1.INTRODUCTION 第 51 巻第 6 号 (2014)

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1 439 総説 A Modification of Shaft Drive Up System of Newspaper Web Printing Machine in Order to Reduce Level of Shaft Broken Study Case PT. Masscom Graphy, Semarang, Indonesia Antono Adhi*, S. Adi Susanto*, Eko Afriyanto*, Eli Mas idah**, Hersatoto Listiyono*** and Misbah Fikrianto**** * Faculty of Engineering, University of Stikubank, Semarang, Indonesia ** Faculty of Engineering, University of Sultan Agung, Semarang, Indonesia *** Faculty of Information Technology, University of Stikubank, Semarang, Indonesia **** Faculty of Printing Engineering, Polytehnic of Media Creative, Jakarta, Indonesia Abstract PT. Masscom Graphy Semarang is a newspaper printing company. One of Printing Web Machine, PT. Masscom Graphy used Manugraph Cityline with a capacity of 35,000 CPH. Unfortunately this machine has a lack in rotation transmission that continued rotation of the electric motor to the main tower. This transmitter has a limitation because of the angle of the propeller shaft has high position. It has not standard requirement that universal joint cannot accept the load of electric motors and often broken by a period of 3 until 6 months. It make the system damaged, the engine should not be stopped several days for repairing. Modification designs add transmission-gearing system to replace the position of propeller shaft in order that it position becomes straight, and the acting forces become twisting force. Universal joint become more durable and the level of damage that often occurs can be reduced. Modification design the engine transmissions of Manugraph type Cityline, it is required several components namely cone gears, solid axle and embedded cotter pin. Spiral cone gear, can be used to change transmission angle until 90 0, has a bigger contact angle, and cannot slip. The results of the calculation the number of pinion teeth are 26 and 53 pieces of large teeth on the gears. Chosen material is SNC 22. Diameter of shaft is 70 mm. Material of shaft is S55C and cotter pin size mm with material S50C. 1.INTRODUCTION PT. Masscom Graphy engaged in the printing and publishing industry. It has implemented a production quality control system. The company even has achieved ISO 9001: 2000 from management consulting RWTUV Germany in 2008 and a certificate of PPGI (Indonesian Association of Graphic Company)as an admission that the company has implemented a good quality management accordance with the guidelines of quality standards. PT. Masscom Graphy has several divisions namely Division of Newspaper Printing, Division of General Printing, Division of Creative and Publishing. Implementing of the research done in Division of Newspaper Printing, especially on printing machines made in India, Manugraph. This machine was imported into PT. Masscom Graphy to support demand along with increasing of paper production and to reduce production costs. The engine has capability to produce a newspaper with a capacity 35,000 cph. It is expected to reduce the burden of the old machine. This study focuses on the optimization of Manugraph web engine system as in Fig.1. This machine has a deficiency on the part of the transmitter round tower to the main engine. The transmitter uses the tilt angle of the propeller shaft which exceeds the tolerance limit. Therefore the propeller shaft is often damaged in the universal join. The damage happened in short durations, 第 51 巻第 6 号 (2014) [41]

2 440 総 説 for 3 until 6 months. The damage of this system cause stopping production until several days for repairing. In order that it is necessary to modify the propeller shaft by adding transmission gears therefore the tilt angle of the propeller shaft is reduced. Shafts are the main drivers affecting the engine rotation speed of the engine. From the data field of observations, electric motor used to drive the Manugraph web printing machines, has power 89.4 KW and the motor rotation is 1460 rpm. design is design of the engine rotation axis transmitter before modification, as shown in Fig.2 Axis transmitter has tilt angle reaches 250. The impact is it often broken on the universal joint propeller shaft, because the transmitter shafts have to move two towers on Manugraph printing machine. Design and calculation of transmission shaft, include cone gear, shaft, and cotter pin with result is shown in Table 1, 2, and 3 1 7). The result of the modifications design of drive shaft system on Manugraph web printing machine use gear box with spiral cone gear, in order to obtain the position of the propeller shaft as shown in Fig.3. Propeller shaft becomes straight therefore the working load acting of the propeller shaft changes from turning and pulling force to only turning force as shown in Fig.4. 3.ANALYSIS OF THE RESULT Fig.1 Current machine 2.MACHINE MODIFICATION Modifications for the Manugraph web-printing machine are modification of main electric motor rotation to the tower. This transmitter use propeller shaft has slope angle exceeds the tolerance limits therefore it often damaged in the universal joint or coupling. The initial Manugraph printing machine used in PT Masscom Graphy currently has lack in production process. The lack lies on the electric motor propeller shaft to the tower. Durability of universal joint is very short, therefore when the production process is running, suddenly there was damage on the transmitter shaft. It happens because of the conductive shaft has a high angle therefore the workload of universal joint is very heavy to forward rotation of the electric motor. Due to the modification of the propeller shaft before redesigning is turning and Fig.2 Design of transmission shaft before it is changed [42] 日本印刷学会誌

