Industry

In the sheet metal industry chatter marks on the finished metal product can cause significant issues for customers. Marks on metal strip affect the quality of the product in industries such as automotive and can-making and can often lead to finished coils being rejected by the customer. These marks are often invisible to the naked eye but can show up further down the line, for example when a car door is being painted.

One of the main causes of chatter marks on finished metal is marked rolls being used in the mill. This is where the rolls used in the rolling mills arrive with chatter marks caused by the roll grinding process. As with the finished product, the chatter marks on the roll can often be invisible to the naked eye, meaning that the grinder operator has no way to tell whether the rolls have chatter marks or not before they are sent to the mill.

An ideal solution to this problem is this innovative Chatter_Detect system. Since Farrat’s acquisition of UniVib – a specialist industrial vibration consultancy – in 2020, Farrat has made use of Chatter_Detect technology in a wide range of businesses around the world.

Chatter_Detect is a post-process roll inspection system that detects chatter marks that may have been ground onto the surface of finish-ground rolls by vibrations generated during the grinding process.

It uses a high-resolution, non-contact capacitive sensor that can detect invisible chatter marks which can be small but still significant enough to affect the rolling process and cause chatter on the strip.

The Chatter_Detect system can identify the pitch and depth of the chatter marks and also enables the operator to set a depth threshold level, so that marks that are not significant enough to affect the rolling process, don’t trigger the Chatter_Detect alarm.

The Chatter_Detect system has helped some of the biggest names in the sheet metal industry ensure that only chatter free rolls are sent to the mill and quality is maintained throughout the roll grinding process.

Chatter_Detect with Farrat

If you’re looking to monitor floor vibration levels or for a bespoke, tailored vibration isolation solution that optimises performance, efficiency and accuracy of industrial machinery within an industrial or production setting, get in touch with the team at Farrat for more information.

Aluminium cans are one of the best forms of packaging when it comes to sustainability. The key reason for this is that aluminum as a material retains its quality each time it is reprocessed which means it can be transformed back into itself an infinite number of times, unlike plastic.

As both companies and individuals work to reduce their impact on the environment, can making factories are looking to maximise efficiency to meet demand, and the Farrat team has been at a beverage can production factory in Turkey to investigate excessive machine vibrations that are creating production challenges.

In this instance, the bodymakers were transmitting excessive vibrations to the surrounding factory floor, and this in turn was causing quality issues in nearby machines. Whilst the quality of manufacturing was the key issue to address, the vibrations were also affecting the work environment for those working on-site, with excessive noise in the office area.

A member of our Industrial Vibration Control team went across to the factory to investigate behaviour of machines under vibrations and the wider applications engineering team is now analysing the results to propose corrective action.

Corrective action that resolves issues long term is vital not just for the immediate problem, but also to prevent premature wear of tooling and significantly improve life span of the machinery.

Find out more about industrial vibration control

To find out more about the types of industrial vibrations found in factories and manufacturing plants, and some of the ways in which you can control vibrations to maximise efficiency and minimise disruption, watch our 10-minute digital CPD module on Vibration Control of Machinery.

For more information on how we add value in beverage can production, visit Farrat’s can making hub, dedicated to the can making industry, vibration control solutions that help achieve operational excellence in beverage can manufacturing, and recent case studies within the industry.

Farrat works with Production Engineers and OEM’s (Original Equipment Manufacturers) within high-capacity rolling mills around the world, to ensure the accuracy and efficiency of a wide range of machinery through vibration control.

A key role we play within the rolled metal and aluminum industry is preventing ‘chatter’.

Chatter refers to the inaccuracies and/or faults in the finish of a manufactured product as a result of vibration sources impacting machine accuracy.

In the recent case study below, we demonstrate how Tuned Mass Dampers can be used as an effective industrial vibrational solution for large milling machines.

