Part 01. 설비 진단 및 계측
제1장 설비 진단의 개요와 진동의 기본
1. 설비 진단 기술의 정의 ···············14
1-1 설비 진단 기술의 정의 ·····14
1-2 설비 진단 기술의 필요성 ···15
1-3 설비 진단 기술의 구성 ······15
1-4 진동 상태 감시 ··················15
1-5 설비 진단 기법 ···················16
2. 진동의 기본 ·································17
2-1 진동의 기본 ·························17
2-2 진동의 측정 기본량 ···········19
2-3 변위, 속도, 가속도 관계 ···19
2-4 진동 단위 ····························20
2-5 진동의 종류 및 댐핑 영향 ···21
제2장 진동 측정
1. 진동 측정 시스템 ·······················33
1-1 개 요 ····································33
1-2 측정 시스템 ·························33
1-3 센 서 ····································33
1-4 진동 센서의 선정 조건 ······35
1-5 진동 센서의 설치 ···············35
1-6 진동 센서의 영향 ·············37
제3장 진동 신호 해석
1. 개 요 ·············································43
1-1 진동 신호 처리의 정의 ·····43
1-2 신호 처리 시스템 ·············43
제4장 기계 진동 방지 기술
1. 개 요 ·············································53
1-1 진동 방지의 목적 ················53
2. 일반적 진동 방지 기술 ···············53
2-1 진동 차단기 ·························53
2-2 질량이 큰 경우 거더의 이용 ········································54
2-3 2단계 차단기의 사용 ·········54
2-4 기초의 진동을 제어하는 방법 ········································54
3. 진동 차단기의 선택 ····················54
3-1 강철 스프링 ························55
3-2 천연고무 또는 합성고무 절연재 ····································55
3-3 패드 ·····································56
3-4 공기 스프링 ························56
4. 댐 핑 ·············································56
5. 방진 지지 이론 ····························57
5-1 완충 지지 ····························57
5-2 방진 지지 ····························57
5-3 방진 지지에 미치는 주파수···58
제5장 회전 기계의 진단
1. 기계의 고장 원인 ························65
2. 이상 현상의 특징 ······················65
3. 진단의 분류 ·································66
3-1 간이 진단 ····························66
3-2 정밀 진단 ····························66
4. 회전 기계의 간이 진단 ···············67
4-1 측정 주기의 결정 ···············67
4-2 판정 기준의 결정 ···············67
5. 회전 기계의 정밀 진단 ···············67
5-1 진동 분석 방법 ···················67
6. 이상 진동 주파수 ························69
제6장 소음 이론
1. 소음과 진동의 관계 ·····················77
2. 소음의 물리적 성질 ····················77
2-1 음파의 종류 ·························77
2-2 음의 굴절 ····························77
2-3 반사, 투과와 흡수 ·············78
2-4 간섭 ·····································78
2-5 호이겐스 원리 ····················79
2-6 마스킹 효과 ························79
2-7 음의 회절 ····························79
2-8 도플러 효과 ························80
3. 음의 제량 및 단위 ······················80
3-1 음파 ······································80
3-2 음의 dB 단위 ·····················82
제7장 소음 방지 기술
1. 소음 발생과 대책 ························91
1-1 기계 소음의 발생원 ············91
1-2 음원 대책 ····························93
1-3 공장 건물의 방음 대책 ······93
1-4 소음 방지 대책 ···················93
제8장 계 측 기
1. 온도, 압력, 유량, 액면의 계측 ···105
1-1 온도의 계측 ·······················105
1-2 압력의 계측 ·······················107
1-3 유량의 계측 ·······················112
1-4 액면의 계측 ·······················117
2. 회전수의 계측 ····························130
2-1 펄스 출력형 검출기 ··········130
2-2 디지털 계수식 회전계 ·····131
2-3 각도 검출용 센서 ·············131
3. 전기의 계측 ································136
3-1 전류 검출용 센서 ·············136
제9장 센서와 신호 변환
1. 센 서 ···········································138
1-1 센서의 개념 ·······················138
1-2 센서의 종류 ·······················138
1-3 검출 대상별 센서 ·············139
1-4 센서용 재료 ·······················142
2. 신호 변환 ···································144
2-1 기계적 변환 ·······················144
2-2 압력으로의 변환 ···············146
2-3 전기적 변환 ······················146
2-4 광학적 및 기타의 변환 ····149
3. 프로세스 제어 ····························156
3-1 피드백 제어의 기초 ··········156
3-2 프로세스 특성 ··················158
3-3 조절계의 제어 동작 ·········162
3-4 시퀀스 제어 ······················167
Part 02. 설비 관리
제1장 설비 관리 개론
1. 설비 관리의 개요 ·····················174
1-1 설비 관리의 의의와 발전 과정 ······································174
1-2 설비 관리의 목적과 필요성···175
