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2013 Vol.45 No.2

IHI ENGINEERING REVIEW

2013 Vol.45 No.2

1. Products

Products1Lubricant Health Monitoring Sensor for Slidable Mechanical Equipment

DIESEL UNITED, LTD.

At the hearts of wind power generators, engines, pumps, and other such machines are sliding and rotating components. Whether these “hearts” are in good condition or not can be diagnosed by electrically detecting the metal powder that is mixed into the lubrication oil that serves as the blood of the machine.

2. Technologies

Technologies1Brand New Concept Flameless Gas Heater!-IHI leading edge combustion technology produce the high efficiency closed flameless gas heater-

IHI Corporation
SATOH Kimiyoshi

The new gas heater provides clean heating with its sealed structure by eliminating the exposed flame of the gas combustion. The heater is available radiation or conduction heating through its metal surface. The internal waste heat recovery makes both high efficiency and high combustion stability possible at the same time.

3. Technical Papers

Technical Papers1IHI is Striving to Make Renewable Energy Widely Available

ISOMOTO Kaoru

It is urgent that renewable energy be promoted in order to prevent global warming and secure sufficient quantities of fossil fuel for the next generation. IHI is committed to the development of renewable energy, especially marine and biomass energy, (which uses wood and algae), to contribute to Japan's domestic energy self-sufficiency, with an eye to further global expansion. Furthermore, we are able to offer a lithium ion battery system to supplement inconsistent sources of energy such as solar and wind power. IHI is always striving to realize the dream of sustainable global development based on renewable energy.

Technical Papers2Development of Automation Technology for Precision Finishing Works Employing a Robot Arm

SONEHARA Mitsuharu, HAYASHI Koichiro, NISHIJIMA Kazuyuki, MURAKAMI Hiroki

There is demand for the automation of finishing processes that require technical skills in the manufacturing of metal parts with a complex shape. Such processes can be categorized into two major types of processes: polishing the surface and chamfering the edges. In this paper, a robot system with model following force control is applied to a polishing process and the method proposed in this paper is applied to a chamfering process. The proposed method consists of two steps: the edge of a part is measured by a tool with model following force control and then the edge is chamfered using position feedback control along the measured path. The validity of these methods has been confirmed by experiments involving actual polishing and chamfering.

Technical Papers3Application of Structural Strength Evaluation Technology in the Development of Reciprocating Engines

TODA Yasuko, SAITO Toshiyuki, WATANABE Yasuhide, KATO Shoji, GOTO Satoru

Engine development in recent years must be able to address the severe demands of the market. Therefore, CAE (Computer Aided Engineering), including structural strength evaluation using FEM (Finite Element Method) and CFD (Computational Fluid Dynamics), is a clearly important part of a design for the realization of lightweight and reliable engines. Niigata Power Systems has applied structural strength analysis using FEM to various engine components in consideration of complex physical phenomena during the assembly of components and engine operation to achieve optimized design, fast development and lower costs. This paper reports on certain aspects of the structural analysis of main engine components performed during the development of the 28AHX, which is a high-performance and eco-friendly engine.

Technical Papers4Characteristics and Line-up of IHI's Non-Ferrous Metal Rolling Mills

NAKAYAMA Katsumi, KUCHI Masahiro, OGAWA Shu, MATSUZAWA Tsukasa, SATO Kazuyuki

As well as steel mills, IHI also supplies non-ferrous metal rolling mills for aluminum and copper alloys. Due to many kinds, grades, and sizes of non-ferrous metal material being used in industry, diverse requirements exist for non-ferrous metal rolling mills, which have unique characteristics unlike those of steel mills. It is expected that the demand for non-ferrous metal rolling mills will increase due to the expansion of the use of non-ferrous metal materials in industry. This paper provides an outline of rolling mills for aluminum and copper alloy and describes their characteristics.

Technical Papers5High Efficiency Machining through the Employment of Machining Simulation Technology

SASAKI Wataru, IWASAKI Takayuki, HASEGAWA Masanobu, SAGA Tatsuro, SAWADA Noriyoshi

In recent years, there have been demands for higher quality, shorter lead time and cost reduction with regard to the manufacturing of products. In addition, high accuracy and efficiency is also required in machining process. However, attempts are still being made to resolve machining process problems based on past experience and trial and error. On the other hand, numerical simulation is being used in machining processes to predict processing phenomena by making use of advances in numerical analysis. This paper shows the possibilities for improving machining efficiency using machining simulation that employs the finite element method, the prediction of chatter vibration in machining through vibration analysis and the optimization of NC programs through cutting forces analysis.

Technical Papers6Development of Welding Methods for Dissimilar Joint of Alloy 690 and Stainless Steel for PWR Components

MATSUOKA Takaaki, YAMAOKA Hiroto, HIRANO Kenji, HIRANO Takashi

PWR nuclear power plants extensively use alloy 690 materials with higher chromium content in view of ensuring corrosion resistance. In order to select the optimal welding material fabricating components intended for use in PWR nuclear power plants, evaluation tests were conducted with various alloy 690 welding materials. In addition, suitable welding conditions were selected for the dissimilar metal joints where it is harder to perform welding. The welding conditions were validated by simulating the dissimilar metal piping of the actual equipment. As a result, the defect was not found in several test, excellent joints could be obtained.

Technical Papers7Development of Luffing Jib Crawler Crane CCH3000LJ

TERAUCHI Tetsuyuki, KAWAMOTO Ryo, NAKAJIMA Takashi, MIMURA Hitosi, MACHIDA Masakazu

In recent years, the need for the construction of social infrastructure, particularly in developing nations such as India and Southeast Asia countries, has greatly increased. In these circumstances, IHI Group is making contributions to development in such countries through the construction of infrastructure such as thermal and nuclear power plants, bridges, and flood gates. As leading players in such massive construction projects, the crawler cranes provided by IHI Construction Machinery Limited are having increasing opportunities to shine, and through the realization of even larger-scale modular construction methods, we are contributing to increasing our customers' level of construction efficiency. Furthermore, we compete with other manufacturers through our efforts to introduce new models of large construction equipment and to increase our equipment's fundamental capabilities, such as lifting capacity. Now, IHI Construction Machinery Limited has developed a crawler crane that not only can compete in head-to-head contests with its rivals with regard to such fundamental capabilities, it can also contribute to the making of total cost savings by our customers, as it also includes a number of addedvalue features. For example, it can be assembled in a short period of time and moving it requires only a limited number of transporters.

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