Noise Control in Textile Machineries

Jagannath Sardar
(2008TTZ8165)

Submitted to Prof. K. Gupta

Department of Mechanical Engineering

Department of Textile Technology Indian Institute of Technology Delhi New Delhi

Indian Institute of Technology Delhi 1

Noise control in Textile Machineries:

Contents:
Page: 1. Introduction: .... 2. Definitions and Background:. . 2.1 Noise Control Principles... 2.2 Approach to Analysis of Problems... 3. Analytical Survey of Noise Study in Textile Industry:....... 3.1 Spectrum Analysis. 3.2 Standards for noise abatement in industry..... 3.3 The Machinery Directive 4. Structure of Textile Industry: 4.1. Machineries in Spinning and Noise emission.... 4.1.1. Existing mechanism of Noise control in Spinning... 4.2. Machineries in Fabric manufacturing and Noise emission... 4.2.1. Existing mechanism of Noise control in Fabric Manufacturing 5. Some ideas to control noise in textile machinery:.. 5.1. Active Noise Control.. 5.2. Passive Noise Control... 5.2.1. Primary function of Damping materials.. 5.2.1.1Definition.. 5.2.1.2 How does the damping material works. 5.2.2. Function of Barrier materials.... 5.2.2.1 How does the barrier material works 5.2.3. Function of Absorption materials... 5.2.3.1. How does the absorption material works.. 6. Conclusion:.. 7. Reference:... 23 24 25 27 28 28 29 30 31 32 33 35 37 1 3 4 5 6 9 10 10 12 12 14 18

Indian Institute of Technology Delhi

Acknowledgement
I would like to show my high gratitude to our Respected Sir, Prof. Kshitij Gupta, who has taken the course Design for Noise, Vibration and Harshness and I have got a plenty of knowledge regarding Noise and Vibration from his kind teaching. Before doing this course I have had least knowledge about Noise and Vibration. Even I did not know the exact definition of sound as well as Vibration. I am also grateful to my entire classmates of this course. Specially, I am thankful to Mr. Changadev Desai who has helped me to understand the course as well. I am also thankful to Mr. Ajay, M.Tech final year student, who has taken care of us during practical classes of the same course.

Indian Institute of Technology Delhi

1. Introduction:
Textile is one of the major economic Industries all over the world. In the field of noise at the workplace, in spite of national regulations on noise at work in force for many years, lots of people are still getting hearing losses due to machinery noise throughout the world. In order to progress, there was a need for a policy enforcing noise reduction at source at the design stage and allowing market forces to encourage less noisy machinery being put on the market. This was made possible in Europe through a specific European regulation [1]. In parallel to the strong action on noise reduction at source at the design stage, a standardization programme developed at the European and international levels on workplace noise in particular on designing low-noise workplaces, designing means to reduce noise on the propagation path and measuring their effectiveness. Now a days the machine layout and operation pattern has been changed in textile industry. Management of the industry are concerned to preserve floor space and optimize production in both the natural and man-made fibres industries. Noise in the mills and factories is increasing, and one of the main reasons is that in the face of keen competition and already on a 24 h basis, machines are being operated at speeds higher than ever before to increase production rates. This is possible to a great extent with the man-made fibres; continuous threads can be produced and wound more quickly because of their inherent strength and other advantageous properties compared with natural fibres. As a direct result of the speed increase, out of balance forces and vibration increase and more energy is released as sound [2] Due to the complex nature of Textile industry, versatile machineries are used in the field of textile product. Different type of machineries produces different level of noise. Generally workers are exposed in that level of sound during production. They have been effecting by that sound at any instance. OSHA (Occupational Safety and Health Act 1970) prescribed permissible exposures in industries. These levels are shown in the table below (Table 1): [3]:

Indian Institute of Technology Delhi

In a textile mill, minimum and maximum noise level can be achieved as 82.82 dBA and 102.3 dBA (approximately) respectively [4]. To prevent health hazards of the workers in that level of sound, different type of techniques can be applied. But due to unconcerned and un educated workers, the implementation of those techniques are partially failure. This is a challenging job to prevent noise in textile industry as well as enlightening to the unconcerned workers and administrative in Textile industry. In this literature we will discuss about some approaches to make a pleasant working environment not only for worker but also the beneficial for the management of the Textile Sociaty.
Table 1.1: Permissible daily noise exposure limits for industrial noise (OSHA)

