Constant improvement in machine performance in recent years is accompanied with increase in impact power in the field of metal forming and metal cutting. This results in increase in vibrations transmitted to the ambient surroundings. Therefore, reduction of vibration plays a crucial role in the operation of plant and machinery. Nashik-based, ISO 9001-2000 certified, Machine House is a manufacturer and exporter of anti-vibration systems, and is an important player in this niche area. N T Ahire, Managing Director of Machine House, talks about the current scenario in an interview with Nilesh Guhagarkar of Industrial Products Finder.

What specific benefits accrue from the usage of your products?

Bilz mounts offer precision and stable levelling and are fitted with most modern insulation plates for absorbing vibrations and noise normally associated with all types of machine tools and machinery.

Bilz insulation plates, which are highly resistant to all common cutting oils and lubrication media, offer very long service life. These are designed and engineered for different machines depending upon the kind of vibrations generated.

With our products, the customer gets the following benefits:

• Civil foundation is not required
• Reduced cost due to flexible machinery
• Prolonged tool and machinery life
• Total flexibility in a workshop
• Quality improvement through vibration suppression, and
• Vibration and structure-borne noise insulation through the most modern materials.

Actually, we had started with components manufacturing for a few big companies like Crompton and Siemens, besides some small scale industries, in 1985, before getting into the field of anti-vibration mountings in 1986. Today, we have established our presence in all parts of India as manufacturer of anti-vibration mounts and levelling elements in technical collaboration with Bilz Vibration Technology AG, Germany, with buy-back arrangement.

What is the basic principle of vibration isolation?

The objective of using insulation mechanisms for machine mounting is the reduction of pulsating (repetitive), or sinusoidal vibrations. The task is to keep the motion (amplitude) of the flexibly mounted machine within permissible limits for operation. The vibration insulators selected must have sufficient dampening capacity!

Please elaborate on the technical aspects.

Bilz insulating plates are ideally suited for vibration suppression of foundations and base-plates. The main purpose of the foundation is to stabilise the machine as well as to increase the moment of inertia. The foundation thus positively influences machine vibration by reducing the amplitude of oscillation.

It is wrong however to assume that any foundation can be large enough to eliminate all vibration problems. It is important that as much information as possible be supplied regarding the machine to be isolated, to arrive at the optimum solution. This will include machine size and weight, any dynamic features of its operation, location including group type, conditions where optimal performance is required and a vibration analysis of the machine and site conditions.

A correct isolation between machine foundation and surrounding area will result in trouble free operation. As a result of years of experience we have the necessary expertise in vibrations, planning and construction design.

What solutions do you offer for the automobile industry?

In recent years, ever-higher requirements of test stands and test systems for the automobile industry have led to the need for better performing vibration isolation systems. Bilz air springs with level control system are ideally suited for this demanding application Bilz services:

• Interpretation and supply of the vibration isolation system
• Supply and installation from cast-iron plates to customer's request, and
• Start-up of the vibration isolation system.

Application range includes: engine test stands, swivelling test stands, Formula 1 test stands (BMW, Daimler, Chrysler, Ferrari, Toyota, Renault), and acoustic engine test stands

How about your customers?

Our OE and other major customers include:

• For CNC lathes/VMCs: Bharat Fritz Werner (BFW), ACE Manufacturing System Ltd., Liebherr Machine Tools, Lokesh Machine Tools, Macpower CNC
• For Presses: ISGEC, Singhal Power Presses, Godrej & Boyce Mfg Co Ltd
• For CMMs: Accurate Gauging And Instruments, Carl Zeiss, Mitutoyo
• For Injection Moulding Machines: L&T Demag Plastics, Windsor Machines Ltd, and
• Other Major Customers: Fairfield Atlas Ltd, Caparo Maruti Ltd, Subros Ltd, Jay Bharat Maruti Ltd, Coetz India Ltd, Omax Auto Ltd, Grind Master Machines, Micromatic Grinding Technologies, among many others.

What is the difference between spring technology and rubber technology?

Spring technology is also a very good technology. If you compare spring technology with rubber technology, you will find that the frequency of spring technology is low compared to rubber technology due to the high amplitude. But as you know, every system has some disadvantages.

Springs have some major disadvantages. With springs, system levelling of machines is not possible. Imagine, if some presses are on springs without levelling; the presses will deflect more on one spring while other springs will have less load. In such a case the life of springs is less and machines without levelling will get heavily damaged over a period of time. Even a small table in our homes also needs some kind of basic levelling, therefore how can we install such a big machine without levelling? Control on the settling time is not possible, as the spring will get settled as per its natural frequency. In such cases, productivity will be decreased and the strokes/min would be less.

What is the difference between locally made mounts and Bilz?

There are so many local players in the field of anti-vibration mounts. Here, I want to tell you one thing: it is very easy to imitate anybody's rubber and start making anti vibration mounts but Bilz is different from them in other terms. For example:

• Machine House has a strong technical backup from Germany. Bilz is in this field for the last 40 years, hence you can say that we are one of the leaders or pioneers in anti vibration mounts
• We are the only one in India to give a written rubber warranty on the catalogue. Nobody in India gives you in writing about the life of their product
• Customers can check the composition of our product. It is 100% Nitrile with cork and cross link polyester fibre
• Normally customers can check the composition of rubber by asking samples of rubber. It is always beneficial to check the rubber composition before buying, and
• Finally, you can find that Neoprene and natural rubber rates are higher than Nitrile, but you can find out in the market that Neoprene mounts are 10 times cheaper than Nitrile. How is this possible? A customer has to think about such things before arriving at a decision.

You have a tradition of launching new solutions for vibration every year. So what are you introducing this year?

As you have rightly noted, we have been introducing new products in this field like Ht block as a TPM solution, every year for the last 10 years. This year we are going to introduce a new product called VITAP (Vibration Isolated Table Top Platforms), which is an affordable measuring table with low frequency. You can say that it is a revolution in engineering field. It is like a "Mobile Metrology Department" that one can carry the VITAP near any machine and check the job's frequency, VITAP has very low natural frequency Bilz rubber air springs, i.e., you can reduce the vibration above 6 Hz. This will help customers reduce handling of materials as well as increase productivity.