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Optimization of Heating Characteristic and Energy

Consumption at Bearing Heater U Model 220 Volt using


Induction Electromagnetic Principle based on Taguchi Method
Candra Bachtiyar, Golfrid Gultom, Manan Ginting

Mechanical Industry Technology Department


Pendidikan Teknologi Kimia Industri, Medan 20228
Tel : (061)7867810. Fax : (061) 7862439
E-mail : candra-b@depperin.go.id

Mechanical Industry Technology Department


Pendidikan Teknologi Kimia Industri, Medan 20228
Tel : (061)7867810. Fax : (061) 7862439
E-mail : golfridg@yahoo.com

Mechanical Industry Technology Department


Pendidikan Teknologi Kimia Industri, Medan 20228
Tel : (061)7867810. Fax : (061) 7862439
E-mail : mananginting@yahoo.com

ABSTRACT 1. INTRODUCTION

In this study, The Taguchi method is used to find The reliability of machine is of paramount
the optimal heating characteristic and energy importance in industry. Bearing play an
consumption of bearing heater U model that it important role in the reliability and performance
make in Electronic Laboratory of PTKI Medan. of machine. Due to the closed relationship
An orthogonal array, the signal to noise (S/N) between machine development and bearing
ratio, and the analysis of variance (ANOVA) are assembly performance, it’s difficult to imagine
employed to investigate the heating the progress of modern rotating machinery
characteristic and energy consumption of without consideration of wide application of
bearing heater U model 220 volt using bearing bearings. In additional faults a rising in
type 6308. Through this study, not only can the machinery are often linked to bearing faults. The
optimal the heating characteristic and energy result of various studies show that bearing
consumption be obtained, but also the main problems accounts for over 40 % of all machine
parameter that effect the heating time and energy failures [1]
consumption can be found. As shown in this
study, the Taguchi method provides a systematic The main factor of bearing faults is dust and
and efficient methodology for design corrosion. Dirt and other foreign matter that is
optimization of heating characteristic and energy commonly present often contaminate the bearing
consumption. It has been shown that heating lubrication. Bearing corrosion is produced by
characteristic and energy consumption can be presence of water, acids, deteriorated lubrication
improved significantly. The confirmation and even perspiration from careless handling
experiments were conducted to verify the optimal during installation. Bearing problems are also
heating time and energy consumption. The caused by improperly forcing the bearing onto
improvement of the optimal heating time and the shaft. This produces physical damage in the
energy consumption from initial parameter to the form of brinelling or false brinelling of the race
optimal parameter is about 794 %. way, which lead to premature failure [2]

