Beruflich Dokumente
Kultur Dokumente
Jagannath Sardar
(2008TTZ8165)
Acknowledgement
I would like to show my high gratitude to our Respected Sir, Prof. Kshitij Gupta, who has taken the course Design for Noise, Vibration and Harshness and I have got a plenty of knowledge regarding Noise and Vibration from his kind teaching. Before doing this course I have had least knowledge about Noise and Vibration. Even I did not know the exact definition of sound as well as Vibration. I am also grateful to my entire classmates of this course. Specially, I am thankful to Mr. Changadev Desai who has helped me to understand the course as well. I am also thankful to Mr. Ajay, M.Tech final year student, who has taken care of us during practical classes of the same course.
1. Introduction:
Textile is one of the major economic Industries all over the world. In the field of noise at the workplace, in spite of national regulations on noise at work in force for many years, lots of people are still getting hearing losses due to machinery noise throughout the world. In order to progress, there was a need for a policy enforcing noise reduction at source at the design stage and allowing market forces to encourage less noisy machinery being put on the market. This was made possible in Europe through a specific European regulation [1]. In parallel to the strong action on noise reduction at source at the design stage, a standardization programme developed at the European and international levels on workplace noise in particular on designing low-noise workplaces, designing means to reduce noise on the propagation path and measuring their effectiveness. Now a days the machine layout and operation pattern has been changed in textile industry. Management of the industry are concerned to preserve floor space and optimize production in both the natural and man-made fibres industries. Noise in the mills and factories is increasing, and one of the main reasons is that in the face of keen competition and already on a 24 h basis, machines are being operated at speeds higher than ever before to increase production rates. This is possible to a great extent with the man-made fibres; continuous threads can be produced and wound more quickly because of their inherent strength and other advantageous properties compared with natural fibres. As a direct result of the speed increase, out of balance forces and vibration increase and more energy is released as sound [2] Due to the complex nature of Textile industry, versatile machineries are used in the field of textile product. Different type of machineries produces different level of noise. Generally workers are exposed in that level of sound during production. They have been effecting by that sound at any instance. OSHA (Occupational Safety and Health Act 1970) prescribed permissible exposures in industries. These levels are shown in the table below (Table 1): [3]:
In a textile mill, minimum and maximum noise level can be achieved as 82.82 dBA and 102.3 dBA (approximately) respectively [4]. To prevent health hazards of the workers in that level of sound, different type of techniques can be applied. But due to unconcerned and un educated workers, the implementation of those techniques are partially failure. This is a challenging job to prevent noise in textile industry as well as enlightening to the unconcerned workers and administrative in Textile industry. In this literature we will discuss about some approaches to make a pleasant working environment not only for worker but also the beneficial for the management of the Textile Sociaty.
Table 1.1: Permissible daily noise exposure limits for industrial noise (OSHA)
Limiting Daily Exposure Time (h) 8 6 4 3 2 1.5 1 0.5 Less Than 0.25
A-Weighted Sound Level Slow Response (dBA) 90 92 95 97 100 102 105 110 115
persons hearing. An increase of 10 dBA is a doubling of loudness with respect to the human ear [5]. Noise generally consists of many tones with varying rates of vibration or frequency. The frequency expressed in cycles per sound or hertz (HZ) usually is in the range of 20 to 20,000 cycles per second. The ear is not very responsive to very low or very high tones as it is to the tones of medium frequency. The dBA scale matches the response of the ear, and is therefore well suited for evaluating noise as it relates to human beings [6]. The noisy industrial machine can be viewed as a sound generator. The noise generated, generally, will be made up of sound waves which encompass the spectrum of 125 cycles per second to 8,000 cycles per second with a certain frequency band being dominant. The noise emitted is either direct airborne sound or noise generated by mechanical vibrations setting up vibrations in sheet metal panels or large solid areas. Sound waves decrease in length as the frequency increases or, more simply, the wavelength is inversely proportional to the frequency. Generally, it is easier to control noise in the higher frequency bands than the lower frequency bands since it is difficult to absorb sound which is made up of long wave lengths.
process of the noise source in its primary functions. Redesign of the noise source may be prohibitive based on the cost to redesign, develop and re-tool. Treatment of the noise receiver is the least desirable approach since each receiver must be treated individually. The addition of earplugs or earmuffs can encumber the receiver to the extent of being impractical. Educating the receiver as to the source of the noise and the purpose of the noise generating mechanism is another possibility. In any case the degree of effectiveness of the treatment will vary since the range of subjective reaction to noise varies from person to person. Treatment of the noise path is conceptually the simplest and therefore the most common approach to a localized noise problem. The approach is to place material in the path of the noise (generally between the noise source and the noise receiver) so that the level of noise at the receiver is reduced. The application of materials is often oversimplified, however, leading to ineffective and/or inefficient use of materials. Also the air paths are typically addressed while the structural paths are often overlooked. Finally, the design of the treatments developed without consideration of assembly procedures can lead to installation errors, which compromise the purpose of the treatment.
