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Mechanical Training System

Courseware Sample

36737-F0

A

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MECHANICAL TRAINING SYSTEM

COURSEWARE SAMPLE

bythe Staff

of

Lab-Volt Ltd.

Copyright 2006 Lab-Volt Ltd.

All rights reserved. No part of this publication may be reproduced,in any form or by any means, without the prior written permission

of Lab-Volt Ltd.

Printed in CanadaJanuary 2007

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II

Table of Contents

Courseware Outline

Introduction to Mechanical Drive Systems Job Sheets . . . . . . . . . . . . . . . V

Introduction to Mechanical Drive Systems Work Orders . . . . . . . . . . . . . VI

Sample Job Sheet Extracted from Introduction to Mechanical Drive Systems

Job Sheet 8 Shaft Alignment and Rigid Couplings . . . . . . . . . . . . . . . . . . 3

Sample Work Order Extracted from Introduction to Mechanical Drive Systems

Work Order 8 Shaft Alignment and Rigid Couplings . . . . . . . . . . . . . . . . . 13

Other Sample Extracted from Introduction to Mechanical Drive Systems

Post-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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IV

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INTRODUCTION TO MECHANICAL DRIVE SYSTEMS JOB SHEETS

Courseware Outline

V

Job Sheet 1 Introduction to the Mechanical Training System

Job Sheet 2 Safety Procedures

Job Sheet 3 Key and Setscrew Fasteners

Job Sheet 4 Speed and Torque Measurements

Job Sheet 5 Efficiency

Job Sheet 6 Shafts and Pillow Block Bearings

Job Sheet 7 Shaft Alignment and Flexible Couplings

Job Sheet 8 Shaft Alignment and Rigid Couplings

Job Sheet 9 Motor Soft Foot Detection and Correction

Appendix A Unit Conversion TableAppendix B Post-Test

We Value Your Opinion!

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INTRODUCTION TO MECHANICAL DRIVE SYSTEMS WORK ORDERS

Courseware Outline

VI

Work Order 1 Introduction to the Mechanical Training System

Work Order 2 Safety Procedures

Work Order 3 Key and Setscrew Fasteners

Work Order 4 Speed and Torque Measurements

Work Order 5 Efficiency

Work Order 6 Shafts and Pillow Block Bearings

Work Order 7 Shaft Alignment and Flexible Couplings

Work Order 8 Shaft Alignment and Rigid Couplings

Work Order 9 Motor Soft Foot Detection and Correction

Appendices A Equipment Utilization ChartB Components of the Universal Base AssemblyC Components of the Motor PackageD Components of the Test and Measurement PackageE Components of the Tool Box Component PackageF Components of the Couplings Shafts PanelG Components of the Pillow Block Bearings Panel

H Unit Conversion TableI Safety ProceduresJ Lockout/Tagout ProcedureK Start-up Procedure for the Constant Speed Motor

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Sample Job Sheet

Extracted from

Introduction to

Mechanical Drive Systems

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8

SHAFT ALIGNMENT AND RIGID COUPLINGS

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS 3

Rigid shaft couplings are used to join lengths of shaft of equal or different diameter.The main use is to extend the length of a shaft. It is rarely used to connect a primemover directly to a load. A rigid sleeve coupling is shown in Figure 8-1.

Figure 8-1. Rigid coupling.

Unlike flexible shaft couplings, rigid shaft couplings do not allow errors in alignment,

which may cause premature failure of bearings or shafts.

Rigid shaft couplings are installed after the shafts have been aligned. A straightedgeand feeler gauge are used to measure and adjust parallel and vertical alignment.

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4 INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

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8



OBJECTIVES

In this job, you will perform a shaft alignment and install a rigid coupling.

EQUIPMENT REQUIRED

C Universal Base Assembly, model 46603C Motor Package, model 46609C Couplings Shafts Panel, model 46610C

Pillow Block Bearings Panel, model 46611C Test/Measurement Package, model 46630C Tool Box Component Package, model 46631

SAFETY PROCEDURES

Before proceeding with this job, complete the following check list.

G You are wearing safety glasses.

G You are wearing safety shoes.

G You are not wearing anything that might get caught such as a tie, jewelry, orloose clothes.

G If your hair is long, tie it out of the way.

G The working area is clean and free of oil.

G The floor is not wet.

G Your sleeves are rolled up.

PROCEDURE

Lockout/Tagout Procedure

G 1. Set the disconnecting switch to OFF.

G 2. Write your name on a tag, and install it in the lockout device.

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G 3. Lock the disconnecting switch with the lockout device.

G 4. Lock the lockout device with your padlock.

G 5. Ask the instructor and each teammate to install their own padlocks in thelockout device.

Note: The universal base should be set up from Job Sheet 7.Repeat Job Sheet 7 if necessary.

Universal Base Setup

G 6. Loosen the pillow block bearing setscrews and slide the shaft away from the

motor.

G 7. Remove the flexible jaw coupling halves, insert, and keys from the twoshafts. Keep the rest of the setup intact.

G 8. Slide the sleeve coupling on the shaft supported by the pillow blockbearings.

