hadis

CLO 1 : classify clearly the basic concept of mechanical

components. (C4)

CLO 3 : organize properly maintenance procedure base

on standard operation procedure. (A4)

This topic explains drive mechanism as a process of

transforming power, gear, belt drives, chain drive,
friction drive, coupled shaft alignment and develop
procedures for power transmission maintenance.

3.0 POWER TRANSMISSION

3.1 Describe the drive mechanism in the process of
transforming power from one point to the other.

 3.1.1 Classify types of

drive mechanisms
II. Timing belt
1. belt drive:
I. V-belt
3.1 Describe the drive mechanism in the process of
transforming power from one point to the other.

2. chain drive
I. Roller chain
II. Inverted-tooth
(silent-chain)
drives
III. Cast chain
3.1 Describe the drive mechanism in the process of
transforming power from one point to the other.

1. gear drive and

2. friction drive.
3.2 Describe gear in power transmission system.

3.2.2 TYPES OF 3.2.2 CHARACTERISTIC 3.2.1 APPLICATION

GEAR
1. Spur •Parallel shafting •Applicable to all types of
•High speeds and loads trains and wide range of
•Highest efficiency velocity ratios.
•Precision rating is excellent

2. Helical •Parallel shafting •Applicable to high speeds

•Very high speeds and loads and loads
•Efficiency slightly less than spur • also used whenever spurs
mesh are used.
•Precision is good

3. Crossed helical •Skewed shafting point contact •Relatively low velocity

•High sliding ratio
•Low speeds •Low speeds and light
•Light loads loads only
•Precision rating is poor •Any angle skew shafts
 3.2 Describe gear in power transmission system.
TYPES OF CHARACTERISTIC APPLICATION
GEAR
4. Internal •Parallel shafts •Required high speeds and loads
Spur •High speeds •Low sliding and high stress loading
•High loads •Good for high capacity
•Precision rating is fair •Long life
•Used in planetary gears to produce
large reduction ratios.
5. Bevel •Intersecting shaft •Suitable for 1:1 and higher velocity
•High speeds ratios.
•High loads •For right angle meshes.
•Precision rating is fair to good
6.Worm mesh •Right angle skew shaft •High velocity ratio
•High velocity ratio •Angular meshes
•High speed and loads •High loads
•Low efficiency
•Nonreversible
•Precision rating is fair to good
3.2 Describe gear in power transmission system.

3.2.3 THE PROPER DRIVE BASED

ON AGMA (AMERICAN GEAR
MANUFACTURE ASSOCIATION).
GEAR DRIVE
 Gear drives deliver power to
equipment.
 Many variables must be
considered when sizing and
selecting a gear drive based
on AGMA, such as:
1. service factor
2. gear drive rating
3. thermal capacity
4. speed variation
5. drive ratio
3.2 Describe gear in power transmission system.

3.2.4 IDENTIFY GEAR MESHING

AND BACKLASH.

 Gear meshing is a gear

to mesh with another
gear.
 backlash is the striking
back of connected
wheels in a piece of
mechanism when
pressure is applied.
3.2 Describe gear in power transmission system.

APPLY COUPLING CONCEPT INTO

GEAR SYSTEM. UNIVERSAL JOINTS
Gear couplings and universal joints are
used in similar applications.

Gear couplings have higher

torque densities than universal joints
designed to fit a given space while
universal joints induce lower vibrations.

The limit on torque density in

universal joints is due to the limited
cross sections of the cross and yoke.

The gear teeth in a gear coupling have

high backlash to allow for angular GEAR COUPLING
misalignment. The excess backlash can << video 1 – backlash dial gauge>>
contribute to vibration. <<video2 – backlash filler gauge>>
MAINTENANCE PROCEDURE FOR POWER TRANSMISSION
DIVISION ‘N’ SERIES HIGH SPEED GEARBOX

N-SERIES HIGH SPEED GEAR

MAINTENANCE
INSPECTION TYPE PROCEDURE FOR POWER TRANSMISSION
AND TIME INTERVALS
High Speed
DIVISION ‘N’Gearboxes
SERIES plan maintenance
HIGH intervals in line with the following
SPEED GEARBOX
operational time periods:

1. Noise and Vibration Inspection

A comprehensive Noise & Vibration Inspection is performed at 8,000
hours of operation (one year) after commissioning.

2. Visual Inspection
A visual inspection is performed at 40,000 hours of operation (five years).
It is necessary to stop and isolate the gearbox, remove the guards,
acoustic covers, and inspection covers to allow access to the internal
components of the gear. A comprehensive Noise & Vibration Survey
should be conducted at least one month in advance of the scheduled
inspection.
MAINTENANCE PROCEDURE FOR POWER TRANSMISSION
DIVISION ‘N’ SERIES HIGH SPEED GEARBOX

3. Major Inspection
The complete gearbox will be dismantled and mechanically inspected for wear or
deterioration of the bearings, seals, and gear teeth at 80,000 hours of operation
(10 years). During this overhaul, any auxiliary drive rolling element bearings
should be replaced along with any pring/locking devices. A comprehensive Noise
and Vibration Inspection should be performed at least one month prior to and
one month after the Major Inspection.
Further examination periods should be established by reviewing the operating
conditions found during these initial health checks. If the gearbox is found in
poor condition, then the inspection interval should be reduced. If no issues were
identified, it may be acceptable to increase the inspection interval.