Keywords : Taguchi method, Optimization, In practically, the way to maintenance and the
Bearing Failure, Induction best process during installation of bearing are
Electromagnetic tools to avoid the failure this component. Study
of bearing show premature failure at bearing
cause of the way during installation bearing use a optimal heating characteristic and energy
simple method (improperly forcing the bearing) consumption parameters with regard to
contribute 25 % until 30 % from total failure at performance indexes such as heating time and
bearing [3]. Failure this part will disturb working energy consumption are considered. Finally, the
efficiency of machine and this condition create paper concludes with a summary of this study.
new problem at industry. To reduce and solve
this problem, studying bearing and method of 2. DESCRIPTION OF THE TAGUCHI
installation become important. A recent method METHOD
during installation of bearing had been
developed by induction electromagnetic Taguchi is the developer of the Taguchi method.
principles. Methods use bearing heater which is He proposed that engineering optimization of a
heating by winding of wire through current process or product should be carried out in a
electricity. These methods will generated energy three-step approach, i.e. system design,
then use induction process to transfer of heat and parameter design, and tolerance design. In
change the dimension of bearing. Research had system design, the engineer applies scientific and
been done by Candra Bachtiyar and Golfrid engineering knowledge to produce a basic
Gultom (2008) at Electronic Laboratory – functional prototype design, this design
Pendidikan Teknologi Kimia Industri (PTKI - including the product design stage and the
Medan) success made bearing heater Umodel at process design stage. In the product design stage,
laboratory scale and observed this equipment the selection of materials, components, tentative
[4,5,6]. Recent bearing research shown prevent product parameter values, etc., are involved. As
failure focused on condition based on to the process design stage, the analysis of
monitoring. Advantages this monotoring is processing sequences, the selections of
prevent catastropic breakdown and eficiency production equipment, tentative process
during production. Application this method on parameter values, etc., are involved. Since
motor using vibration monitoring, current system design is an initial functional design, it
analysis, and thermal analysis [7,8,9,10]. On may be far from optimum in terms of quality and
other side, mounting bearing to shaft to reduce cost. Following on from system design is
failure focus on chossing type of bearing, parameter design. The objective of parameter
tolerance and prevent missaligment. In 2009, this design is to optimize the settings of the process
equipment increased a number of winding that parameter values for improving quality
can connect to 220 volt [11]. Study installation characteristics and to identify the product
of capasitor at electric equipment could improve parameter values under the optimal process
power factor [12]. Through this study, parameter values. In addition, it is expected that
implementation of capasitor and Taguchi method the optimal process parameter values obtained
at this equipment will adopt to improve power from parameter design are insensitive to
factor and get optimum design parameter. variation in the environmental conditions and
other noise factors. Finally, tolerance design is
Basically, the Taguchi method is a powerful tool used to determine and analyze tolerances around
for the design of high quality systems. It the optimal settings recommend by the parameter
provides a simple, efficient and systematic design. Tolerance design is required if the
approach to optimize designs for performance, reduced variation obtained by the parameter
quality, and cost. The methodology is valuable design does not meet the required performance,
when the design parameters are qualitative and and involves tightening tolerances on the product
discrete. Taguchi parameter design can optimize parameters or process parameters for which
the performance characteristics through the variations result in a large negative influence on
settings of design parameters and reduce the the required product performance. Typically,
sensitivity of the system performance to sources tightening tolerances means purchasing better-
of variation. In recent years, the rapid growth of grade materials, components, or machinery,
interest in the Taguchi method has led to which increases cost. However based on the
numerous applications of the method in a world- above discussion, parameter design is the key
wide range of industries and nations [13]. In the step in the Taguchi method to achieving high
following, the Taguchi method is introduced quality without increasing cost. To obtain high
first. The experimental details of using the cutting performance in turning, the parameter
Taguchi method to determine and analyze the design proposed by the Taguchi method is
optimal parameters are described next. The adopted in this paper. Basically, experimental
design methods were developed originally by quality characteristics based on the optimal
Fisher [13,14]. However, classical experimental design parameters [13,14].
design methods are too complex and not easy to
use. Furthermore, a large number of experiments 3. PROCESS EXPERIMENT
have to be carried out when the number of the
process parameters increases. To solve this Researchers decide to divide activity become 4
problem, the Taguchi method uses a special steps during experiment to find contribution
design of orthogonal arrays to study the entire parameter that chosen during heating time and
parameter space with a small number of energy consumption at bearing heater U model :
experiments only. The experimental results are 1. Literature study. Consist of collecting
then transformed into a signal-to-noise (S/N) books, especially related with bearing,
ratio. Taguchi recommends the use of the S/N failure at bearing, induction
ratio to measure the quality characteristics electromagnetic process topic, and
deviating from the desired values. Usually, there Taguchi method
are three categories of quality characteristic in 2. Journal. Collect journal also activity to
the analysis of the S/N ratio, i.e. the-lower-the- support literature study which is
better, the-higher-the-better, and the nominal- information from journal will use to
the-better. The S/N ratio for each level of process support final report in this paper.
parameters is computed based on the S/N 3. Collect data of experiment. Activity
analysis. Regardless of the category of the collect data of experiment based on lay
quality characteristic, a greater S/N ratio out experiment to find heating time and
corresponds to better quality characteristics. energy consumption
Therefore, the optimal level of the process 4. Conclusion of Experiment. After study
parameters is the level with the greatest S/N data of experiment, the next step is
ratio. Furthermore, a statistical analysis of concluding of experiment based on
variance (ANOVA) is performed to see which orthogonal array, signal-to-noise (S/N)
process parameters are statistically significant. ratio and analysis of variance (ANOVA).
With the S/N and ANOVA analyses, the optimal
combination of the process parameters can be
predicted. Finally, a confirmation experiment is
conducted to verify the optimal process
parameters obtained from the parameter design.