Limiting Daily Exposure Time (h) 8 6 4 3 2 1.5 1 0.5 Less Than 0.25

A-Weighted Sound Level Slow Response (dBA) 90 92 95 97 100 102 105 110 115

Indian Institute of Technology Delhi

2. Definitions and Background:

What is Noise? Noise is disagreeable or undesired sound by the recipient. In many instances, noise is a relative definition of a sound since one persons music may be another persons noise. It is difficult to give a very clear definition of an irritating noise. Generally, noise is an unwanted sound, regardless of its intensity or duration [5]. Noise Pollution has been recognized as a major threat to human well being. Much discussion and legislation has evolved in an attempt to recognize and combat the problem of noise pollution. It has been recognized that noise, of sufficient intensity, can damage hearing and be classified as a hazard. In combating the problem of noise pollution it is necessary to use a means of measuring noise levels and a system of classification. The decibel is a number which relates sound intensity or sound pressure. When most people use the term decibel or discuss noise levels in decibels they are referring to decibels as related to the A-weighted scale or, dBA [3]. The A-weighted scale parallels the sensitivity of the human ear and uses the lowest audible sound that the human ear can detect as the reference point for determining the decibel level of a noise. The reference intensities used above represent the threshold of audibility where sound is just loud enough to be heard. At 140 decibels or more acute pain is experienced. Some common noise values are as follows: Ordinary conversation 60 dBA Heavy traffic 80 dBA Cocktail Party 90 dBA Moving subway train 100 dBA Riveting gun 130 dBA Hard rock band 100 to 138 dBA Jet plane heard at close range 150 dBA Any noise rating above 80 dBA produces physiological effects and any long term exposures at much or above 90 or 100 decibels will cause permanent damage to a

Indian Institute of Technology Delhi

persons hearing. An increase of 10 dBA is a doubling of loudness with respect to the human ear [5]. Noise generally consists of many tones with varying rates of vibration or frequency. The frequency expressed in cycles per sound or hertz (HZ) usually is in the range of 20 to 20,000 cycles per second. The ear is not very responsive to very low or very high tones as it is to the tones of medium frequency. The dBA scale matches the response of the ear, and is therefore well suited for evaluating noise as it relates to human beings [6]. The noisy industrial machine can be viewed as a sound generator. The noise generated, generally, will be made up of sound waves which encompass the spectrum of 125 cycles per second to 8,000 cycles per second with a certain frequency band being dominant. The noise emitted is either direct airborne sound or noise generated by mechanical vibrations setting up vibrations in sheet metal panels or large solid areas. Sound waves decrease in length as the frequency increases or, more simply, the wavelength is inversely proportional to the frequency. Generally, it is easier to control noise in the higher frequency bands than the lower frequency bands since it is difficult to absorb sound which is made up of long wave lengths.

2.1 Noise Control Principles

It is necessary to treat at least one element in the noise system if the perceived level of noise is to be reduced. By reducing the noise level at the source or along the path, the noise level at the receiver point of interest is accordingly reduced. Treating the receiver in such a way as to minimize the sensitivity to high noise levels is another approach to the general noise problem. Each element of the noise system has associated with its treatment advantages and disadvantages. Treatment of the noise source is the most effective approach to a localized noise problem. The noise source treatment is often, however, the most difficult to properly implement. Treatment would be accomplished by addition of noise control materials or the re-design of the noise source. Addition of noise control materials could hinder the

Indian Institute of Technology Delhi

process of the noise source in its primary functions. Redesign of the noise source may be prohibitive based on the cost to redesign, develop and re-tool. Treatment of the noise receiver is the least desirable approach since each receiver must be treated individually. The addition of earplugs or earmuffs can encumber the receiver to the extent of being impractical. Educating the receiver as to the source of the noise and the purpose of the noise generating mechanism is another possibility. In any case the degree of effectiveness of the treatment will vary since the range of subjective reaction to noise varies from person to person. Treatment of the noise path is conceptually the simplest and therefore the most common approach to a localized noise problem. The approach is to place material in the path of the noise (generally between the noise source and the noise receiver) so that the level of noise at the receiver is reduced. The application of materials is often oversimplified, however, leading to ineffective and/or inefficient use of materials. Also the air paths are typically addressed while the structural paths are often overlooked. Finally, the design of the treatments developed without consideration of assembly procedures can lead to installation errors, which compromise the purpose of the treatment.

2.2 Approach to Analysis of Problems

As pointed out earlier, the end recipient of noise is the human ear. An expedient solution to a noise problem comes through the use of earplugs or other ear protection. Legislation has taken the position that hearing protection of this nature will not be tolerated if effective means for controlling noise at the source exists. The first step in quieting a noisy environment is to clearly identify the problem. An ideal starting point is to obtain the dBA levels emitted at various frequency bands. This should also be done at several positions around the machinery. This can be done with a simple sound level meter, however, with more sophisticated equipment, more detailed data can be compiled regarding the frequency characteristics and nature of the sound source.