The Scenario

Farrat was contacted by the Production Manager at a global aeronautics company, who had identified reporting issues with the performance of a large milling machine within a busy manufacturing plant.

The milling machine was used to machine titanium aero-engine components; therefore, accuracy was essential for the precision part.

On further inspection by Farrat Applications Engineers, the machine was noticeably severely hampered by chatter instability, occurring at the 64 Hz frequency.

The Investigation

Farrat Applications Engineers conducted modal analysis to measure the effects of vibrations on surrounding machinery, as well as activity on the milling machine. The data showed that torsional resonance of the spindle and drivetrain was causing the issue.

If left unresolved, the chatter disturbance would continue and potentially worsen as the effects of the vibration increasingly affected the milling accuracy.

The Conclusion

In order to reduce the effects of the surrounding vibration, a vibration Tuned Mass Damper was fitted to the rear face of the milling cutter. The damper was then carefully tuned to the specific frequency of the torsional resonance that was disrupting the performance of the milling machine, resolving the torsional vibration problems.

As a result of this damper being installed, the chatter was completely eliminated, and the milling machine has performed at the required level of accuracy ever since.

 

For more information on how we’re supporting manufacturers and machine refurbishers with our vibration consultancy, analysis, and troubleshooting services, take a look at our Industrial Vibration Isolation hub or contact our Industrial Applications team.

 

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In our latest project showcase below, we share a few of our recent Industrial Vibration Control projects, which highlight how our expert vibration control systems are being used to maximise accuracy, efficiency, and ensure the health & safety of production employees across can making and power generation industries.

The Lakeside EfW facility, UK

Based near Slough, this energy from waste power plant processes over 450,000 tonnes of residual waste per year, whilst generating 306GWh of power. It led the way in terms of environmental impact back in 2017, by becoming the first in the country to achieve the zero waste to landfill target by recycling all the residues left behind from waste processing and turning it into sustainable energy.

An education centre is located adjacent to the facility, where schools and other groups can learn about sustainable waste management and energy from waste to promote the switch to zero waste in the future.

Farrat have designed and manufactured a bespoke vibration control system, which is currently being installed on critical overhead machinery within the facility, to maximise efficiency and minimise the effects of vibration on the surrounding structure.

Farrat NR62 Hybrid Bearings and bespoke Shear Key Bearings form part of the overall solution to support the crane structure.

Ceylon Beverage Can, Sri Lanka

This is the most advanced facility in the region with state-of-the-art technology in metal forming and printing. The plant is equipped with the latest machinery and quality gauges with the capacity of producing 720 million cans and 2 billion ends per year. With cans as a highly recyclable liquid packaging option on the increase due to their sustainability credentials, the efficient running of this facility is essential to meet demand.

Farrat recently completed a machine foundation isolation project for a cupper press and bodymaker that was installed on site. The vibration isolation system comprised of Farrat Isomat , which is made from Nitrile rubber, and Vidam, which is made of cork composite.

Farrat Isomat offers excellent damping characteristics for impact applications such as presses, while Vidam works well to damp lateral loads coming onto the foundation walls. Together the anti-vibration materials work to mitigate the impact of vibration on the machinery, and ensure high levels of productivity and efficiency.

Pomini Tenova, Italy

Pomini Tenova is a global leader in the production of roll grinders, for rolls belonging to flat products mills such as steel and other non-ferrous metals such as copper and aluminum, processed in beverage can manufacturing plants and paper mills. Pomini Tenova also delivers special machines for the grinding of heavy components across the industrial sector.

A bespoke Farrat Isolated Foundation system was recently supplied for two roll grinding machines, that went on to be installed at a sheet metal plant in the United States.

This form of precision equipment should be protected from all sources of external vibrations, to avoid chatter marks on the finished rolls (reducing wastage), and also to ensure the health & safety of both the machinery and employees.

