This is a sample of Modernization of Industrial Machines (full version can be downloaded at http://bin95.com/modernization-of-industrial-machinery.htm )
The full 217 page full eBook "Modernization of Industrial Machines", addresses the problem of what to do with the vast number of old conventional machines existing in good working condition but not meeting the new technological requirements. It touches on a broad range of industry segments for a good understanding of renovating or modernizing industrial equipment.
People who who may need this knowledge in their career are industrial maintenance and engineering. Those from process and manufacturing to those in the small CNC shops.
2. †—•–”‹ƒŽ ƒ…Š‹‡•
By Prof. Bhagwati Prasad Gupta
This sample includes the detailed table of contents, the preface, some sample pages
from eBook and the author bio.
To download the entire eBook, please visit
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42. PREFACE
In a competitive environment, the growth of a business depends upon well-developed
industries. The industry operations must be efficient requiring the use of well-maintained and
state-of-the-art machines and equipment.
On an average, for an engineering industry, 15 years can be safely considered as the useful
working life for a medium and heavy machine. Moreover, during this period, technology of
the product and process are very likely to also change. Replacement of old plants and
machinery is an expensive proposition. The life of a machine can be extended to a great
extent by reconditioning before it is discarded as useless scrap. But the problem is what to do
with the vast number of old conventional machines existing in good working condition but
not meeting the new technological requirements.
Retrofitting and modernization is the only solution. This is what I have experienced while
working in maintenance of plants and machines rebuilding field in engineering industries for
more than 35 years. In this book, effort has been made to compile, in brief, the experience
and the relevant information in the machine modernization area gathered during this period.
The modernization of a machine means an introduction of changes into the design of
machines which improve their performance and capacity and prolong their service life. But
before initiating the modernization effort, one needs to study the operating cycle of the
machine in order to be aware of the technical behavior of the machines. Modernization of
equipment is one of the principal trends in comprehensive mechanization and automation of
production processes. It permits conversion of obsolete machines into semiautomatic and
completely automatic machines with low expenditure in terms of labor, time and money. The
first and second chapters of this book have been written to cover these topics explaining the
modernization trends and guidelines. The first two chapters form the basis for the subsequent
chapters.
Operational regime varies depending on the material of the job, tooling and technology
followed. Chapter 3 discusses different parameters including cutting speed, feed, cutting
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43. forces involved and power required for improving the operational regime and the drives
required for ensuring the same from the machine have been explained in chapter 4. Selection
of drives is the most important consideration for any modernization. An overview of
different options have been given for motors and drives, including servo-drives, and their
selection criteria for various technological needs.
A drive can serve its purpose only when the desired motion, providing appropriate torque and
speed, is available. This may mean a change of speed with a corresponding change in torque,
a change in output direction or position, or more commonly, a combination of the above. So,
there is a need for proper selection of rotary motion transmission devices. But, for feed
mechanism usually a linear motion is required. Since devices used in old conventional
machines are not very efficient, modernizing linear motion mechanism is therefore essential.
In order to couple the transmission devices with the drive, suitable clutches and couplings are
required. Details for such transmission devices and selection of clutches and couplings for
precision applications are given in Chapters 5, 6 and 7, respectively.
By improving the drives and transmission devices, speeds and feeds can be increased and
appropriately regulated. But without smooth rotary motion of the spindle and linear motion of
slides on guide-ways, desired results cannot be achieved. Improvements in spindle assembly
have been described in chapter 8. This chapter describes not only the methods for the
restoration of old spindle, but also the standard (readily available) spindle and different types
of bearings including substitution by other types of bearings. Modernization of housing
guides and slide-ways have been explained in chapter 9. This chapter explains not only about
the restoration of different types of conventional guide-ways but also different types of lowfriction slide-ways for retrofitting during modernization of the machines. Chapter
10,'Improving lubrication system', gives the complete details of lubrication arrangements
both for rotary as well as sliding motion units.