Fig. 1 Mean hearing levels (dB) at different frequencies. The results of the study establish the fact that noise level in certain sections of the plants i.e Loom Shed, Spinning, Ring Frame, TFO Area is more than the acceptable limit of 90
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dBA for 8 h exposure stipulated by OSHA. The noise level in other sections like carding, blow room, combing etc., although is less than 90 dB(A), but is quite higher than limits used for assessment of noise for community response. Octave band analysis of the noise shows the presence of high sound level in 4,000 Hz frequency range, which can be a major reason for causing occupational hearing loss. The results of the interview questionnaire which included a number of parameters reveal the following; (i) only 29% workers are aware about the effects of noise on health (ii) 28% workers are using ear protectors (iii) the satisfaction with the working environment is related to noise level, as workers exposed to comparatively less noise level report better satisfaction (iv) 70% of the workers reported that high noise level causes speech interference (v) 42% workers report the noise to be annoying. The study thus demonstrates the presence of gross occupational noise exposure in both the plants and the author believes that occupational noise exposure and the related effects in India is a widespread problem. The equivalent A-weighted sound pressure level LAeq has been calculated using the equation:
The details of the Leq values of noise to which the workers are exposed in various work areas in a textile mill is shown in the Table 2 and Table 3 below:
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Madbuli H. Noweir et al. [8] has shown, the dBA means of Leq, Max (SPL) and Min (SPL) of the surveyed factories are in Table 4. The most used and possibly, the most meaningful parameter, the Leq has varying degree of variance, ranging from 1.5 dBA2 (Hygienic Paper Products Co.) to 5.9 dBA2 (Nasr Printing Factory). Factories with smaller variance of Leq could be treated with general noise control and reduction techniques. However, factories with high variation may have hot spots which would need individual noise control at the sources in addition to any general measures. Table 4
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Exposure to continuous and extensive noise at a level higher than 85 dBA may lead to hearing loss. Continuous hearing loss differs from person to person with the level, frequency and duration of the noise exposed [9.]. Negative effects of noise on human beings are generally of a physiological and psychological nature. Hearing losses are the most common effects among the physiological ones. It is possible to classify the effects of noise on ears in three groups: acoustic trauma, temporary hearing losses and permanent hearing loss [10]. Blood pressure increases, heart beat accelerations, appearance of muscle reflexes, sleeping disorders may be considered among the other physiological effects. The psychological effects of noise are more common compared to the psychological ones and they can be seen in the forms of annoyance, stress, anger and concentration disorders as well as difficulties in resting and perception [11, 12, 13].
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A great majority of people working in industry are exposed to noise. Therefore, in this study, the effects of noise on human beings have been investigated with respect to the level of noise they are exposed to [14] assembly procedures can lead to installation errors, which compromise the purpose of the treatment.
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Figure 4 illustrates the essential role of standards in the current strategy for reducing noise in industry.
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Draw twisting or Roving machines are used to produce twisted roves or slivers. For all the operations, pneumatic pressure compressors are required. place to control noise in air jet spinning machinery [ 15]. After pre-processing, roves or slivers are used to manufacture yarns. In this section, as per the end use, different types of spinning machines are used such as ring spinning, rotor spinning DREF machines etc. According to the speed of the machines, the emissions of sound levels are different in different machineries. In the twisting zones, the rotor speed is maximum compare to other spinning machines. The rotor speed is approximately 120000 rpm and the opening roller speed is 5000-6000 rpm. Most of the sound emits due to the high speed of rotor. Similarly, the speed of the spindle of Ring spinning approximately 20000 rpm and in draw twisting machine, the speed of the spindle approximately 14000 rpm. The approximate emissions of sound levels in spinning machineries are given in the table 5. Table 5 Name of the Machines Blow Room Carding Combing Drawing Roving Ring Spinning Rotor Spinning DREF Spinning Max. Sound Level (dBA)(apprx.) 82-84.8 86.2-89.2 84.5 85 88-95.5 99.5-100.2 102-104 89.9 Those machines are emitted noise in different levels. An US patent has reveals some features which takes
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Fig. 6 Noise spectra of five processes 1. Staple fibre cutter, 2. Spinning, 3. DrawTwisting, 4. Weaving, 5. Winding. It is very difficult to control huge amount of noise in direct approach. Ear protector could be a solution to prevent hazardous effect direct to the human physic as well as psychology. But there are objection from hygiene, safety and comfort consideration. The solution then is to reduce noise level in active approach. The active approach is to overhauling and maintenance periodically that reduce the noise at source. A necessary step to noise reduction at source is a detailed knowledge of the source mechanisms, transmission path and noise radiating surface [2]. A typical diagram of a drawtwister has shown in the fig. 7.