Indian Institute of Technology Delhi

3. Analytical Survey of Noise Study in Textile Industry:

Occupational Noise exposure has been linked with a range of negative health effects by various researchers. The resulting injury of occupational hearing loss is also a well recognized and global problem. To protect workers from hearing damage due to noise exposure and other related health effects, a vast store of knowledge has been accumulated till date about its nature, etiology and time course. There is still ignorance, amongst majority of people working in industries in developing and third world countries including India about ill effects of exposure to high values of noise. Equivalent sound pressure level Leq has given in various sections of a plant with the help of a digital sound level meter. The noise spectrum has been evaluated with the help of 1/3 octave filter set. A cross sectional study involving 112 workers exposed to different levels of occupational noise has been conducted [4]. Meliksah ERTEM et al [7]. shows the comparison of the mean hearing threshold levels (dB) of control subjects with carpet mill and cotton textile factory workers. 4000 Hz notch was plotted in carpet mill and cotton textile workers audiograms in the figure 1.

Fig. 1 Mean hearing levels (dB) at different frequencies. The results of the study establish the fact that noise level in certain sections of the plants i.e Loom Shed, Spinning, Ring Frame, TFO Area is more than the acceptable limit of 90
Indian Institute of Technology Delhi 9

dBA for 8 h exposure stipulated by OSHA. The noise level in other sections like carding, blow room, combing etc., although is less than 90 dB(A), but is quite higher than limits used for assessment of noise for community response. Octave band analysis of the noise shows the presence of high sound level in 4,000 Hz frequency range, which can be a major reason for causing occupational hearing loss. The results of the interview questionnaire which included a number of parameters reveal the following; (i) only 29% workers are aware about the effects of noise on health (ii) 28% workers are using ear protectors (iii) the satisfaction with the working environment is related to noise level, as workers exposed to comparatively less noise level report better satisfaction (iv) 70% of the workers reported that high noise level causes speech interference (v) 42% workers report the noise to be annoying. The study thus demonstrates the presence of gross occupational noise exposure in both the plants and the author believes that occupational noise exposure and the related effects in India is a widespread problem. The equivalent A-weighted sound pressure level LAeq has been calculated using the equation:

The details of the Leq values of noise to which the workers are exposed in various work areas in a textile mill is shown in the Table 2 and Table 3 below:

Indian Institute of Technology Delhi

10

Madbuli H. Noweir et al. [8] has shown, the dBA means of Leq, Max (SPL) and Min (SPL) of the surveyed factories are in Table 4. The most used and possibly, the most meaningful parameter, the Leq has varying degree of variance, ranging from 1.5 dBA2 (Hygienic Paper Products Co.) to 5.9 dBA2 (Nasr Printing Factory). Factories with smaller variance of Leq could be treated with general noise control and reduction techniques. However, factories with high variation may have hot spots which would need individual noise control at the sources in addition to any general measures. Table 4

Indian Institute of Technology Delhi

11

3.1 Spectrum Analysis

The octave band analysis of the noise in various work areas shows the presence of high sound level in 4000 Hz. Figure 2 and 3 shows the octave band analysis of sound spectrum in Ring Frame and loom shed respectively. The high level of sound present in this frequency region can be a major reason for causing noise induced occupational hearing loss.

Exposure to continuous and extensive noise at a level higher than 85 dBA may lead to hearing loss. Continuous hearing loss differs from person to person with the level, frequency and duration of the noise exposed [9.]. Negative effects of noise on human beings are generally of a physiological and psychological nature. Hearing losses are the most common effects among the physiological ones. It is possible to classify the effects of noise on ears in three groups: acoustic trauma, temporary hearing losses and permanent hearing loss [10]. Blood pressure increases, heart beat accelerations, appearance of muscle reflexes, sleeping disorders may be considered among the other physiological effects. The psychological effects of noise are more common compared to the psychological ones and they can be seen in the forms of annoyance, stress, anger and concentration disorders as well as difficulties in resting and perception [11, 12, 13].
Indian Institute of Technology Delhi 12

A great majority of people working in industry are exposed to noise. Therefore, in this study, the effects of noise on human beings have been investigated with respect to the level of noise they are exposed to [14] assembly procedures can lead to installation errors, which compromise the purpose of the treatment.

3.2 Standards for noise abatement in industry

In the field of noise at the workplace, in spite of national regulations on noise at work in force for many years, lots of people are still getting hearing losses due to machinery noise in Europe as well as throughout the world. In order to progress, there was a need for a policy enforcing noise reduction at source at the design stage and allowing market forces to encourage less noisy machinery being put on the market. This was made possible in Europe through a specific European regulation. In parallel to the strong action on noise reduction at source at the design stage, a standardization programme developed at the European and international levels on workplace noise in particular on designing low-noise workplaces, designing means to reduce noise on the propagation path and measuring their effectiveness.

3.3 The Machinery Directive

A major new approach directive is Directive 89/392/EC (first published in 1989, subsequently amended and renumbered in 1998 as 98/37/EC), so-called Machinery Directive. Three types of standards, so-called type A, type B and type C standards, are elaborated to accompany this directive. Type A is for standards covering basic safety concepts, type B standards covering horizontal issues (e.g. noise emission measurement in general) applicable to a large number of machinery and type C standards concerning safety aspects (including hazards due to noise emission) of single types of machinery [1].

