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1

A way of supporting the servicing of production machines using reverse engineering and 3D printing techniques

Loska Andrzej, Palka Dorota, Bień Alicja, Substelny Katarzyna

Technologia i Automatyzacja Montażu

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2022

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nr 1

28--36

EN

The use of machines and devices causes their components to wear out, which leads to damage. The easiest and fastest method of repair is to replace this element with a new one. The problem arises when the desired element is not available on the market, technical documentation is unavailable or the costs of acquiring a new element are too high. In such a situation, engineering reconstruction, also known as reverse engineering, is used, which allows for the reconstruction of technical documentation and the production of a new product thanks to additive technology. The article presents the process of reverse engineering and the types of additive manufacturing technology. The aim of the article is to present the possibilities of using the reverse engineering method and 3D printing in the reconstruction of sample machine parts. The work uses the FDM (Fused Deposition Modeling) spatial production technology. The relevance of the article is confirmed by the possibility of its practical use in the field of machine servicing support.

PL

Eksploatacja maszyn i urządzeń powoduje, że ich podzespoły zużywają się, a to prowadzi do uszkodzeń. Najprostszą i najszybszą metodą naprawy jest wymiana tego elementu na nowy. Problem pojawia się, gdy pożądany element nie jest dostępny na rynku, niedostępna jest dokumentacja techniczna lub koszty pozyskania nowego elementu są zbyt wysokie. W takiej sytuacji zastosowanie znajduje rekonstrukcja inżynierska nazywana również inżynierią odwrotną, która pozwala na odtworzenie dokumentacji technicznej oraz wykonanie nowego produktu dzięki technologii addytywnej. W artykule przedstawiono proces przebiegu inżynierii odwrotnej oraz rodzaje technologii wytwarzania przyrostowego. Celem artykułu jest przedstawianie możliwości zastosowania metody inżynierii odwrotnej oraz druku przestrzennego w rekonstrukcji przykładowych części maszyn. W pracy wykorzystano technologię wytwarzania przestrzennego FDM (Fused Deposition Modeling). Zasadność artykułu potwierdza możliwość jego praktycznego wykorzystania w zakresie wspomagania serwisowania maszyn.

2

The role, importance and impact of the methane hazard on the safety and efficiency of mining production

Palka Dorota, Brodny Jarosław, Tutak Magdalena, Nitoi Dan

Production Engineering Archives

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2022

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Vol. 28, Iss. 4

390--397

EN

Underground mining production is an extremely important process for the economy and carried out in very difficult and complex environmental conditions. The disturbance of the balance of this environment makes it also a very dangerous process. Due to the importance of coal, mainly as an energy raw material, the process of its exploitation is carried out all over the world. The specificity of its production is mainly determined by mining and geological conditions, which determine the method of operation and the selection of machines and devices for this process. One of the most dangerous natural hazards associated with this process are ventilation hazards, including methane hazard. The reason for this threat is methane, an odorless and colorless gas, which becomes a flammable and explosive gas under certain criteria. These features make this gas a huge threat to mining operations. Its huge amounts, contained in coal seams, are released into the mine atmosphere during the exploitation process, causing a very high threat to work safety. Events related to the occurrence of methane are most often the cause of mining disasters, in which people die and the technical and mining infrastructure is destroyed. The reason for the growing methane hazard is the increasingly difficult mining conditions, and mainly the increasing depth of mining, and thus also the increase in methane-bearing capacity of the seams. Taking into account the huge impact of methane hazard on the mining process, the article discusses its impact on the safety and efficiency of this process. The results of the literature review with regard to this risk are presented and the accident statistics are presented. On the basis of actual data, an analysis of interruptions in the exploitation process related to exceeding the permissible me-thane concentrations was carried out in one of the mines. The problem of limiting the production process due to these exceedances is an important factor reducing the efficiency of this process. The obtained results clearly indicate that the losses resulting from these breaks deteriorate the profitability of the entire process and affect the economic efficiency of the industry. In order to effectively counteract the dangerous phenomena related to the methane hazard and to improve the efficiency of the mining production process, solutions were proposed to improve this state and the directions for further research were proposed.

3

Modeling and Simulation of the Methane Risk in the Mining Production Process

Palka Dorota

Multidisciplinary Aspects of Production Engineering

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2021

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Vol. 4, Iss. 1

1--13

EN

The mining production process is of particular importance for the area of Upper Silesia, as well as a very significant impact on the economy of the entire country. One of the most common and most dangerous threats to this process is the methane hazard. It is related to the presence of methane in coal seams, which under appropriate conditions is a flammable and explosive gas. Events related to the methane hazard constitute a huge threat to the life and health of the crew as well as the infrastructure and equipment of excavations. Therefore, they have a huge impact on the efficiency of the entire mining production process. In order to ensure the safety and continuity of the production process, it is necessary to prevent the formation of dangerous methane concentrations in the area covered by the operation. One of the tools that can be used to assess the state of methane hazard are model studies supported by numerical simulation. Based on these studies, the article analyzes the distribution of methane concentration in the mining area. This area included an actual mining excavation in one of the hard coal mines. The model tests were carried out with the use of the finite volume method in the ANSYS Fluent software. The obtained results can be used for preventive measures and constitute an important source of information for the assessment of the methane hazard state.