The Farrat industrial vibration isolation solution was engineered from a combination of Farrat Isomat base isolators and Farrat Isofoam Wall isolators. This solution effectively isolates all incoming frequencies from the base, as well as walls of the foundation, and improves the overall efficiency of the machine.

On a mission across the globe

The growth of the can-making industry means that with the right incentives, liquid packaging using cans could become 100% recyclable, and our vibration isolation solutions ensure that the manufacturing of these cans and tops can be done at optimal levels of productivity and efficiency.

Where businesses are committing to zero waste, onsite recycling, and energy generation through original approaches, Farrat is equally committed to using our specialist knowledge and bespoke vibration isolation solutions to optimise these innovative solutions.

 

For more information on Farrat Industrial Vibration Isolation solutions including Isolated Foundations take a look at our Industrial Vibration Control centre, or our  Can Making Hub.

 

#onamission

Cupper Presses are often used in canning factories, producing cups for 2-piece beverage cans from aluminium or steel coil, or draw-redraw food cans from steel, aluminium, coil or sheet.

It is important to isolate a Cupper Press because the vibrations created by the machinery will not only interfere with the efficiency, productivity and accuracy of surrounding machinery, but it can also affect the health and wellbeing of those working in the factory, and those living and working in the surrounding area.

Ahead of choosing the best option for isolating a Cupper Press, it is recommended to organise an investigation to understand the level of the vibrations the Cupper Press will be transmitting. The results from this investigation provide crucial inputs helping design team choose the best solution for your environment.

Installing a Cupper Press Isolation system

In order to isolate a Cupper Press, the area should first be clean and tidy, so make sure that the floor is clean and dry. First step is to install base void fillers along the edges at the bottom of the pit. These voidfillers are supplied in form of sheets that are easy to cut on site. Farrat provides project specific installation drawings to help the installers or the contractor to identify the correct product type and the sizes to be cut. Once the strips are cut to the specified size, install them along the edge of the pit. Next, start installing wall void fillers with the help of adhesive tapes supplied.

Adhesive tapes hold the void fillers intact on the walls and minimize the possibility of the isolation layer falling into the pit until the concrete is poured. Once the wall void fillers are installed, the next step is to install the stiffer top strip. Higher stiffness of the top strips brings more stability to the inertia block, minimizing chances of rocking under dynamic loads. All joints should be sealed to avoid seepage of wet concrete into the isolation strips.

A typical foundation pit with completed wall isolation looks like this:

Next step is to cover the remaining are of the foundation base with voidfillers. Due care should be taken by the installer to not damage the base voidfiller. A flat surface, such as light weight plywood, should be used when one needs to move around in the pit.

Below image represents completed base void filler installation:

Next step is to install the base isolators. This starts with marking the area in the base isolators as shown in the installation drawing. Once the locations are marked, respective size of voidfiller should be cut out from the base voidfiller to make space for isolators. Isolators should be carefully installed in the cut our space and the joints should be sealed with joint line tape.

A completed foundation is shown adjeacent.

The last step is installing the DMP membrane throughout the pit base and wall. This is a secondary layer to prevent any seepage of wet concrete in the isolation strips. The rebar cage should be designed in such a way that the support points are on isolators and not on the base voidfiller. Rebar cage should be carefully lowered into the pit to avoid any damage to wall voidfiller sot the DPM sheet.

The concrete should then be poured carefully and evenly across the entire area to ensure that the concrete does not build up in mounds (which could crush the voidfiller). It may be advised that the concrete is poured in 2 stages to ensure a flat and even load spreading base.

A Bespoke Approach for Cupper Presses

Isolating Cupper Presses isn’t a one size fits all approach. It is only by adopting a bespoke approach that you will effectively isolate a Cupper Press to a level where it no longer affects the efficiency of nearby machinery.

Farrat engineers are available to support you right from vibration investigation to installation. For more information on solutions for the can making industry, visit our Can Making Hub here or submit an enquiry with our engineers here.