Indian Institute of Technology Delhi

13

Figure 4 illustrates the essential role of standards in the current strategy for reducing noise in industry.

Fig. 4 Global strategy for noise abatement in industry

Indian Institute of Technology Delhi

14

4. Structure of Textile Industry:

A composite industry of Textile can be described as in the Structure of four types of categories as Spinning mill, Weaving mill, Dyeing mill and Composite mill. In spinning mill, only the yarns are produced using different type of twisting and pre processing machines. In weaving mill, the yarn comes from the spinning section. First, the yarn goes to the winding section to make the bigger packages to manufacturing the fabrics. In weaving section, different types of looms are used for producing different categories of fabrics according to the requirements of market demands. Similarly, in the dyeing mill, they only make the fabric dyed and printed and finished. In the composite mill, all three types of sections, which are mentioned above, are involved. Some composite mill produce garments in further process. The structure of a specialized composite mill has shown below:

Fig.5. Structure of a typical composite mill

4.1. Machineries in Spinning and Noise emission

In the spinning section, various machineries are used in the pre-spinning process as well as twisting process. In pre-spinning process, generally Carding, Combing, Drawing and
Indian Institute of Technology Delhi 15

Draw twisting or Roving machines are used to produce twisted roves or slivers. For all the operations, pneumatic pressure compressors are required. place to control noise in air jet spinning machinery [ 15]. After pre-processing, roves or slivers are used to manufacture yarns. In this section, as per the end use, different types of spinning machines are used such as ring spinning, rotor spinning DREF machines etc. According to the speed of the machines, the emissions of sound levels are different in different machineries. In the twisting zones, the rotor speed is maximum compare to other spinning machines. The rotor speed is approximately 120000 rpm and the opening roller speed is 5000-6000 rpm. Most of the sound emits due to the high speed of rotor. Similarly, the speed of the spindle of Ring spinning approximately 20000 rpm and in draw twisting machine, the speed of the spindle approximately 14000 rpm. The approximate emissions of sound levels in spinning machineries are given in the table 5. Table 5 Name of the Machines Blow Room Carding Combing Drawing Roving Ring Spinning Rotor Spinning DREF Spinning Max. Sound Level (dBA)(apprx.) 82-84.8 86.2-89.2 84.5 85 88-95.5 99.5-100.2 102-104 89.9 Those machines are emitted noise in different levels. An US patent has reveals some features which takes

Indian Institute of Technology Delhi

16

4.1.1. Existing mechanism of Noise control in Spinning

There are many kind of machines are existing in the spinning or any field of operations. And the result that each operation has its own noise emission spectrum. Below, in the figure, shown the noise spectrum for different process in textile sector

Fig. 6 Noise spectra of five processes 1. Staple fibre cutter, 2. Spinning, 3. DrawTwisting, 4. Weaving, 5. Winding. It is very difficult to control huge amount of noise in direct approach. Ear protector could be a solution to prevent hazardous effect direct to the human physic as well as psychology. But there are objection from hygiene, safety and comfort consideration. The solution then is to reduce noise level in active approach. The active approach is to overhauling and maintenance periodically that reduce the noise at source. A necessary step to noise reduction at source is a detailed knowledge of the source mechanisms, transmission path and noise radiating surface [2]. A typical diagram of a drawtwister has shown in the fig. 7.

Indian Institute of Technology Delhi

17

Fig. 7. Diagram of a drawtwister From the fig. 8 we have seen that the loudest narrow band sound is produced from the spindle and bobbin zones.

Fig 8. SPL of Drawbox and Bobbin

Indian Institute of Technology Delhi 18

A spindle diagram has shown in the fig. 9. The noise source can be control by the detail study of the material and mounting mechanism of the spindle. Generally, spindle and ball-bearing are produced by the metal, which produce more noise. It is possible to change the material, metal to polymeric one.

Fig. 9. Spindle Use of Polyurethane gear, flexibly mounted gears, redesigned headstock and various vibration isolation of parts, the noise contours change and the levels are reduced to meet the recommended levels at the operators position. Some noise reduction techniques on the draw-roll assembly has shown in (Fig 10). One approach used a polyurethane bonded bush between the gear and the shaft. It reduced the overall noise level of one shaft assembly by 7-8 dB. Another trial was made substituting a copper-manganese alloy shaft for the steel shaft. The use of this material not only introduced its high damping properties but also lowered the shaft critical below the running range. The

Indian Institute of Technology Delhi

19

result of using the copper-manganese shaft was to reduce the overall noise level by 4.5 dB.

Fig.10 Treated draw roll. In the figure 11 octave band levels for the modified machine are compared to the average drawtwist noise and a deafness risk criterion n.r.85. There is a reduction of noise from 128 sones to 77 sones, i.e. a reduction in loudness od 40%. These noise levels are for the modified machine running with full bobbins at spindle and drawroll speeds higher by 11% and 20% respectively than the maximum production speeds commonly used [16].

