Mechanical Training System

Courseware Sample

36737-F0

AB

MECHANICAL TRAINING SYSTEM

COURSEWARE SAMPLE

by the 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 Canada January 2007

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

Courseware Outline
INTRODUCTION TO MECHANICAL DRIVE SYSTEMS JOB SHEETS Job Sheet 1 Job Sheet 2 Job Sheet 3 Job Sheet 4 Job Sheet 5 Job Sheet 6 Job Sheet 7 Job Sheet 8 Job Sheet 9 Introduction to the Mechanical Training System Safety Procedures Key and Setscrew Fasteners Speed and Torque Measurements Efficiency Shafts and Pillow Block Bearings Shaft Alignment and Flexible Couplings Shaft Alignment and Rigid Couplings Motor Soft Foot Detection and Correction

Appendix A Appendix B

Unit Conversion Table Post-Test

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Courseware Outline
INTRODUCTION TO MECHANICAL DRIVE SYSTEMS WORK ORDERS 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 B C D E F G H I J K

Equipment Utilization Chart Components of the Universal Base Assembly Components of the Motor Package Components of the Test and Measurement Package Components of the Tool Box Component Package Components of the Couplings Shafts Panel Components of the Pillow Block Bearings Panel Unit Conversion Table Safety Procedures Lockout/Tagout Procedure Start-up Procedure for the Constant Speed Motor

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VI

Sample Job Sheet Extracted from Introduction to Mechanical Drive Systems

8 SHAFT ALIGNMENT AND RIGID COUPLINGS

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 prime mover 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 straightedge and feeler gauge are used to measure and adjust parallel and vertical alignment.

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

8 SHAFT ALIGNMENT AND RIGID COUPLINGS

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

EQUIPMENT REQUIRED C C C C C C Universal Base Assembly, model 46603 Motor Package, model 46609 Couplings Shafts Panel, model 46610 Pillow Block Bearings Panel, model 46611 Test/Measurement Package, model 46630 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, or loose 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 G

1. Set the disconnecting switch to OFF.

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

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

SHAFT ALIGNMENT AND RIGID COUPLINGS

G G G

3. Lock the disconnecting switch with the lockout device.

4. Lock the lockout device with your padlock.

5. Ask the instructor and each teammate to install their own padlocks in the lockout device.
Note: The universal base should be set up from Job Sheet 7. Repeat Job Sheet 7 if necessary.

Universal Base Setup

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

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

8. Slide the sleeve coupling on the shaft supported by the pillow block bearings.

Vertical Angular Alignment

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 two
points using a feeler gauge as shown in Figure 8-2. Mark the position of the two points with a soapstone marker.

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

SHAFT ALIGNMENT AND RIGID COUPLINGS

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 gap
from 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 Sr 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:

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

SHAFT ALIGNMENT AND RIGID COUPLINGS

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

where St is the shim thickness in inches; Sr 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:

G 17. 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 angular
misalignment. Gap at point 1: Gap at point 2: Vertical angular misalignment:

Vertical Parallel Alignment

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

G 20. Add shims with a total thickness equivalent to the gap under the four screws
of 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.

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

SHAFT ALIGNMENT AND RIGID COUPLINGS

G 23. Loosen the four motor screws, and adjust the motor position until there is no
gap 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 each
shaft.

G 26. Slide the sleeve coupling along both shafts and make sure there is no
interference 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: Instructor's approval:

Date:

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

Sample Work Order Extracted from Introduction to Mechanical Drive Systems

8 SHAFT ALIGNMENT AND RIGID COUPLINGS

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

PROCEDURE

G G G

1. Perform the Safety Procedures listed in Appendix I.

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

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

Figure 8-1. Rigid coupling.

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

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

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SHAFT ALIGNMENT AND RIGID COUPLINGS

G G

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

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

Figure 8-2. Measurement of a parameter.

Vertical Angular Alignment

7. Record the following parameters: Gap at point 1: Gap at point 2: Vertical angular misalignment: Position of the larger gap: Distance between measurement points: Shim ratio: Shim thickness: Side to be shimmed:

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INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

SHAFT ALIGNMENT AND RIGID COUPLINGS

G
8. Instal the shims.

Vertical Parallel Alignment

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: Instructor's approval:

Date:

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

15

Other Sample Extracted from Introduction to Mechanical Drive Systems

Post-Test
1. What does the meter indicate on the control panel? a. b. c. d. The voltage at the built-in AC outlet on the side of the control panel The voltage at the built-in AC outlet on the universal base The current delivered at the built-in AC outlet on the universal base 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 the constant speed motor on the universal base? a. b. c. d. Fixed Variable Any position is correct 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. b. c. d. Controls the motors mounted on the universal base Produces an emergency noise De-energizes the built-in AC outlet on the universal base 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. b. c. d. Each person involved in the job Only one of the person involved in the job The instructor only It is never mandatory to install a padlock.

5. When should the safety panels be installed? a. b. c. d. When there is an obvious risk of injury When the constant speed motor is used When asked by the instructor Before any setup is powered

6. What does a photo-reflective tachometer measure? a. b. c. d. The amount of light reflected by an object The current in a component The voltage in a component The angular velocity of a rotating component

INTRODUCTION TO MECHANICAL DRIVE SYSTEMS

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Post-Test (cont'd)
7. What is a prony brake used for? a. Measure the input power of a prime mover b. Provide a means for applying an adjustable load torque to the output shaft of a prime mover c. Brake a motor until it stops completely d. Measure the current consumed by a motor when it stops

8. Where should a setscrew be tightened on a shaft? a. b. c. d. Only on a key On the flat surface of the shaft or on a key Directly on the shaft keyseat Preferably on the round portion of the shaft

9. What type(s) of coupling(s) can compensate for slight errors in shaft alignment? a. b. c. d. Flexible couplings only Rigid and flexible couplings Rigid couplings only Any existing type

10. What are the two basic types of shaft misalignment? a. b. c. d. Horizontal angular and parallel Angular and linear Parallel and angular Vertical angular and horizontal angular

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INTRODUCTION TO MECHANICAL DRIVE SYSTEMS