4

Use of Reverse Engineering and Additive Printing in the Reconstruction of Gears

Palka Dorota

Multidisciplinary Aspects of Production Engineering

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2020

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Vol. 3, Iss. 1

274--284

EN

Despite the very rapid technological development, the general concept of mechanical devices has not changed. Still, the most common element of these devices are gears, whose range of use is very wide. There are both technological and historical considerations for the reconstruction of gears and other elements. In particular, this applies to spare parts for technical facilities that are not available on the market or service costs are too high. Contemporary reconstruction is called Reverse Engineering, which offers tools that allow transformation of an existing object through a virtual model into the final real product. Modern production engineering is based on innovative CAD – Computer Aided Designed design methods and computer-aided manufacturing technologies, CAM – Computer Aided Manufacturing. The rapid development of 3D CAD systems has led to the development of solutions to obtain the designed object, already at the development stage. Such a solution is the Rapid Prototyping method, designed for fast, precise and repeatable production of machine components. Widespread use and growing interest in the use of additive printing influenced the development of this technology. The purpose of the article is to present the practical application of the Reverse Engineering method and 3D printing in the reconstruction of gears. The object of research is the real gear, which has been reconstructed using Reverse Engineering and 3D printing. The article presents the basic assumptions of the methods used and the methodology for conducting reconstruction work. FDM (Fused Deposition Modeling) technology was used for the research. The results obtained are a real example of the practical application of the presented methods. At the same time, they create great opportunities for their wider use.

5

Influence of the Permeability of the Longwall Goaf Zones on the Location of an Area With Explosive Methane Concentration Levels

Tutak Magdalena, Palka Dorota

Multidisciplinary Aspects of Production Engineering

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2020

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Vol. 3, Iss. 1

238--247

EN

One of the basic ventilation hazards and, at the same time most dangerous, in hard coal mines is the methane hazard. During the exploitation process using the longwall system with the breaking down of roof rocks, methane is released into mining excavations from both mined coal and the one left in goaves. Significant amounts of methane also flow from the underworked and overworked seams, through cracks and fissures formed in the rock mass. When accumulated at an explosive concentration level in goves and at an appropriate oxygen concentration level and the occurrence of a trigger (e.g. a spark or endogenous fire), methane may either explode or ignite. These are immensely dangerous phenomena. Therefore, the possibility of their occurrence should be limited. The article presents the results of the research aimed at determining the impact of the permeability of goaf zones on the distribution of methane and oxygen concentration levels in these goaves. The study was carried out for the longwall ventilated with the Y system. The model analysis was conducted, the results of which allowed the authors to determine these distributions. On their basis, both the location and size of the areas in which hazardous methane concentrations could occur were designated. The results are of great practical importance as they indicate areas in goaves where preventive measures should be implemented.

6

3D Object Digitization Devices in Manufacturing Engineering Applications and Services

Palka Dorota, Sobota Marcin, Buchwald Paweł

Multidisciplinary Aspects of Production Engineering

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2020

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Vol. 3, Iss. 1

450--463

EN

The rapid development of CAD 3D systems has led to the development of solutions enabling the physical achievement of the designed object, already at the design stage. Such a solution is the rapid prototyping method, intended for fast, precise and repeatable production thanks to additive technology. The first basic step of this method is a 3D scan. It is a technique that analyzes a real object in order to collect data about its basic (geometric) and additional (e.g. color) features. The collected data is used to generate three-dimensional, virtual models. Scanning can be performed in various ways using different devices. The aim of the article is to review the available technologies for digitizing 3D objects and to compare them in the context of individual application areas. It presents selected tools and software that will economically and efficiently increase the range of applications of digitization methods in the production process and offering various services on the market.

7

The concept of hard coal mine in the perspective of Industry 4.0

Palka Dorota, Rizaoğlu Tamer

Multidisciplinary Aspects of Production Engineering

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2019

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Vol. 2, Iss. 1

327--335

EN

For the Polish economy, hard coal is the basic raw material for the production of electricity and heat, guaranteeing energy security. To ensure safe and effective work in underground mines, the most modern technical solutions are implemented. Innovative achievements of production automation are increasingly being used. Introduction of the Industry 4.0 concept elements is an opportunity for: improvement of coal exploitation processes, use of IT tools supporting decision-making processes and ensuring real-time process management. However, the specificity of the mining environment poses many barriers, for example limitations resulting from geology, extent and volume of excavations, device mobility and telecommunications. The article describes mining threats and limitations as well as the current technical condition of Polish mining. The latest trends in mining development are described in line with the ideas of the fourth industrial revolution. The main goal of the article is to analyze the feasibility of implementing Industry 4.0 concept solutions for underground mining. The analysis was performed with a tabular descriptive method, based on the conducted mining documentation, own observations, surveys and literature research. The indicated limitations and recommendations developed can serve as a guide to further scientific research and implementations in this area.

8

Prospects for development movement in the industry concept 4.0

Palka Dorota, Ciukaj Jolanta

Multidisciplinary Aspects of Production Engineering

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2019

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Vol. 2, Iss. 1

315--326

EN

The aim of the article is to present the perspective of maintenance development in the context of the 4.0 industry concept. One of the factors that determine the safe and effective use of machines and devices is the properly maintained maintenance process. Correct performance of activities as part of this process requires the use of appropriate knowledge and experience from people implementing this process. Very important in this process is, above all, good organization of work and technical knowledge. The very rapid development of technology causes that teams dealing with the maintenance of traffic in enterprises must systematically acquire knowledge and optimize their activities. Effective exploitation of all types of devices is a set of rules, rules, procedures and actions, the main aspect of which is a human being. Knowledge resources should have appropriate substantive content adapted to the recipient. The article presents a modern solution supporting the maintenance process, taking into account the tools supporting the activities of human teams. The basic principles of maintenance in the enterprise covering machine monitoring systems, production management and management of information on the state of the machine park are discussed. There are also examples of the use of selected tools in the mining industry. Reference was also made to the prospects and directions of the development of maintenance in relation to the fourth industrial revolution.