To summarize, the parameter design of the


Taguchi method includes the following steps: (1)
identification of the quality characteristics and
selection of design parameters to be evaluated;
(2) determination of the number of levels for the
design parameters and possible interactions
between the design parameters; (3) selection of
the appropriate orthogonal array and assignment
of design parameters to the orthogonal array; (4)
conducting of the experiments based on the
arrangement of the orthogonal array; (5) analysis
of the experimental results using the S/N and
ANOVA analyses; (6) selection of the optimal
levels of design parameters; and (7) verification Note :
of the optimal design parameters through the 1. Bearing 7. Power Supply
confirmation experiment. Therefore, three 2. Thermocouple 8. Heating area 1
objectives can be achieved through the parameter 3. Temperatur 9. Heating area 2
design of the Taguchi method, examples: (1) controller 10. Cos Phi
determination of the optimal design parameters 4. Core 11. Clamp on meter
for a process or a product; (2) estimation of each 5. Winding 12. Vari Ac
design parameter to the contribution of the 6. Push bottom 13. Capasitor
quality characteristics; and (3) prediction of the
Figure. 1 Design experiment
3.1 Selection of parameter and their level be computed. The degrees of freedom are
defined as the number of comparisons between
The experiments were carried out on bearing design parameters that need to be made to
heater U model 220 volt and bearing type 6308. determine which level is better and specifically
The initial parameters were as follows: capasitor, how much better it is. For example, a three-level
sensor location and ratio heating area and inner design parameter counts for two degrees of
diameter bearing 6308. The feasible space for freedom. The degrees of freedom associated with
parameters was defined by varying the capasitor the interaction between two design parameters
in the range 0-64 μF , sensor location rate in the are given by the product of the degrees of
range inner side of bearing, middle and outer freedom for the two design parameters [13,14].
side, and ratio in the range 0.016-0.033. In the In the present study, the interaction between the
parameter design, three levels of the parameters heating characteristic and energy consumption
were selected, shown in Table 1. parameters is neglected. Therefore, there are
eight degrees of freedom owing to there being
Table 1: Parameter and their level three parameters. Once the required degrees of
Leve freedom are known, the next step is to select an
Sym Level Level
bol
Parameter Unit
1 2
l appropriate orthogonal array to fit the specific
3 task. Basically, the degrees of freedom for the
A Capasitor μF 0 48
a 64 orthogonal array should be greater than or at
least equal to those for the design parameters. In
Ratio
heating this study, an L9 orthogonal array with four
0.03
B area and - 0.016 0.025
a columns and nine rows was used. This array has
3
diameter eight degrees of freedom and it can handle there
bearing
-level design parameters. Each parameter is
Sensor a
C
Location
mm Inner Mid out assigned to a column, nine parameter
a initial parameter , mid = middle and out = outer combinations being available. Therefore, only
nine experiments are required to study the entire
3.2 Performance measurement parameter space using the L9 orthogonal array.
The experimental layout for the three heating
Heating characteristic of bearing heater consist characteristic and energy consumption
of three parameter, heating time and energy parameters using the L9 orthogonal array is
consumption. Heating time measured from shown in Table 2. Since the L9 orthogonal array
heating bearing until reach set point temperature. has four columns, one column of the array is left
Energy consumption measured from variable of empty for the error of experiments: orthogonality
voltage, current, cos phi and time to reach set is not lost by letting one column of the array
point of this equipment during heating bearing. remain empty.