Indian Institute of Technology Delhi

20

Fig. 11 Octave band levels at centre of machine for modified drawtwist machine. 1. Average drawtwist noise, 2. Modified machine noise, 3. n.r. 85 criterion

4.2. Machineries in Fabric manufacturing and Noise emission

As earlier discussion we have seen, various machineries are being used in fabric manufacturing section, such as different type of Winding machine, Looms and knitting machines. In winding zone, TFO (Two for one Twist), Doubling, Cheese winding, cone winding, Precision winding machines are being used. And it is obvious that all the machines are produced different levels of noise. Similarly, different types of looms are used as per the requirement of fabric construction. Now a days most preferable looms are shuttle less automatic looms. Production of this type of loom is higher. It means the speed of the loom is higher and it is understood that the loom produce higher level of noise. The approximate emissions of sound levels in Fabric manufacturing are given in the table 6.

Indian Institute of Technology Delhi

21

Table 6 Name of the Machines TFO Doubling Cheese Wing Cone winding Precision Winding Shuttle Loom Shuttle less Loom Air jet Loom Water jet Loom Max. Sound Level (dBA)(apprx.) 100 92-95.5 93 92 91-92 99-100 100-105 110 96-99

The noise source of winding machine is almost similar to that of spinning machineries. In case of TFO, the noise generates due to the revolution of the spindle in the spindle chamber. The whole assembly of spindle and chamber vibrates due to it high revolution. The maximum spindle speed is 16000 RPM [17] And the outcome of the result is high amplitude narrowband noise [fig. 12]. arrangement in the gearbox. Another major source of noise is gearing

Indian Institute of Technology Delhi

22

Fig. 12. TFO Spindle chamber arrangement. Similarly, in Loom shed, there are many types of looms are use and it is obvious that all different looms have different speed according to their production rate and frequency. Due to the different sped and mechanism, the looms are produced different levels of noise. Like, Air jet looms produce higher level of noise compare other looms (table 6). In the figure 13 a typical Air jet loom has shown. Basically Air nozzle produces much noise in this loom. Not only air nozzles, reed of the looms are produced high noise when it strikes on the base plate of the reeds.

Indian Institute of Technology Delhi

23

Fig 13. Air jet Loom In the Shuttle loom, most sound generates due to the movement of the shuttle. During Weft insertion takes place through the Warp shed, shuttle caries the weft thread and it strikes to the end of the shuttle path called sley end (fig 14.). Shuttle nose strikes on the solid material and make noise in a high level. In this occasion, there have a active control arrangement take place. At the end of the shuttle path there have a buffer, which is made by rubber. The rubber buffer consume kinetic energy of the shuttle and indirectly protects the noise.

Indian Institute of Technology Delhi

24

Fig. 14. Shuttle Loom and Shuttle

But there have no such type of arrangement to control noise in the reeds section. According to the pattern of the fabrics, the reeds are acting up and down. Due to this movement of the reeds a huge noise emits from the loom. When reeds moved down, it strikes metallic parts inside the loom. Not only has this event, the friction between reeds and slot of the reeds emitted noise in each movement. A typical reed has shown in the figure 15.

Fig. 15. Reed

Indian Institute of Technology Delhi 25

4.2.1. Existing mechanism of Noise control in Fabric Manufacturing

An air jet loom makes cloth using compressed air to insert the weft into the warp. The weft is inserted into the warp by the rocking motion of the sley, sword, reed, and rocking shaft. By reducing the vibration produced by the rocking motion of this nonbalanced load, Toyota Industries has successfully improved the workplace environment of its customers weaving mills. Some model of air jet loom was designed to optimize the cross-sectional shape of the sley, the weight of which was reduced by 20% [18]. In addition, the material of the sword was changed and by perfecting its placement of ribs using computer analysis, it was possible to lighten and harden the sword. By attaching the balance weight to the rocking shaft, the load was reduced. As a result, vibration was greatly decreased by reducing the dynamic load on the floor by 20%. As earlier discussion, a conventional loom has changed very little since the industrial revolution[19] Much of the noise arises from the impact and general clatter of the shuttles, picking arms and harness. The spectrum is mainly high frequency and the sources are difficult to eliminate, mainly because impact is inherent in the process. Noise control of shuttle and picking arm noise in the jute industry [20] can reduced a loom by up to 10 dB. This can has been achieved by replacing metallic picking points and picking cones with polyethylene parts [21]. Nylon driving pinions and nylon bushes have been used in lieu of cast iron. Figure 16 has shown the different sound level in Shuttle and water jet looms [2]

Indian Institute of Technology Delhi

26

Fig. 16. Noise comparison, 1.Shuttle loom (205ppm) 2.Water Jet Loom (400ppm)

5. Some ideas to control noise in textile machinery:

It has already been discussed that controlling noise is challenging job in textile machinery. There have so many barriers to control noise or to protect health hazards of workers. In this text we will discuss the probable controlling system of induced noise from textile machineries. Noise control in textile machinery can be classified in two broad sections. One is active and another is passive control. Probable noise control system in textile machineries has shown in the flow chart in figure 17.