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Fig. 7. Diagram of a drawtwister From the fig. 8 we have seen that the loudest narrow band sound is produced from the spindle and bobbin zones.
A spindle diagram has shown in the fig. 9. The noise source can be control by the detail study of the material and mounting mechanism of the spindle. Generally, spindle and ball-bearing are produced by the metal, which produce more noise. It is possible to change the material, metal to polymeric one.
Fig. 9. Spindle Use of Polyurethane gear, flexibly mounted gears, redesigned headstock and various vibration isolation of parts, the noise contours change and the levels are reduced to meet the recommended levels at the operators position. Some noise reduction techniques on the draw-roll assembly has shown in (Fig 10). One approach used a polyurethane bonded bush between the gear and the shaft. It reduced the overall noise level of one shaft assembly by 7-8 dB. Another trial was made substituting a copper-manganese alloy shaft for the steel shaft. The use of this material not only introduced its high damping properties but also lowered the shaft critical below the running range. The
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result of using the copper-manganese shaft was to reduce the overall noise level by 4.5 dB.
Fig.10 Treated draw roll. In the figure 11 octave band levels for the modified machine are compared to the average drawtwist noise and a deafness risk criterion n.r.85. There is a reduction of noise from 128 sones to 77 sones, i.e. a reduction in loudness od 40%. These noise levels are for the modified machine running with full bobbins at spindle and drawroll speeds higher by 11% and 20% respectively than the maximum production speeds commonly used [16].
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Fig. 11 Octave band levels at centre of machine for modified drawtwist machine. 1. Average drawtwist noise, 2. Modified machine noise, 3. n.r. 85 criterion
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Table 6 Name of the Machines TFO Doubling Cheese Wing Cone winding Precision Winding Shuttle Loom Shuttle less Loom Air jet Loom Water jet Loom Max. Sound Level (dBA)(apprx.) 100 92-95.5 93 92 91-92 99-100 100-105 110 96-99
The noise source of winding machine is almost similar to that of spinning machineries. In case of TFO, the noise generates due to the revolution of the spindle in the spindle chamber. The whole assembly of spindle and chamber vibrates due to it high revolution. The maximum spindle speed is 16000 RPM [17] And the outcome of the result is high amplitude narrowband noise [fig. 12]. arrangement in the gearbox. Another major source of noise is gearing
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Fig. 12. TFO Spindle chamber arrangement. Similarly, in Loom shed, there are many types of looms are use and it is obvious that all different looms have different speed according to their production rate and frequency. Due to the different sped and mechanism, the looms are produced different levels of noise. Like, Air jet looms produce higher level of noise compare other looms (table 6). In the figure 13 a typical Air jet loom has shown. Basically Air nozzle produces much noise in this loom. Not only air nozzles, reed of the looms are produced high noise when it strikes on the base plate of the reeds.
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Fig 13. Air jet Loom In the Shuttle loom, most sound generates due to the movement of the shuttle. During Weft insertion takes place through the Warp shed, shuttle caries the weft thread and it strikes to the end of the shuttle path called sley end (fig 14.). Shuttle nose strikes on the solid material and make noise in a high level. In this occasion, there have a active control arrangement take place. At the end of the shuttle path there have a buffer, which is made by rubber. The rubber buffer consume kinetic energy of the shuttle and indirectly protects the noise.
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But there have no such type of arrangement to control noise in the reeds section. According to the pattern of the fabrics, the reeds are acting up and down. Due to this movement of the reeds a huge noise emits from the loom. When reeds moved down, it strikes metallic parts inside the loom. Not only has this event, the friction between reeds and slot of the reeds emitted noise in each movement. A typical reed has shown in the figure 15.
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Fig. 16. Noise comparison, 1.Shuttle loom (205ppm) 2.Water Jet Loom (400ppm)
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bearing machine, balancing is done at a frequency lower than the resonance frequency [Figure 18] of the suspension [23].