Table 2 : Experiment Layout using L 9 an orthogonal


4. DESIGN AND ANALYSIS OF array
PARAMETER Heating Characteristic Parameter Level
Experiment A B C D
In this section, the use of an orthogonal array to No. Sensor
Capasitor Ratio Error
reduce the number of the experiments for design Location
optimization of the heating characteristic and 1 1 1 1
energy consumption parameters is reported. 2 1 2 2
Results of the experiments are studied using the 3 1 3 3
S/N and ANOVA analyses. Based on the results 4 2 1 3
of the S/N and ANOVA analyses, optimal 5 2 2 1
settings of the parameters for heating time and 6 2 3 2
energy consumption are obtained and verified
7 3 1 2
[13].
8 3 2 3
4.1 Orthogonal Array Experiment 9 3 3 1

To select an appropriate orthogonal array for the


experiments, the total degrees of freedom need to
4.2 Analysis of S/N Ratio The mean S/N ratio for each level of the other
parameters can be computed in the similar
In the Taguchi method, the term ‘signal’ manner. The mean S/N ratio for each level of the
represents the desirable value (mean) for the parameters is summarized and called the S/N
output characteristic and the term ‘noise’ response table for heating time (Table 4). In
represents the undesirable value (S.D.) for the addition, the total mean S/N ratio for the four
output characteristic. Therefore, the S/N ratio is experiments is also calculated and listed in Table
the ratio of the mean to the S.D. Taguchi uses the 4. Fig. 2 shows the S/N response graph for
S/N ratio to measure the quality characteristic heating time.
deviating from the desired value. The S/N
ratioη is defined as Table 4 :S/N response for heating time
η = - 10 log (M.S.D.) (1) Sym Mean / SN Ratio (dB)
Parameter Level Level level Max
where M.S.D. is the mean-square deviation for bol
1 2 3 -Min
the output characteristic. As mentioned earlier,
A Capasitor -65.82 -70.50 -68.65 4.68
there are three categories of quality
characteristics, the-lower-the-better, the higher- B Ratio -72.49 -71.57 -60.91 11.5
Sensor
the-better, and the-nominal-the-better. To obtain C Location -64.93 -70.72 -69.32 5.78
optimal heating characteristic and energy The total mean S/N ratio = - 68.32 dB.
consumption, the-lower-the-better quality
characteristic. The mean-square deviation
(M.S.D.) for the-lower-the-better quality Parameter

characteristic can be expressed as: -59.00


A1 A2 A3 B1 B2 B3 C1 C2 C3
⎡1 n n ⎤
-61.00

M.S.D. = ⎢ ∑ Yi ⎥
Mean S/N Ratio -63.00
(2) -65.00

⎣ n i =n ⎦ -67.00
-69.00
where n is the number of tests and Yi is the value -71.00
of heating time and the i the test [13]. Table 3 -73.00

shows the experimental results for heating time


and the corresponding S/N ratio using equation
(Eqs. (1) and (2)). Since the experimental design Figure 2 :S/N graph for heating time
is orthogonal, it is then possible to separate out
the effect of each parameter at different levels. On the other hand, the-lower-the-better quality
For example, the mean S/N ratio for the capasitor characteristics for energy consumption should be
at levels 1 and 2 can be calculated by averaging taken for obtaining optimal energy consumption
the S/N ratios for the experiments 1–3, and 4–6, during heating period. The M.S.D. for the the-
respectively. lower-the-better quality characteristic.