 

#onamission

Farrat was recently instructed to conduct a vibration survey on two different Isolated Foundation systems supporting Cupper Presses in a canning factory in Europe. The aim of the investigation was to evaluate and compare levels of system performance and to identify any opportunities for improvement.

The Investigation

Cupper Presses are typically connected to their foundation by resilient mounts, offering a soft connection. The inertia block placed below is supported by anti-vibration material and is therefore isolated from the rest of the factory.

Two vibration isolation systems were measured during the investigation.

The first vibration isolation system comprised of a cupper press running at 156 RPM, installed on a 3.9 m x 3.9 m inertia block. The cupper press foundation was isolated by a competitor vibration isolation material. The second vibration isolation system comprised of the same type of press running at 158 RPM, installed on a Farrat Isolated Foundation.

The latter system was configured using a 6.1 m x 4.8 m x 1.5 m inertia block supported by Farrat Isomat pads.

Impact on nearby machinery

Located close to the cupper press production line in a nearby office was a direct laser exposure system using a laser engraving method. This machine is used to produce masks that decorate the variety of cans produced within the factory. This process requires machine precision and stability.

It was reported by the Line Manager that this sensitive machine was subjected to excessive vibrations, altering its process quality and interrupting business functionality. To determine the influence of the press, vibrations were measured on the printer in three directions while the press was on and off.

The first few peaks – all located below 20 Hz – were generated by other machines, positioned only 7 meters from the printer. However, clear differences are noticed in all directions between 20 and 50 Hz, presenting the influence of the Cupper Press, even though it was located 30 meters away from the printer.

Note: Z axis means vertical direction, X axis is defined as parallel to the length of the machine and Y axis refers to the width of the machine.

Conclusion

Farrat was asked to find a vibration isolation solution to mitigate this problem and a bespoke solution was designed. Farrat vibration isolation pads made of polyurethane foam were installed below the printer to soften the connection from the machine to the floor and tackle the disturbing frequencies. As a result, there have been no further complaints regarding the process quality, and the issue is considered resolved.

One of the key objectives when designing a vibration isolation system is to maintain a low level of vibration within the machine to help plants reduce spoilage and increase productivity. Another key aspect is to limit vibration transmission to the surroundings. This investigation highlighted the impact that an ineffective isolation system can have on sensitive machinery positioned nearby – decreasing productivity and resulting in complex and costly engineering solutions.

The client’s requirements have been met by the Farrat Isolated Foundation solution, which has significantly lowered the movements of the machine while maintaining a quiet environment for nearby buildings. This demonstrates the efficiency of Farrat Isomat systems for Cupper Press machine applications, where bespoke design solutions are needed to solve complex engineering challenges.

Vibration Isolation Systems from Farrat

For more information on how our application engineers can work with your design teams, production managers and OEM partners to integrate industrial vibration control and Isomat System, contact our team here.

 

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A simple guide to the Farrat Chatter_Detect system

 

What is Chatter_Detect?

Chatter_Detect is a stand-alone PC-based post-process roll surface inspection system, used for the detection of regular undulations that might grind into the surface of a finish-ground metal roll. These imperfections are caused by vibrations generated during the grinding process.

The hardware is contained in a Chatter_Detect enclosure which is normally mounted on the wheel head of the machine, as shown in Figure 1.

When is it used and why?

Vibration generated by the grinding process may cause undulations to grind into the surface of the metal roll. The degree of which depends on the type of vibration and its frequency relative to the speed of rotation of the roll.

The undulations can be parallel with the roll axis or can lie at an oblique angle to the roll axis.

If they are of sufficient depth, they may appear as “chatter marks”, as shown in Figure 2.

However, most often they are either difficult, or impossible to see by eye, but are significant enough to affect the rolling process. The Chatter_Detect system is designed to detect these invisible marks and to measure their pitch and depth.

How does it work?