Indian Institute of Technology Delhi

27

Fig. 17. Control Flow chart

5.1. Active Noise Control

According to the flow chart, it is possible to control of noise that emits from the machineries by two ways. In active system, directly we can control the noise bye controlling the machine itself. Generally the noise generates from the machine due to its unwanted vibrations in various levels of frequencies and material to material friction [22]. If we are able to control that unwanted vibration friction as well, to some extent we can control the noise directly. Machine vibration can be controlled by three ways; first, we can control by proper balancing the machines, There are two main types of balancing machines, hard-bearing and soft-bearing. The difference between them, however, is in the suspension and not the bearings. In a hardIndian Institute of Technology Delhi 28

bearing machine, balancing is done at a frequency lower than the resonance frequency [Figure 18] of the suspension [23].

Fig. 18. Resonance frequency In a soft-bearing machine, balancing is done at a frequency higher than the resonance frequency of the suspension. Both types of machines have various advantages and disadvantages. A hard-bearing machine is generally more flexible and can handle pieces with greatly varying weights, because hard-bearing machines are measuring centrifugal forces and require only a one-time calibration. Only five geometric dimensions need to be fed into the measuring unit and the machine is ready for use. Therefore, it works very well for low- and middle-size volume production and in repair workshops. A softbearing machine is not so flexible in respect of amount of rotor weight to be balanced. The preparation of a soft-bearing machine for individual rotor types is more time

Indian Institute of Technology Delhi

29

consuming, because it needs to be calibrated for every individual part. It is very suitable for high-production volume and high-precision balancing tasks. Hard- and soft-bearing machines can be automated to remove weight automatically, such as by drilling or milling, but hard-bearing machines are more robust. Both machine principles can be integrated into a production line and loaded by a robot arm or gantry, requiring very little human control. Soft-bearing machines are also generally more expensive because of the higher complexity in the design and manufacturing. Secondly, proper material selection for vibrating parts and in which parts material to material frictions takes place; as an example metallic gear arrangements. For our experience, it is visible that metallic gear to metallic gear arrangement produces more noise compare to polymeric gear. Although, there have many advantages as well as disadvantages for polymeric gear arrangements. However, in account of control of noise, polymeric gears are more suitable rather than metallic one. Generally polyurethane, polyester, polyamide polymers are used for this purpose. It is known that where the rotational movements takes place in the machine parts, the vibration occurs more, as an example spindles, gears, crank shaft etc. those parts can be replaced by polymeric materials instead of metallic one. On the other hand, noise can be reduced by keeping control the noise source. That means, overhauling is important to reduce noise. Periodically lubrication is required in the zone of gears to gear arrangement, ball-bearing and other rotational parts. For all the machines overhauling duration and indication of lubrication is mentioned [24].

5.2. Passive Noise Control

The passive noise control system is nothing but the control after emission of noise. Emitted noise can be controlled by two ways; one is to making casing around the noise source and another is hearing protection. Many cases in textile machineries casing arrangement is difficult because of the production front. Generally, the production front
Indian Institute of Technology Delhi 30

in textile machineries is kept open to doffing conveniently after preparation of final products for spinning as well as weaving. It is easy to casing the gearbox effectively. Casing arrangement will be discussed as the following ways: Casing arrangement can be prepared by three ways; using damping material, barrier materials and absorptive materials. In both the cases the aim is to control vibration. Details discussions about those materials are given below.

5.2.1. Primary function of Damping materials

A damping material is used to reduce the vibration level in a vibrating system. The terms damping and deadening have long been used to describe the effects of general noise control measures. The topic taken up here is vibration damping as opposed to sound absorption, sound transmission loss or vibration isolation [25].

5.2.1.1Definition
Damping is the reduction of kinetic energy present in a system through transformation into another form of energy. The efficiency of damping present is evaluated by determining the systems loss factor. The dimensionless loss factor () is defined as:

=
Where, Q = System damping factor

f D W 1 = 0 = n = d Q 2T0 fn 2U

D0 = Total energy dissipated in the system as the result of damping for one cycle T0 = Total vibration energy of the system fn = Undampted resonant frequency (Hz) fn = Half power bandwidth (Hz) Wd = Energy dissipated from the system U = Max. energy stored in the system

Indian Institute of Technology Delhi

31

Half power bandwidth is shown in the figure 19.