Table 3 : Experiment result for heating time and S/N Table 5: Experiment result for energy consumption
ratio and S/N Ratio
Exper Heat. S/N Ex
Capa Sens peri Energy S/N
iment Ratio time ratio Capa Ratio Sens
sitor Loct me Cons ratio
No. (s) (dB) sitor Loct
nt (dB)
1 0 0.016 In 1614 -64.15 No
2 0 0.025 Mid 5040 -74.04 1 0 0.016 In 69.04 -36.78
3 0 0.033 out 918 -59.25 2 0 0.025 Mid 176.4 -44.93
3 0 0.033 out 39.27 -59.25
4 48 0.016 Out 8190 -78.26 4 48 0.016 Out 268.63 -48.58
5 48 0.025 In 3240 -70.21 5 48 0.025 In 106.27 -40.52
6 48 0.033 Mid 46.576 -33.36
6 48 0.033 Mid 1420 -63.04 7 64 0.016 Mid 339.06 -50.60
7 64 0.016 Mid 5670 -75.07 8 64 0.025 Out 199.19 -45.98
8 64 0.025 Out 3331 -70.45 9 64 0.033 In 62.84 -35.96
Ratio = ratio heating area and diameter of bearing
9 64 0.033 In 1051 -60.43 Sens Loct = Sensor location
Ratio = ratio heating area and diameter of bearing Energy Cons = Energy consumption
Sens Loct = Sensor location
Heat time = Heating time
Table 5 shows the experimental results for The total sum of spared deviations SST is
energy consumption and the corresponding S/N decomposed into two sources: the sum of
ratio using Eqs. (1) and (2). The S/N response squared deviations SSd due to each design
table and S/N response graph for energy parameter and the sum of squared error SSe. The
consumption are shown in Table 6 and Fig. 3. percentage contribution r by each of the design
Regardless of the-lower-the-better of the the parameters in the total sum of squared deviations
higher-the-better quality characteristic, the SST is a ratio of the sum of squared deviations
greater S/N ratio corresponds to the smaller SSd due to each design parameter to the total sum
variance of the output characteristic around the of squared deviations SST. Statistically, there is a
desired value (Eqs. (1)–(2)). tool called an F test named after Fisher to see
which design parameters have a significant effect
Table 6 : S/N response for energy consumption on the quality characteristic. In performing the F
Mean / SN Ratio (dB) test, the mean of squared deviations SSm due to
Sym
Parameter Level level level Max- each design parameter needs to be calculated.
bol
1 2 3 Min The mean of squared deviations SSm is equal to
A Capasitor -46.98 -40.82 -44.18 6.16 the sum of squared deviations SSd divided by the
B Ratio -45.32 -43.81 -42.86 2.46 number of degrees of freedom associated with
Sensor the design parameter. Then, the F value for each
C Location -37.75 -42.96 -51.27 13.51 design parameter is simply the ratio of the mean
The total mean S/N ratio = - 44.00 dB. of squared deviations SSm to the mean of squared
error. Usually, when F >4, it means that the
change of the design parameter has a significant
Parameter
effect on the quality characteristic [13,14,15,16].
-36.00 A1 A2 A3 B1 B2 B3 C1 C2 C3
Table 7 shows the results of ANOVA for heating
-38.00 time. It can be found that capasitor and location
Mean S/N Ratio