The system uses a non-contacting displacement sensor to measure the topography of a finished roll circumference. The test results are displayed as shown in Figure 3 below.

There are two main windows:

The upper window shows a graphical plot of the roll surface to provide an exact visual representation of the topography of the roll circumference, “unpeeled” and laid out flat. The undulations in the surface are the chatter marks. This window shows whether the marks are continuous or localised – in the example above they can be seen to be continuous.

The lower window shows a histogram in which the circumference of the roll is split into equal sectors. The depth of any regular marks detected in each sector is represented by the height of the bars (coloured green or red depending on whether the detected marks exceed a user-settable threshold or not). The actual marking pitch is displayed numerically above each bar. The position of the marks around the circumference of the roll relative to the trigger point is also displayed.

What are the benefits?

The Chatter_Detect software is proving successful in helping several Aluminium producers ensure that all ground rolls sent to the mill are free from chatter marks, resulting in almost complete eradication of strip chatter and increased throughput.

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Testimonials from Farrat Chatter_Detect users:

Andy Wilkes, TSM2 Mill Start Up & Roll Grinding Manager at Bridgnorth Aluminium, UK

“Since our acquisition of the Chatter_Detect system, we have not had a single issue of strip chatter, as the system ensures that all rolls sent to the mill are free from chatter. Because of the success of the system an additional system has recently been acquired by Bridgnorth Aluminium”.

 

Francis RINGLER, General Manager at Rhenaroll, France

”Chatter_Detect and AVAS Monitoring Systems are proving to be very useful on our grinding machine, helping our operators find the best grinding conditions that minimise vibrations and ensure chatter free rolls”.

 

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Further development

Recently, at the request of several customers, a vibration monitoring module has been integrated within the Chatter_Detect software (using the same enclosure as above, but with additional hardware including 2 accelerometers and signal conditioning hardware).

This monitors the vibration of the machine during grinding and warns the operator when the levels of vibration exceed a threshold level, turning the green bar graph into red, as illustrated in Figure 4.

The operator normally reacts to this by changing his grinding conditions (feeds and speeds) in a way that the alarm level reduces and turns to green colour.

Several monitoring screens are available, for example on the spectrum screen (Figure 5) it is possible to link each frequency component with a marking pitch, by simply moving the cursor along the frequency axis. This helps in identifying which frequency component is responsible for chatter on the roll, which is invaluable information for the maintenance engineer.

This monitoring option is proving to be very useful for the operators, as explained in the testimonials above.

Most of the systems sold by Farrat in the last couple of years include this option.

Did you find this Farrat 101 Article useful?

For more information on Chatter_Detect and to explore how Farrat can support manufacturers and machine refurbishers with rapid on-site services, please visit our Vibration & Chatter Control of Machinery page.

In 2019 Farrat were pleased to welcome Paul Mellish as our new Head of Engineering and Operations. A few months in, we’d like to tell you a little more about one of our new additions to the team.

What led you to Farrat?

I completed a degree in Manufacturing Engineering & Management at Loughborough University. I then spent almost 11 years at Rolls-Royce (aero engines) in a variety of Manufacturing Engineering roles. Following that, I moved into the automotive industry as a Technical Manager at Bentley Motors.

I was drawn back to aerospace for a couple more years in a consultant role, assisting a number of domestic SME’s to become more globally competitive. Following a short stint in Additive Manufacturing as an Operations Manager, I became the Operations Director for an aerospace surface treatments business, before moving to Farrat.

What are you most looking forward to getting involved in/doing at Farrat?

Assisting an already successful company to achieve the next big step and become world-leaders in our industry sector! I am also looking forward to enabling each area of the business to achieve its objectives and develop a high-performing community that is sustainable for the long-term future.

What drives you on a day to day basis?

Knowing that I have made a tangible contribution to the performance and success of the business. On a personal level, my main drive is to make my family proud and to provide them with a comfortable way of life.

