pore walls occur forces of friction. This forces transform irreversible a part of acoustic energy of
the waves into the heat:

The dissipation of the acoustic energy of waves who cross the absorbing material is performed by the
thermal conductivity of air. This thing is because once with the air and the fibers of material are set in
motion with bending movements and internal friction of the fibers of material (who appear from their
deformations) have the result the increased sound absorption of the material. Hence, the importance to
use as sound absorbing material the ones with open pores and to form deep channels for
communication:

Sound absorbing materials are classified into:

- absorbents porous with rigid or flexible framework:

• porous plasters;

• plates of mineral wool;

• vegetable fiber stiffened with binder;

• mineral fiber stiffened with binder.

- absorbents on the resonators simple and grouped type;

- vibrating membranes;
- compound structures.

2.2.2. Methods to reduce noise by the soundproofing structures

The absorbing structures are the damped oscillatory systems that absorb sound energy because under
the action of incident sound waves start to vibrate and the accumulating energy becomes the partial
heat by friction mechanisms. Sound absorption of these structures is maximum at the resonance
frequency, because at this frequency are obtained the highest values of velocity oscillation. The
intensification of the friction phenomenon is resulting sound energy dissipation in a higher proportion.

In Figure 1.a is represented a sound absorption structure and on the surface of the incidence of acoustic
field is placed a perforated screen away from the base wall. The role of perforations is to allow
penetration into the interior wave front, and is resulting attenuation of acoustic energy transmitted
through multiple reflections.

The other variants of soundproofing are represented in Figure 1.b, which is a double-walled structure,
efficient in areas with high noise level. The second is an insulation structure with a double-screen who
used the soundproofing materials between the interstice and those two screens (Figure 1.c) [18].
 a) b) c)

Fig. 1. Wall with perforated screen (a) and double screens (b, c) [18].

Figure 2 shows a structure consisting of concrete blocks with enclosures resonators, at which are used
prefabricated elements in various materials, with one or more cavities that communicate with the
indoor air through a calibrated channel.

Expanding the use of fibrous materials, lightweight and good acoustic properties involves establishing
specific criteria for design for soundproofing treatments to construction and equipment.

Fig. 2. Sound absorption structure with three cavities :1 - soundproofing materials; 2 – cavities; 3 –
channel; 4 - metal membrane.

2.2.3. Methods to reduce noise: acoustic isolation with components from

Acoustic enclosure must be made to ensure the cooling of equipment components in the optimal
conditions. The presence of slots in the wall of enclosure reduces noise attenuation capacity. To avoid
this phenomenon, it is necessary to be provided with silencers the access at holes for cooling air.

The acoustic enclosure is a rigid construction, box-shaped, surrounding the noise source completely or
partially, is presented in Figure 3.
Fig. 3. Location modality of acoustic enclosure with the soundproofing material and equipment
installation on vibroinsulator elements:

1 – equipment; 2 - sound absorbing material; 3 - acoustic enclosure; 4 - vibroinsulator

elements.

2.2.4. Methods to reduce noise: the acoustic isolation by acoustic screens

Acoustic screens are the soundproof walls, located between the noise source and the protected area.
The screens are made in various ways.

Acoustic screens are used to provide a work area with a less noisy environment, by attenuation of the
direct waves and allowing to the waves refracted and the waves reverberated passing of the top edges
of the screen.

Where they are not recommended, it may use the acoustic screens modulated with which sources can
be screened any form, giving areas with lower noise level. Screens can be built and of stiplex or glass.
A screen with a thickness of 5 mm giving a attenuation of about 26 dB in the middle of the audible
range. The refracted components are stronger at the lower frequencies. The evaluation of the fraction
refracted is based on the angle of refraction reported to virtual height of the screen. The refracted
waves may have important effects only at low frequencies; hence the effectiveness of the acoustic
screen is significant at mid and high frequencies. The most important quota of the acoustic energy in
the protected area is given by the reverberated waves and to reduce this effect, the ceiling room and
part of the walls it necessary be covered with sound absorbing structures. In such conditions the
reverberated component reaches the same order of magnitude with the one refracted.

2.3. Ways to combat noise at receiver

To combat noise at the receiver is recommended in addition to individual means of protection, its
protection in soundproof cabin. this thing is possible only in case of technological processes that can
be operated, controlled and monitored from a distance, thus reducing to a minimum the period of noise
exposure of workers (less, the maintenance operations on equipment).

The personal protection on noise pollution in industrial environments is achieved by using special
systems called earplugs, divided into two categories.
 - on intern type: stoppers or tampons, made by cotton, rubber, plastics. They are introduced and
adapted for the external auditory canal;

- on external type: the headphone which covers the entire pavilion of the ear, used usually for the
most intense noise, because they have a great capacity for sound insulation.

Studies of the issues related to protection against the harmful effects of noise, using the individual
means for protection at receptors have revealed two trends:

- the use of selective earplugs, noise depending on the nature of work performed and the duration
of exposure, the particular receptor, so if high noise levels and reduced demand for certain work
with attention, it is recommended ear type external, in the case of the low exceeding of the
levels of permissible limits is recommended intern earplugs;

- the development of the earplugs to allow a normal conversation and to neutralize the high
frequency noise.

The greatest attenuations are made earplugs of external type which performs better at high frequencies
where the ear is more sensitive. These earplugs require no maintenance demanding. The variation of
attenuation is about 45 dB than 30 dB for intern earplugs. However the internal type are lighter and
can be worn longer, require a much simpler technology of implementation, low cost price and can be
worn in environments with higher temperatures (not prevent breathing and perspiration), the worker
can use in the same time other equipment or devices or protective work.

The negative characteristic is given by means of individual protection that defends only the auditory
organ and excessive noise can disturb the general condition of the body exposed, even if the ears are
protected .

Such personal protective equipment such as ear plugs can reduce or block selectively the perception of
noise and enable the speech perception. They are considered suitable and adequate when worn
correctly and the noise level is under 80 dB(A) for the employee's ear.

Complementary measures of protection against noise are:

- limit time of the exposure to noise of the operator;

- change periodic the job;
- ensuring the silence on during breaks.
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