Unbalance by vibration analysis on steel reels in wire production line

Steel reels used in the wire production line wear and deteriorate over time. The unbalance and imbalance in the reels cause vibration in the machines and the wire not being wound properly on the reel. Therefore, sudden breakdowns occur, faulty products are formed, and great financial losses occur by disrupting the production plan. As a result of this situation, the service life of the machine is shortened, it causes sudden malfunctions, and financial losses occur in the company due to the losses in the product. Most of these errors can be prevented by detecting and eliminating the imbalance (unbalance) in the reels. In this study, a test device was designed to detect the defects on the surface of the spool, to make vibration measurements and to diagnose the imbalance condition before the wire production line goes into production. Vibration analysis was performed and it was revealed how to detect which types of unbalance faults can be made by means of spectrum phase angle and graphs. At the point of solving the reel unbalance fault, it is decided what action should be taken according to the balance and runout status of the reel depending on this diagnosis. During the rotation of the reel connected to the test device at certain speeds with the help of Programmable Logic Control-Programmable Logic Control (PLC), vibration and unbalance measurements are made by means of vibration analyzer and distance measuring sensors, and monitoring, reporting and warning of vibration and secretion data collected simultaneously with the designed PLC software targeted. Analysis of the collected data and evaluation of the reel is carried out by checking the conformity of ISO 1940, TS ISO 1940/1, S2.19-1972, BS 6861-part 1 and VDI 2060 balance standards, ISO 10816 vibration standards and DIN 46397 surface tolerance standards. The unbalance should be measured after each use of the steel reels used in various production stages in the copper wire industry. Before re-entering production on the steel reel, it should be carried out in accordance with the measurements made on the unbalance and winding surfaces, because the imbalance of the steel reel and the secretion on the winding surface, sudden stops and winding errors cause great financial loss to the company. The unbalance and run-out status of the reels should be checked and it should be decided which machine to connect the reel according to the imbalance status. If it needs to be repaired according to the imbalance situation, it should be used after the secretion and imbalance are eliminated. In copper wire production, reels deform over time due to use at various stages of production, and the balance values and runout values on the wire winding surfaces increase. When we do not know the condition of the reel, the reels with increasing balance values increase the vibration of the machines in production. As a result of this situation, the service life of the machine is shortened, it causes sudden malfunctions and financial losses occur in the company due to the losses in the product. By detecting and eliminating the imbalance of the steel reels used for winding the copper wire, sudden stops in production were prevented. Approximately 600 kg of copper wire is wound on a reel. Due to the unbalance of the reel, the line speed is reduced from 30 m/sec to 15 m/sec. An unbalanced reel rotates at 15 Hz (900 rpm). A copper wire with a diameter of Ø0.7 mm and a length of 130.000 m is wound on a reel in 1.3 hours. In case the reel is unstable, copper wire with Ø0.7 mm diameter and 130.000 m length is wound on the reel in 2.6 hours. This causes loss of time and production. In an unbalanced reel, the winding quality of copper wire also decreases. While 600 kg of copper wire is to be wound, it causes less winding. As a result of less copper winding, it causes the reel to be sent to the customer without filling its capacity. Unbalanced rollers cause unplanned stoppages as they damage the machine bearings over time. This situation causes product loss and financial loss. Failure in a reel causes high vibrations in the machine to which it is connected. It is important that the rollers working by connecting to the machine are smooth and have low vibration values. High roller vibration values also increase the vibration of the machine and may cause undesirable results. Before connecting to the machine, it should be checked whether the balance values of the reel are at the desired level. Otherwise, an unbalanced pulley will cause the machine to vibrate excessively and damage the machine, causing the production to be interrupted. Roller vibration can also be measured by connecting to the machine. But it has several problems. Connecting a reel to the machine takes approximately 5 minutes, including the preparation phase. If the reel is in trouble, it also causes loss of time by scrapping the copper wire wound on the reel and changing the reel by stopping the machine because the machine is started. For this reason, checking the vibration and balance status of the reel with a separate test device will provide important benefits such as being more economical and eliminating the need to stop production. As seen in previous studies, the most common fault in rotating machines is imbalance. In this study, the unbalance problem of steel reels used for winding wire in industry has been investigated. This problem may be caused by the wear of the reels over time depending on the usage period, as well as the usage, transportation and stocking errors of the reels. A PLC controllable test device has been developed to detect unbalance faults in the reels. The reels are connected to this test device and rotated at determined speeds. Meanwhile, vibration and surface tolerance data collected simultaneously with PLC software can be monitored and reported thanks to vibration sensors and distance measuring sensors on the device. In the study, vibration measurements taken from rotor bearings for different pulleys connected to the test device, spectrum analysis and phase angles were examined and unbalance failure was detected. In addition, the surface tolerances of the reel were examined according to the distance values taken from four points with the sensors fixed on the machine body, and the distortions on the surface causing the unbalance were determined. While evaluating the condition of the reels as a result of the measurements made on the reels, it is checked whether they comply with ISO 1940, TS ISO 1940/1, S2.19-1972, BS 6861-part 1 and VDI 2060 vibration standards and DIN 46397 surface tolerance standards.