Fig. 19. Half power bandwidth

5.2.1.2 How does the damping material works

The damping materials generally reduce the vibration amplitude by generating heat energy. Viscoelastic dampers are adhered to the vibration surface. This materials generates heat when it undergoes deformation. By optimizing a materials stiffness and internal losses, the damping performance can be optimized. It should be noted that the addition of damping material changes the stiffness to mass ratio of the system and accordingly, the resonances of system are affected. The damping performance of the viscoelastic material can be improved by spacing the material from the sheet metal. These applications take advantage of the extensional deformation of the damping material. By placing the viscoelastic material between two relatively inelastic materials, the viscoelastic material experiences shear deformation (figure 20). This also results in improved damping performance. Because of the different mechanisms of inducing deformation in the damping material, a material that performs well as a free layer may not perform as well as a constrained layer and vice versa.

Indian Institute of Technology Delhi

32

Fig. 20. Different damping applications

5.2.2. Function of Barrier materials

A barrier material also reduces the amplitude of sound waves propagating in a certain direction. The barrier material interferes with sound waves as they propagate away from the sound source. The portion of the sound energy which continues to propagate along the original path is then of significantly lower amplitude than the original wave. In the figure 21, it has been that how the barrier material works.

Fig. 21. Noise incident on a barrier material

Indian Institute of Technology Delhi

33

A barrier material, which reduces sound energy as the sound wave is transmitted through the material. The measure of a materials effectiveness as a transmission loss as earlier discussion. Transmission loss is the fraction of energy dissipated as a result of sound being transmitted through the material. Transmission loss is measured in decibels as: TL = 10log10 Incident sound intensity (Ii) Transmitted sound intensity (It)

5.2.2.1 How does the barrier material works

As the sound wave interacts with the barrier material, the mass of the material opposes the wave motion of the air molecules, thus causing a reflection of some portion of the sound energy. A fraction of the energy is absorbed and dissipated as heat due to the internal damping of the material. The remaining energy is converted to sound energy on the side of the barrier material opposite the impinging sound wave. The transmission loss (TL) of a material is principally determined by the mass of the material. At low frequencies the materials stiffness and mass determine the TL. At high frequencies the material stiffness, damping and the mass determine the TL. For frequencies where the TL is essentially mass controlled, the TL by 6 dB for most frequencies. The effectiveness of the barrier is dependent on its ability to sufficiently interfere with the sound wave. The barrier must have effective dimensions much greater than the wavelength of the sound to have significant influence on the sound level. The material should be impervious with respect to air. Holes in the barrier affects its performance. They significantly reduce the effective dimensions of the barrier and they allow for air pressure communication directly through the barrier material. Thus reduction the potential acoustic value of the barrier.

Indian Institute of Technology Delhi

34

5.2.3. Function of Absorption materials

Sound absorption materials reduce the acoustic energy of a sound wave as the wave passes through the material. They are commonly used to often the acoustic environment of an enclosed volume by reducing the amplitude of reflected sound waves. The benefit of the absorption material is multiplied by applying the material to a reflective surface since the sound is made to pass through the absorption material more than once. In the figure 22 a absorption material has shown.

Fig.22. Noise incident on an absorption material For a sound absorption material applied to an acoustically reflective surface, sound energy incident (Ii) on the material is partially absorbed by the material (Ia) and the remaining sound energy is reflected (Ir). The sound absorption capability of a material is expressed in terms of the sound absorption coefficient; the sound absorption coefficient is defined as:

Acoustic energy absorbed by a surface (Ia=Ii-Ir) Acoustic energy incident on a surface (Ii)

The absorption coefficient can have values between 0 and 1.

Indian Institute of Technology Delhi 35

5.2.3.1. How does the absorption material works

In order for a material to have good sound absorption performance, the material has to be a porous or fibrous one. Sound waves propagate into the material and loss energy by viscous dissipation. Sound waves inside the material also caused the fibres to rub against each other, thereby producing heat energy and dissipation sound energy. The absorption characteristics of a material are a function of frequency. Performance generally increases with an increase in frequency. As a rule of thumb, the material thickness should be a quarter of the wavelength () of the sound wave to be effective. Therefore, material thickness is an important determinant of absorption performance. It has shown in the figure 23.

Fig.23. Random incidence sound absorption for Polyurethane foam of various thicknesses.

Indian Institute of Technology Delhi

36

So, from the above discussion, it is proved that the noise induce from textile machineries can be controlled by designing some special features in a particular place of a specified noisy part. Some cases when machines are not in controlled for emission of noise, the workers of supervising authority can have ear protector. Using ear protector, to some extent, noise hazards can be controlled for human health.