3 A Modification of Shaft Drive Up System of Newspaper Web Printing Machine in Order to Reduce Level of Shaft Broken Study Case PT. Masscom Graphy, Semarang, Indonesia 441 Table 1 Data of cone gear 第 51 巻第 6 号 (2014) [43]

4 442 総 説 Table 1 Data of cone gear (cont.) [44] 日本印刷学会誌

5 A Modification of Shaft Drive Up System of Newspaper Web Printing Machine in Order to Reduce Level of Shaft Broken Study Case PT. Masscom Graphy, Semarang, Indonesia 443 Table 2 Data of shaft Table 3 Data of cotter pin Fig.3 Design of transmission 第 51 巻第 6 号 (2014) [45]

6 444 総 説 Fig.4 Position of propeller shaft after modification pulling force. The result is fractures often happened in that section. And the maintenance repair takes a long time, therefore the machine cannot operate and the production process is obstructed. The transmission shaft is very important because it continue rotation of the electric motor to the tower. The similarity of the current engine and the modification is the capacity of the machine is not changed. The results of the transmission to the engine design web Manugraph using the transmission system. The modification of this transmission system model more robust and precision on the angle contact side. It contains a combination of two pinion gears and two large gears. Transmission use to change the position of the transmission shaft on rotation machine becomes more aligned by changing position. By changing the position of the transmission shaft, the workload received by universal joint can be reduced. Compared with the current engine, the modification design has advantages in reducing of workload received by transmission shaft. And new design is more durable. It helps company to reduce the cost of repair. 4.CONCLUSIONS Designing by adding the transmission to the transmission shaft of CityLine Manugraph printing machine uses two pairs of cone gears. They are useful for changing the position of the transmission shaft rotation. By changing the position of transmission shaft become straight therefore workload becomes lighter, because the working force on the universal joint is turning force. The cost of components repair and replacement is reduced because of the universal joint is not easily broken away compare with current design that damage occurs 3-6 months. It is expected that with the addition of transmission for transmission shaft, the machine performance can be optimized without any damage on the transmission shaft. Type of transmission is cone gear and the material type used for big gear and pinion is SNC 22. Based on the results of the calculations, material type of shaft is S55C, and material of cotter pin is S50C. Lack of this design is dimension of the case to hold gears and need of lubricant used to lubricate and to cool transmission. For maximum results, maintenance of the components should be done regular activity therefore the performance of the engine is in optimum condition. It needs to replace lubricant periodically in order that gears do not become worn down. REFERENCES 1) Chan, Yefri., Diktat Elemen Mesin, Penerbit Erlangga, Jakarta, ) Dobrovotsky V., Machine Elements, Peace Publishers, Moscow, ) Halliday, Resnick., Fisika, Penerbit Erlangga, Jakarta, ) Martin, George H., Kinetika dan Dinamika Teknik. Edisi ke-2, Penerbit Erlangga, Jakarta, ) Niemann, Gustav., Machine Elements Design and Calculation in Mechanical Engineering, Allied Publishers Private Ltd, India, ) Sears, Zemansky., Fisika Untuk Universitas 1 Mekanika Panas Bunyi. Edisi ke-8, PT. Bina Cipta, Jakarta, ) Suga Kiyokatsu, Soelarso., Dasar Perencanaan dan Pemilihan Elemen Mesin. Edisi ke -10, PT. Pradnya Paramita, Jakarta, [46] 日本印刷学会誌