In order to equip the machines with the latest features available in the modern machines, it is
necessary to be aware of the systems, devices and facilities that can be applied during the
modernization. Chapter 11, 'Modernization with hydraulic and pneumatic system', includes
the details of different types of hydraulic and pneumatic circuits and the components
involved in them. It also provides a brief explanation of electro-hydraulic system like
proportional valve and servo-valves which enable machines to perform complicated
operations. A machine can be made versatile if it can be equipped with features that enable it
to perform the subsequent operations also in the same setting without the need of taking the
work-piece on the other type of machine. An example is key-way cutting on the shaft after
turning on lathe machine in the same settings. Similarly, performance can be improved if
time for the auxiliary operations can be reduced by providing self-cantering arrangements,
multi-tool turrets, multi-position job setting as in pallet changer, provision of auto tool
changer, on job digital measuring devices like DRO, etc. This is the topic of chapter 12,
'Retrofitting with additional features and attachments'. Performance of a machine can be
further improved by incorporating copying attachments. Other arrangements including
protective coverings and fitting of chip conveyors have also been discussed in this chapter.
Operations on a machine can be performed only through its control system. This means the
performance of a machine can be improved to the best possible level by modernization of the
control system. Controls can be manual or automatic depending upon the frequency of
changing operations required. Chapter 13 discusses almost all types of popular controls
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44. applied in the industrial equipment including PLC, NC and CNC. Chapter14 exclusively
focusses on CNC retrofitting and the steps followed by the author on the shop floor while
modernizing the old conventional machines.
Automation in manufacturing operations is the ultimate objective of modernization. All
operations need to be performed and controlled through an automatic control mechanism.
Programmable automation is achieved by incorporating CNC system, Robotics, and PLC.
Effort has been made in this direction in chapter 15 concluding with flexible manufacturing
system (FMS). By installing FMS in a manufacturing industry, automation can be increased
to such an extent that the dependence on operators can be reduced and so, reliability of the
operations can be improved to a great extent.
This book has been written keeping in mind the requirements of engineers, managers and
investors with technical background and working in an engineering industry. Technical
students seeking employment in an engineering industry will also find this book useful.
After going through the text, a lot of ideas will be generated to modernize machines and save
capital by reducing fresh investment in new expensive equipment. I welcome feedback and
suggestions from the readers.
Bhagwati Prasad Gupta
January 2014
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103. About the Author:
Bhagwati Prasad Gupta, a Professor in Deptt.of Mechanical Engineering at Inderprastha
Engineering College near Delhi, has spent more than 35 years in the field of maintenance,
and has been exposed to various industries in India, Russia, Germany and Switzerland. As
General Manager (Facility Rebuilding Division) in Bharat Heavy Electricals Ltd, he has been
responsible for Machine-rebuilding and Modernization of the plants and machinery. He has
organized several training workshops, made presentations at seminars and published papers
on various topics of Operation and Maintenance of Machine-tools and Equipment in different
technical journals. His book on “Machinist Handbook on Precision Machining and
Equipment Maintenance” was published in electronic format by Feed Forward Publications
and is available on website www.FeedForward.com.au.
His other book Industrial Hydraulic Systems and Circuits is available on website
http://www.feedforward.com.au/hydraulic_control_system.htm. His third book on Industrial
Maintenance was published by S. Chand Co. New Delhi. He is Fellow of Institution of
Engineers and Member of All India Management Association. As consultant, recently, he
visited machine-tool manufacturing industries in Taiwan and South Korea for technical
discussions on latest trend followed in designing and manufacturing of industrial machines.
http://bin95.com/modernization-of-industrial-machinery.htm
Keywords: modernization of industry, modernization of industrial machinery, equipment
modernization, machine tool retrofit, retrofitting machines, industrial machinery design,
industrial design, machine design book pdf
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105. †—•–”‹ƒŽ ƒ…Š‹‡•
By Prof. Bhagwati Prasad Gupta
To download the entire eBook, please visit
http://bin95.com/modernization-of-industrial-machinery.htm
Other related titles by Prof. Gupta
Industrial Hydraulic Control Systems, component and Circuits
By Prof. Bhagwati Prasad Gupta
See http://www.bin95.com/ebooks/Industrial_Hydraulic_Systems.htm
Machinist Handbook for precision machining equipment maintenance
By Prof. Bhagwati Prasad Gupta
See http://www.bin95.com/ebooks/machining_equipment_maintenance.htm
(Business Industrial Network provides industrial related eBooks and Software.)
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