Indian Institute of Technology Delhi

37

6. Conclusion:
For the textile, industry control of noise emission from the textile machineries is a challenging job. Some of the cases noise control has been taking place in few industries. Most of the textile industry in India, they are unable to implement the noise control system. To understand for noise control it is experienced that the controlling systems not only reduce the noise at source to acceptable levels, but also reduces the energy consumption in to some extent and at the same time leads to a better design of the machines too. For example, polymeric gear-gear arrangement or polymeric spindle consumes less energy compare to metallic one for the same r.p.m., it means that less energy consumption can leads to give higher speed as well as higher production. In this occasion, we have seen that it is possible to reduce emission of noise as well as control of noise when human health is concerned. There have number of possible procedure to control noise. We have also seen that the control can be achieved by two ways, such as Active and Passive control. There have different features for those control system. For active control, our aim is to reduce vibration and friction in situ of the noise parts by replacing materials as well as parts configurations. In this case, rotational metallic parts can be replaced by polymeric where noise comes out due to friction. For passive control, we want to reduce the noise level which has already been emitted from the source. There are some procedures to control the noise. The noise source can be covered fully of the cover can be treated by different process such as using damping, barrier and absorption materials. Some cases ear protectors are used to prevent noise hazards.

Indian Institute of Technology Delhi

38

7. References:
1. Jean Jacque, Noise And Standardization, Focussing On Machinery And Workplace Domains, Institut National de Recherche et de Scurit, I.N.R.S. Standardization Unit CEN Consultant for Noise, 30 rue Olivier Noyer, 75680 Paris, Cedex 14, France 2. R. Crawford, Noise Control On Textile Machinery, Phil. Trans. R. Soc. Lond. A. 1968 347-367 263 3. L.E.Kinsler, A R. Frey, A B. Coppens, J V. Sanders, Fundamentals of Acoustics, pp377 4. Raman Bedi, Evaluation of Occupational Environment in Two Textile Plants in Northan India with specific reference to noise, Industrial Health 2006, 44, 112-116 5. Dr. D.P.Raychaudhuri Advance Acoustics, , University of Kalyani, pp 283 6. Acoustical Solutions, Inc. 2852 East Parham Rd., Richmond, VA 23228 Ph: 800-7825742 fax: 804-346-8808, www.acousticalsolutions.com 7. Meliksah Ertem, Ersen Ilin, Faruk Meri, Noise Induced Hearing Loss Among Cotton Textile and Carpet Mill Workers, Tr. J. of Medical Sciences 28 (1998) 561-565 TBITAK 8. Madbuli H. Noweir And A. T. M. Jamil, Noise Pollution In Textile, Printing And Publishing Industries In Saudi Arabia, Environmental Monitoring and Assessment 83: 103111, 2003. 2003 Kluwer Academic Publishers. Printed in the Netherlands 9. USEPA (United States Environmental Protection Agency). Information on levels of environmental noise requisite to protect public health and welfare with adequate margin of safety, (EPA/ONAC Rep. No. 550/9-74-004); 1974 10. Melamed, S., Fried, Y., Froom, P. The interactive effect of chronic exposure to noise and job complexity on changes in blood pressure and job satisfaction: A longitudinal study of industrial employees, Journal of Occupational Health Psychology, 6, 182, 2001 11. Cheung, C. K. Organizational influence on working peoples occupational noise protection in Hong Kong. Journal of Safety Research, 35, 465, 2004 12. hrstrm, E. Sleep disturbance psycho-social and medical symptoms a pilot survey among person exposed to high levels of road traffic noise, Journal of Sound and Vibration, 133, 117; 1989

Indian Institute of Technology Delhi

39

13. Finegold L. S., Harris C. S., Gierke Von. H. E. Community annoyance and sleep disturbance; Updated criteria for assessing the impact of general transportation noise on people. Noise Control Eng. J. 42 (1) Jan.-Feb. 1994 14. E. Atmaca1, I. Peker1, A. Altin, Industrial Noise and Its Effects on Humans, Polish Journal of Environmental Studies Vol. 14, No 6 (2005), 721-726 15. B.D. Lassiter et al., Noise control system for textile machinery , US patent, no. 4586323, date may 6,1986 16. W. Klein, A practical guide to Combing and Drawing, Volume 3, pp. 42-56 17. www.himsonoriginal.com 18. Tatsuo Matsuura, Environmental Protection Activities of the Textile Machinery Division Division Manager & Managing Director, Textile Machinery Division 19. Sadao Aso, Rikuhiro Kinoshita, Heihachi Uematsu and Kiyohumi Sasaki, Members, TMSJ, Noise Generated by a Power Loom, Based on Journal of the Textile Machinery Society of Japan, Transactions, 18, T13-19 (1965) 20. Stott , A. 1965, Reducing noise in weaving sheds, Textile Manufacturing Machinery 21. Adanur, S. Handbook of weaving, pp. 175-223 22. K sugita et al., Device for noise attenuation of Weaving Machine, US patent, patent no. 5271062, date Dec. 14, 1993 23. Adolf Lingener: Auswuchten. Theorie und Praxis. Verlag Technik, Berlin und Mnchen 1992, ISBN 3-341-00927-2 24. Talukdar, M.K. et al., Weaving, Machines, Mechanisms, Management, Appendix ViiiXiii, pp. 590-598 25. Application of Noise control and heat insulation materials, American Acoustical products, 6 october Hill road, Massachusetts 01746

Indian Institute of Technology Delhi

40