4. Future Inspections
It is recommended to continue the cycle of inspection as:
• The Visual Inspection is repeated each additional 40,000 hours (5 years) in
service.
• A Major Inspection is conducted each additional 80,000 hours (10 years) in
service.
MAINTENANCE PLAN SUMMARY
Hours (YRS) Noise & Vibration Survey Visual Major Inspection
Inspection
8,000 ( 1 ) √
40,000 ( 5 ) √ √
80,000 ( 10 ) √ √
120,000 ( 15 ) √ √
160,000 ( 20 ) √ √
200,000 ( 25 ) √ √
 BELT DRIVE
 Belt drives are widely used in many industries for power
transmission since they are cheap and easy to maintain.
However they are often a source of vibration due to
misalignments, belt resonance, and belt wear.

 The main purpose of belt drives is to transfer power

between machines such as motor and fan. They are
subject to rotary and push-pull motions with varying
dynamic characteristics. Belts are friction drives, which
mean they depend on friction between the belt and
pulley/sheave to transmit power.
 Types of Belt Drive (1/2)
 The most common types of belt drives include:

1. Round belts 2. V belts

Round belts are generally made of rubber.
This type of belt is generally used for light
loads, such as in a sewing machine or a
vacuum cleaner.
V belts are arguably the most widely
used belts in industry. V belts have a V
shaped cross-section, which rests
against the side of V pulley under
tension. The V shaped cross-section
prevents belt from slipping off.
 Types of Belt Drive (2/2)
3. Flat belts
 Flat belts are also used to transmit power from one shaft to another. They
are generally classified as either small woven endless belts or higher power
flat belts. The woven endless belts are especially useful where minimum
vibration is required at the driven pulley due to semi-elastic material used in
construction.  The higher power flat belts are often useful because they
eliminate the need to high belt tension used to grip pulleys, which in turn
reduces the load on the shaft bearings. The material used for high power flat
belts is sticky yet abrasion-resistant rubber compounds.

4. Timing/toothed belts
 Timing belts are toothed belts that use their teeth for power transmission,
as opposed to friction. This configuration results in no slippage, and
therefore, the driving and driven shafts remain synchronized. It’s more
expensive to manufacture due to complexity of the belt and pulley shapes.
 Belt drive Misalignment

1. Parallel misalignment refers to pulleys that are outside the plane of other
pulleys in the drive system but whose shafts remain parallel. Proper positioning of
a pulley on a shaft will help ensure all pulleys are in a common plane.

2. Angular misalignment refers to pulleys which are within the same drive
system plane but are tilted because their shafts are not parallel. A combination of
both is also possible.

<<Video link>>
Belt Drive Advantages & Disadvantages
Belt drive advantages Belt drive disadvantages
1. Cleanliness 1. Need to retension
2. Lubrication-free periodically
3. Absorbs shock loads 2. Deterioration from exposure
4. Wide selection of speed to lubricants or chemicals
ratios 3. Cannot be repaired, must be
5. Can provide variable speeds replaced
6. Quiet operation
7. Efficiency over 95%
8. Transmits power between
widely spaced shafts
9. Visual warning of failure
 CHAIN DRIVE

 Chain drive is a way of transmitting

mechanical power from one place to another.
Chain is a sequence of items of the same type
forming a line, circle or a closed and open
path.
 Types of Chain Drive

1. Roller chains
3. Silent chains
2. Leaf Chains

4. Engineering Steel Chains 5. Flat Top Chains

 Roller Chain Tension
Tension
When the chain is too tight,
the working parts carry an
extra load and work harder
without delivering any more
power than a properly installed
chain drive. This causes chain
wear due to increased pressure
in the joints. Over-tightening
also overloads the shaft and
support bearings.
Excessive Slack
Too much slack, as shown in
Figure 41, is also harmful to
the drive. Excessive chain
slack causes vibration, whip,
and reduced chain life
because of the flexing
condition.
Correct Slack
For most horizontal and
inclined drives, the chain
should be installed with a
sag in the unloaded span of
approximately 2% of the
sprocket center distance.
 Chain Drive Shaft and Sprocket
Alignment
Proper alignment of sprocket and shaft is necessary to
provide long wear life of the drive unit. Increased wear
results from misalignment, due to rubbing of chain parts
against the sides of the sprocket teeth and excessive
friction wear in the joints caused by whipping and
twisting of the chain.

To ensure correct alignment, the following

steps are recommended:

1. Check to determine if the sprocket is

positioned axially square on the shaft. Use
a dial indicator as shown
2. Level the shafts using a machinist level as
shown

3. Align the shafts parallel, using a tape

measure or a feeler bar as shown. Recheck the
level of the shafts and tighten down the
securing fasteners.

4. Align the sprockets axially on the shafts,

using a straight edge as shown. Locate the
straight edge on a finished surface on the
sprocket face. For long center distances, a
stretched wire or tight cord can be used.
 Chain Drive Advantages &
Disadvantages
Advantages of Chain Drives
1. Do not slip
2. Maintain constant and precise speed.
3. Good service life
4. Easy to install and repair
5. High transmission efficiency

Disadvantages of Chain Drives

6. Noisy
7. Need lubrication
8. Weight of the chain
9. Costly compare to belt

<<Video>>
 THE FUNDAMENTALS OF COUPLING/SHAFT ALIGNMENT

 Basically motors are coupled of pumps. Many

rotating equipment that require shaft
alignment.
 Basic shaft misalignment
 Procedure for shaft and coupling alignment
 Video shaft and coupling alignment – dial gau
ge indicator concept
 Video dial gauge pump & motor alignment