Paul is just one of many new team members in a range of areas of the team including engineering, HR, accounts and operations. We’re looking forward to introducing you to more team members throughout 2020.

2019 has been a busy year for Farrat and full of achievements and projects to be proud of.  There are too many to go into in one post, but here are a few of the highlights of 2019.

Longevity is an ultimate aim for most businesses, and for Farrat to celebrate it’s 60th year this year was a fantastic achievement. A family business now into it’s third generation, Farrat continues to grow with a well-established team, many of whom plan to be here to celebrate 70 years no doubt.

The growth of our non-structural vibration isolation department – new expanding markets has meant the size of this department has nearly doubled in size, with the launch of several new products in our Cine range. The number of projects in the middle east has grown with a number of high-profile openings this year including the largest mall in Egypt, which we were a significant part of.

Growth of cinema in the MENA region is huge with 500 new cinema screens planned between 2018 and 2023, and following attendance of the second MENA cinema forum, Farrat are looking to continue to be a big part of that.

The MENA cinema forum this year introduced a new way to display the power of Farrat’s Cine Range. Affectionately dubbed ‘the cube of silence,’ this demonstration enabled our Commercial Director Ryan Arbabi to show just how much noise and vibration we can isolate!

Farrat has continued a truly global reach in 2019, with more countries than we could go into in much detail. From canning factories in France, Brazil and the UK, shock isolation in Taiwan, vibration control at The Hague in the Netherlands and in Slovakia, in addition to the work in MENA with the growth of cinema in Saudi Arabia on the horizon – it’s been a globe trotting year!

Farrat TBF was a brand-new product launched this year, following numerous requests for a fire safe thermal break product. Fire safe thermal break material is not yet a legal requirement but to be able to launch a product as ahead of the curve, and one we truly believe will be in high demand in the future, was an exciting achievement.

The team has expanded this year to accommodate growth, but in addition to that, Farrat truly believes in developing team members internally. A large number of people within Farrat have progressed to new positions in house.

2020 sees a new level of growth with more exciting plans that we look forward to updating you on from as close as Manchester to the other side of the world.

Farrat TBK Structural Thermal Break Plates have been granted a ‘Certified Passive House Component’ by the Passive House Institute.

Passive House is the standard for energy efficiency, granting certification to structures, components and professionals who have achieved the very best in quality, efficiency and sustainability.

The criteria to gain the title of ‘Certified Passive House Component’ is based on two categories:

• Living health and comfort (‘Comfort criteria’) and
• Energy balance during practical application (‘Energy criteria’)

Components that carry this certification have been tested according to these aforementioned criteria and are of a high standard regarding energy efficiency. This ensures that the specific use of the component meets the essential needs and functions of the professionals that require it (architects, structural engineers, technicians).

Farrat Structural Thermal Break Plates have received multiple certifications in the past. However, this is the first Farrat solution that has received Passive House Certification, cementing Farrat’s committed to developing innovative high-performance building materials with proven performance.

Passive House certification also fits closely into Farrat’s core values of Customer Service Excellence, Responsibility, Ambition and Quality, by ensuring quality assurance, performance and trust in manufacturing excellence.

“Farrat are very proud to have achieved certification to such a highly regarded standard as Passive House. Achieving exemplar level performance with our TBK material confirms our belief in the merits of solid state structural thermal breaks and the benefits of their use throughout general construction detailing.”

Chris Lister, Commercial Manager, Thermal Products

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Farrat’s Passive House certificated Structural Thermal Break materials provide building design professionals with a robust solution to minimise energy loss. Suitable to mitigate against planar, linear and point load thermal bridging, Farrat Structural Thermal Breaks can be used anywhere a penetration or transition exists in a building envelope to help achieve building performance standards. Performance characteristics include low thermal conductivity, high compressive strength and very limited creep under load.

Full specifications are available for import from NBS Plus.

To contact us click here or get in touch on +44 (0) 161 924 1600.