Fig. 18. Resonance frequency In a soft-bearing machine, balancing is done at a frequency higher than the resonance frequency of the suspension. Both types of machines have various advantages and disadvantages. A hard-bearing machine is generally more flexible and can handle pieces with greatly varying weights, because hard-bearing machines are measuring centrifugal forces and require only a one-time calibration. Only five geometric dimensions need to be fed into the measuring unit and the machine is ready for use. Therefore, it works very well for low- and middle-size volume production and in repair workshops. A softbearing machine is not so flexible in respect of amount of rotor weight to be balanced. The preparation of a soft-bearing machine for individual rotor types is more time
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consuming, because it needs to be calibrated for every individual part. It is very suitable for high-production volume and high-precision balancing tasks. Hard- and soft-bearing machines can be automated to remove weight automatically, such as by drilling or milling, but hard-bearing machines are more robust. Both machine principles can be integrated into a production line and loaded by a robot arm or gantry, requiring very little human control. Soft-bearing machines are also generally more expensive because of the higher complexity in the design and manufacturing. Secondly, proper material selection for vibrating parts and in which parts material to material frictions takes place; as an example metallic gear arrangements. For our experience, it is visible that metallic gear to metallic gear arrangement produces more noise compare to polymeric gear. Although, there have many advantages as well as disadvantages for polymeric gear arrangements. However, in account of control of noise, polymeric gears are more suitable rather than metallic one. Generally polyurethane, polyester, polyamide polymers are used for this purpose. It is known that where the rotational movements takes place in the machine parts, the vibration occurs more, as an example spindles, gears, crank shaft etc. those parts can be replaced by polymeric materials instead of metallic one. On the other hand, noise can be reduced by keeping control the noise source. That means, overhauling is important to reduce noise. Periodically lubrication is required in the zone of gears to gear arrangement, ball-bearing and other rotational parts. For all the machines overhauling duration and indication of lubrication is mentioned [24].
in textile machineries is kept open to doffing conveniently after preparation of final products for spinning as well as weaving. It is easy to casing the gearbox effectively. Casing arrangement will be discussed as the following ways: Casing arrangement can be prepared by three ways; using damping material, barrier materials and absorptive materials. In both the cases the aim is to control vibration. Details discussions about those materials are given below.
5.2.1.1Definition
Damping is the reduction of kinetic energy present in a system through transformation into another form of energy. The efficiency of damping present is evaluated by determining the systems loss factor. The dimensionless loss factor () is defined as:
=
Where, Q = System damping factor
f D W 1 = 0 = n = d Q 2T0 fn 2U
D0 = Total energy dissipated in the system as the result of damping for one cycle T0 = Total vibration energy of the system fn = Undampted resonant frequency (Hz) fn = Half power bandwidth (Hz) Wd = Energy dissipated from the system U = Max. energy stored in the system
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A barrier material, which reduces sound energy as the sound wave is transmitted through the material. The measure of a materials effectiveness as a transmission loss as earlier discussion. Transmission loss is the fraction of energy dissipated as a result of sound being transmitted through the material. Transmission loss is measured in decibels as: TL = 10log10 Incident sound intensity (Ii) Transmitted sound intensity (It)
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Fig.22. Noise incident on an absorption material For a sound absorption material applied to an acoustically reflective surface, sound energy incident (Ii) on the material is partially absorbed by the material (Ia) and the remaining sound energy is reflected (Ir). The sound absorption capability of a material is expressed in terms of the sound absorption coefficient; the sound absorption coefficient is defined as:
Acoustic energy absorbed by a surface (Ia=Ii-Ir) Acoustic energy incident on a surface (Ii)
Fig.23. Random incidence sound absorption for Polyurethane foam of various thicknesses.
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So, from the above discussion, it is proved that the noise induce from textile machineries can be controlled by designing some special features in a particular place of a specified noisy part. Some cases when machines are not in controlled for emission of noise, the workers of supervising authority can have ear protector. Using ear protector, to some extent, noise hazards can be controlled for human health.
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6. Conclusion:
For the textile, industry control of noise emission from the textile machineries is a challenging job. Some of the cases noise control has been taking place in few industries. Most of the textile industry in India, they are unable to implement the noise control system. To understand for noise control it is experienced that the controlling systems not only reduce the noise at source to acceptable levels, but also reduces the energy consumption in to some extent and at the same time leads to a better design of the machines too. For example, polymeric gear-gear arrangement or polymeric spindle consumes less energy compare to metallic one for the same r.p.m., it means that less energy consumption can leads to give higher speed as well as higher production. In this occasion, we have seen that it is possible to reduce emission of noise as well as control of noise when human health is concerned. There have number of possible procedure to control noise. We have also seen that the control can be achieved by two ways, such as Active and Passive control. There have different features for those control system. For active control, our aim is to reduce vibration and friction in situ of the noise parts by replacing materials as well as parts configurations. In this case, rotational metallic parts can be replaced by polymeric where noise comes out due to friction. For passive control, we want to reduce the noise level which has already been emitted from the source. There are some procedures to control the noise. The noise source can be covered fully of the cover can be treated by different process such as using damping, barrier and absorption materials. Some cases ear protectors are used to prevent noise hazards.