-40.00
of sensor are the un significant parameters for
-42.00
-44.00
affecting heating time. The change of ratio
-46.00 heating area and diameter of bearing in the range
-48.00 given in Table 1 has an significant effect on
-50.00
heating time. Therefore, based on the S/N and
-52.00
ANOVA analyses, the optimal parameters for
heating time are the capasitor at level 1,ratio
heating area and diameter of bearing at level 3,
Figure 3 :S/N graph for Energy Consumption and the location of sensor at level 1.
4.3 Analysis of Variance Table 7 : Analysis of Variance (ANOVA) for heating
time
The purpose of the analysis of variance D
Para Sum of Mean
(ANOVA) is to investigate which design Smb
meter
O
Square Square
F Contr
parameters significantly affect the quality F
Capa
characteristic. This is to accomplished by A sitor 2 33.41 16.70 0.87 8.91
separating the total variability of the S/N ratios,
B Ratio 2 248.72 124.36 6.53 66.33
which is measured by the sum of the squared Sens
deviations from the total mean S/N ratio, into C Loct 2 54.73 27.36 1.43 14.59
contributions by each of the design parameters Error 2 38.05 19.02 10.14
and the error. First, the total sum of squared
deviations SST from the total mean S/N ratio η m Total 8 374.93 100
Smb = Symbol, DOF = degree of freedom,
can be calculated as: Contr = Contribution, Sens. Loct = Sensor location
n 2 Ratio = ratio heating area and diameter of bearing
SST = ∑ (η
i =1
i −ηm ) (3)
Table 8 shows the results of ANOVA for
where n is the number of experiments in the energy consumption. capasitor, ratio heating
orthogonal array and η i is the mean S/N ratio area and diameter of bearing, and location of
for the i the experiment. sensor are the un significant energy
consumption parameters for affecting energy
consumption. However, the contribution order
of the parameters for energy consumption is Table 10 shows the comparison of the predicted
location of sensor, then capasitor, and then ratio energy consumption with the actual energy
heating area and diameter of bearing. The consumption using the optimal parameters. The
optimal parameters for energy consumption are increase of the S/N ratio from the initial energy
the capasitor at level 1, ratio heating area and consumption parameters to the optimal energy
bearing diameter at level 3, and the location of consumption parameters is 15.98 dB and
sensor at level 1. therefore the energy consumption value is
improved by 6.09 times. In other words, the
Table 8 : Analysis of Variance (ANOVA) for energy experiment results confirm the prior design and
consumption analysis for optimizing the heating time and
D
Smb
Para
O
Sum of Mean
F Contr
energy consumption parameters.
meter Square Square
F
Capa Table 10 : Results of the confirmation experiment for
A sitor 2 57.16 28.58 0.28 10.50 energy consumption
Initial Optimal Parameter
B Ratio 2 9.24 4.62 0.04 1.69
Parameter Prediction Experiment
Sens
C Loct 2 278.84 139.42 1.40 51.25 Level A2B2C2 A1B3C1 A1B3C1
Energy
Error 2 198.79 99.3 118.08 19.37 19.37
consumption
Total 8 544.04 100 S/N Ratio
-41.44 -25.7463 -25.7463
(dB)
Smb = Symbol, DOF = degree of freedom,
Contr = Contribution, Sens. Loct = Sensor location Improvement of S/N ratio = 15.98 dB
Ratio = ratio heating area and diameter of bearing

4.4 Confirmation Test 5. CONCLUSION


This paper has discussed an application of the
Once the optimal level of the design parameters Taguchi method for optimizing the heating
has been selected, the final step is to predict and characteristic and energy consumption at bearing
verify the improvement of the quality heater U model 220 Volt. It has been shown that
characteristic using the optimal level of the heating time and energy consumption can be
design parameters. The estimated S/N ratio using improved significantly. The confirmation
the optimal parameters for heating time can then experiments were conducted to verify the
be obtained and the corresponding energy optimal parameters. The improvement of heating
consumption can also be calculated by using characteristic and energy consumption from the
Eqs. (1) and (2). initial parameters to the optimal parameters is
about 794 %.
Table 9 shows the comparison of the predicted
heating time with the actual heating time using
6. ACKNOWLEDGMENT
the optimal parameters, good agreement between
This research is supported by Pendidikan
the predicted and actual heating time being
Teknologi Kimia Industri Medan – Ministry of
observed. The increase of the S/N ratio from the
Industry, Republic of Indonesia under research
initial heating time parameters to the optimal
grant 2009
heating time parameters is 18 dB, which means
also that the heating time more fast about 7,94
times. 7. REFERENCES
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