Vertical Angular Alignment

G 9. Adjust the gap between the ends of the shafts to approximately 0.125 in.

G 10. Line up the shaft keyseats and position them at the 9-o'clock position.

G 11. Lay a straightedge on the top of the shafts and measure the gap at twopoints using a feeler gauge as shown in Figure 8-2. Mark the position of thetwo points with a soapstone marker.

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Figure 8-2. Vertical angular alignment.

Gap at point 1:

Gap at point 2:

G 12. Calculate the vertical angular misalignment by subtracting the smaller gapfrom the larger. Note the position at which the larger gap was measured.

Vertical angular misalignment:

Position of the larger gap:

G 13. Record the distance between the measurement points (soapstone marks)along the shaft.

Distance between measurement points:

G 14. Calculate the shim ratio using the following formula:

where S r is the shim ratio;L1 is the distance between the slots of the motor base, in inches;L2 is the distance between the measurements points in inches.

Shim ratio:

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G 15. Calculate the required shim thickness using the following formula:

where S t is the shim thickness in inches;S r is the shim ratio;Vam is the vertical angular misalignment in inches.

Shim thickness:

G 16. Determine if the front or the rear of the motor must be shimmed.

Side to be shimmed:

G17. Loosen the screws on the determined motor base side and install the shims.

Note: An equal thickness of shims must be installed under the two front or rear motor screws to raise it evenly.

G 18. Measure the gaps at point 1 and 2, and calculate the vertical angularmisalignment.

Gap at point 1:

Gap at point 2:


Vertical Parallel Alignment

G 19. Measure the gap at one point between the shafts, using a straightedge anda feeler gauge.

G 20. Add shims with a total thickness equivalent to the gap under the four screwsof the motor plate.

Horizontal Alignment

G 21. Line up the shaft keyseats and position them at the 12-o'clock position.

G 22. Lay a straightedge on the side of the shafts at the 3-o'clock position.

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G 23. Loosen the four motor screws, and adjust the motor position until there is nogap between the straightedge and the shafts.

G 24. Tighten the motor screws.

Sleeve Coupling Installation

G 25. Install a key on both shafts. Make sure they are in line with the end of eachshaft.

G 26. Slide the sleeve coupling along both shafts and make sure there is nointerference at any point.

G 27. Tighten the coupling setscrews on the keys.

G 28. Ask the instructor to check your work.

G 29. Disassemble the setup and return the components to the storage location.

Name: Date:

Instructor's approval:

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Sample Work Order

Extracted from

Introduction to


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8



Task: To align two shafts. To install a rigid sleeve coupling.

PROCEDURE

G 1. Perform the Safety Procedures listed in Appendix I.

G 2. Perform the Lockout/Tagout Procedure described in Appendix J.

G 3. What is the main function of a rigid coupling such as the one shown inFigure 8-1.

Figure 8-1. Rigid coupling.

G 4. Which of rigid or flexible couplings can accomodate the higher degree ofmisalignment?

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G 5. Assemble the setup shown in Figure 4-3.

G 6. Install the flexible coupling on the driven shaft and use a feeler gauge anda straightedge to measure the parameters required for the alignment asshown in Figure 8-2.

Figure 8-2. Measurement of a parameter.

Vertical Angular Alignment

G 7. Record the following parameters:

Gap at point 1:

Gap at point 2:


Position of the larger gap:

Distance between measurement points:

Shim ratio:

Shim thickness:

Side to be shimmed:

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G 8. Instal the shims.

Vertical Parallel Alignment

G 9. Measure the gap between the hubs and record it.

Gap:

G 10. Install the shims.

Horizontal Alignment

G 11. Adjust the motor position.

G 12. Complete the sleeve coupling installation.

G 13. Ask the instructor to check your work.

G 14. Disassemble the setup and return the components to the storage location.

Name: Date:

Instructor's approval:

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Other Sample Extracted

from

Introduction to


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Post-Test

1. What does the meter indicate on the control panel?

a. The voltage at the built-in AC outlet on the side of the control panelb. The voltage at the built-in AC outlet on the universal basec. The current delivered at the built-in AC outlet on the universal based. The current delivered at the built-in AC outlet on the side of the control panel

2. To which position should the Output Voltage selector be set when using theconstant speed motor on the universal base?

a. Fixedb. Variablec. Any position is correctd. It depends on the use of the motor.

3. What is the use of the emergency button on the Start/Stop push-button station?

a. Controls the motors mounted on the universal baseb. Produces an emergency noisec. De-energizes the built-in AC outlet on the universal based. De-energizes the built-in AC outlet on the side of the control panel

4. Who must install a padlock on the lockout device?

a. Each person involved in the jobb. Only one of the person involved in the jobc. The instructor onlyd. It is never mandatory to install a padlock.

5. When should the safety panels be installed?

a. When there is an obvious risk of injuryb. When the constant speed motor is usedc. When asked by the instructord. Before any setup is powered

6. What does a photo-reflective tachometer measure?

a. The amount of light reflected by an objectb. The current in a componentc. The voltage in a componentd. The angular velocity of a rotating component

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Cwa 46603

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