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7. References:
1. Jean Jacque, Noise And Standardization, Focussing On Machinery And Workplace Domains, Institut National de Recherche et de Scurit, I.N.R.S. Standardization Unit CEN Consultant for Noise, 30 rue Olivier Noyer, 75680 Paris, Cedex 14, France 2. R. Crawford, Noise Control On Textile Machinery, Phil. Trans. R. Soc. Lond. A. 1968 347-367 263 3. L.E.Kinsler, A R. Frey, A B. Coppens, J V. Sanders, Fundamentals of Acoustics, pp377 4. Raman Bedi, Evaluation of Occupational Environment in Two Textile Plants in Northan India with specific reference to noise, Industrial Health 2006, 44, 112-116 5. Dr. D.P.Raychaudhuri Advance Acoustics, , University of Kalyani, pp 283 6. Acoustical Solutions, Inc. 2852 East Parham Rd., Richmond, VA 23228 Ph: 800-7825742 fax: 804-346-8808, www.acousticalsolutions.com 7. Meliksah Ertem, Ersen Ilin, Faruk Meri, Noise Induced Hearing Loss Among Cotton Textile and Carpet Mill Workers, Tr. J. of Medical Sciences 28 (1998) 561-565 TBITAK 8. Madbuli H. Noweir And A. T. M. Jamil, Noise Pollution In Textile, Printing And Publishing Industries In Saudi Arabia, Environmental Monitoring and Assessment 83: 103111, 2003. 2003 Kluwer Academic Publishers. Printed in the Netherlands 9. USEPA (United States Environmental Protection Agency). Information on levels of environmental noise requisite to protect public health and welfare with adequate margin of safety, (EPA/ONAC Rep. No. 550/9-74-004); 1974 10. Melamed, S., Fried, Y., Froom, P. The interactive effect of chronic exposure to noise and job complexity on changes in blood pressure and job satisfaction: A longitudinal study of industrial employees, Journal of Occupational Health Psychology, 6, 182, 2001 11. Cheung, C. K. Organizational influence on working peoples occupational noise protection in Hong Kong. Journal of Safety Research, 35, 465, 2004 12. hrstrm, E. Sleep disturbance psycho-social and medical symptoms a pilot survey among person exposed to high levels of road traffic noise, Journal of Sound and Vibration, 133, 117; 1989
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13. Finegold L. S., Harris C. S., Gierke Von. H. E. Community annoyance and sleep disturbance; Updated criteria for assessing the impact of general transportation noise on people. Noise Control Eng. J. 42 (1) Jan.-Feb. 1994 14. E. Atmaca1, I. Peker1, A. Altin, Industrial Noise and Its Effects on Humans, Polish Journal of Environmental Studies Vol. 14, No 6 (2005), 721-726 15. B.D. Lassiter et al., Noise control system for textile machinery , US patent, no. 4586323, date may 6,1986 16. W. Klein, A practical guide to Combing and Drawing, Volume 3, pp. 42-56 17. www.himsonoriginal.com 18. Tatsuo Matsuura, Environmental Protection Activities of the Textile Machinery Division Division Manager & Managing Director, Textile Machinery Division 19. Sadao Aso, Rikuhiro Kinoshita, Heihachi Uematsu and Kiyohumi Sasaki, Members, TMSJ, Noise Generated by a Power Loom, Based on Journal of the Textile Machinery Society of Japan, Transactions, 18, T13-19 (1965) 20. Stott , A. 1965, Reducing noise in weaving sheds, Textile Manufacturing Machinery 21. Adanur, S. Handbook of weaving, pp. 175-223 22. K sugita et al., Device for noise attenuation of Weaving Machine, US patent, patent no. 5271062, date Dec. 14, 1993 23. Adolf Lingener: Auswuchten. Theorie und Praxis. Verlag Technik, Berlin und Mnchen 1992, ISBN 3-341-00927-2 24. Talukdar, M.K. et al., Weaving, Machines, Mechanisms, Management, Appendix ViiiXiii, pp. 590-598 25. Application of Noise control and heat insulation materials, American Acoustical products, 6 october Hill road, Massachusetts 01746
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