1-3 설비 관리 기능 ··················176
2. 설비의 범위와 분류 ···················177
2-1 설비의 범위 ·······················177
2-2 설비의 분류 ······················178
3. 설비 관리의 조직과 요원 ·········178
3-1 설비 관리 조직의 개념 ····178
3-2 설비 관리의 조직 계획 ····178
3-3 설비 관리의 요원 대책 ···180
제2장 설비 계획
1. 설비 계획의 개요 ·······················190
1-1 설비 계획의 필요성 ··········190
1-2 설비 프로젝트의 종류 ······190
1-3 프로젝트 엔지니어링 ········191
2. 설비 배치 ···································191
2-1 설비 배치의 개요 ·············191
2-2 설비 배치의 형태 ·············192
2-3 GT 흐름 라인 ··················193
2-4 설비 배치의 분석 기법 ····193
2-5 설비 배치 순서 ·················194
3. 설비의 신뢰성 및 보전성 관리 194
3-1 신뢰성의 의의 ···················194
3-2 신뢰성의 수리적 판단 ·····195
3-3 신뢰성의 평가 척도 ·········195
3-4 보전성과 유용성 ···············196
3-5 신뢰성과 보전성의 설계 ···197
3-6 설비 보전을 위한 설비의 신뢰성과 보전성 ·················198
3-7 고장 분석과 대책 ·············200
4. 설비의 경제성 평가 ···················200
4-1 경제성 평가의 필요성 ······200
4-2 설비의 경제성 평가 방법 ···201
5. 보전 계획 수립 방법 ·················202
5-1 보전 계획의 개요 ·············202
5-2 보전 계획의 분류 ·············202
5-3 보전 계획에 필요한 요소 ···202
제3장 설비 보전의 계획과 관리
1. 설비 보전과 관리 시스템 ··········218
2. 설비 보전 조직과 표준 ·············219
2-1 설비 보전 조직 ·················219
2-2 설비 보전 표준화 ·············220
3. 설비 보전의 본질과 추진 방법 221
3-1 설비 보전의 효과 ·············221
3-2 설비 보전에 의한 설비의 유지 관리 ·····························221
3-3 설비의 최적 보전 계획 ···222
3-4 보전 시간 ··························224
3-5 설비 보전의 추진 방법 ···225
3-6 기본 설비 보전 업무 ·······225
3-7 설비 보전 실시상의 유의사항 ······································225
4. 설비의 예방 보전 ······················226
4-1 예방 보전의 기능 ·············226
4-2 예방 보전의 효과 ·············226
4-3 중점 설비의 분석 ·············227
4-4 예방 보전 검사 제도 ·······227
5. 공사 관리 ···································228
5-1 공사의 목적 분류 ·············228
5-2 공사 관리 제도의 개요 ····229
5-3 공사 전표의 역할 ·············229
5-4 공사 요구의 방법 ·············229
5-5 공사의 완급도 ··················229
5-6 공사의 견적 ······················230
5-7 여력 관리와 일정 계획 ····230
5-8 진도 관리 ··························231
5-9 휴지 공사 ··························231
5-10 긴급 돌발 공사와 외주 공사 ······································232
6. 보전용 자재 관리와 보전비 관리···233
6-1 보전용 자재 관리 ·············233
6-2 보전비 관리 ······················235
7. 보전 작업 관리와 보전 효과 측정··235
7-1 보전 작업 관리 ·················235
7-2 보전 효과 측정 ·················236
제4장 공장 설비 관리
1. 공장 설비 관리의 개요 ·············248
1-1 공장 설비의 종류와 관리 목적 ······································248
1-2 설비의 분류 방법 ·············248
2. 계측 관리 ···································249
2-1 계측화 계획 ·······················249
2-2 계측 관리 추진 방법 ·······250
3. 치공구 관리 ································250
3-1 치공구 관리의 개요 ··········250
3-2 치공구 관리의 기능과 조직···251
3-3 공구가 미치는 영향 ··········251
4. 공장 에너지 관리 ······················252
4-1 개 요 ··································252
4-2 열 관리 ······························253
4-3 전력 관리 ··························254
4-4 대기 오염 방지 ·················254
5. 설비 효율의 분석 ······················254
5-1 시스템의 진단과 형상 수준의 평가 ······································254
5-2 설비 효율 분석과 개선 절차···255
제5장 종합적 생산 보전
1. 종합적 생산 보전의 개요 ··········262
1-1 종합적 생산 보전의 의의 ···262
1-2 TPM의 특징과 목표 ·········262
1-3 TPM 추진 기구의 역할 ···263
2. 설비 효율 개선 방법 ·················264
2-1 설비의 효율화 6대 저해 로스 ······································264
2-2 로스 계산 방법 ·················265
2-3 로스의 6대 개선 목표 ·····266
3. 만성 로스 개선 방법 ·················267
3-1 만성 로스의 개요 ·············267
3-2 PM 분석 방법 ··················267
3-3 결함의 발견 방법 ·············268
3-4 복 원 ·································268
4. 자주 보전 활동 ··························268
4-1 자주 보전의 개요 ·············268
4-2 자주 보전의 진행 방법 ····269
5. 계획 보전 활동 ··························270
5-1 보전 부문과 제조 부문의 분담 ······································270
5-2 계획 보전의 활동 내용 ····271
5-3 기능 교육 ··························271
5-4 MP 설계와 초기 유동 관리 체제 ······································272
6. 품질 개선 활동 ··························272
6-1 문제 해결의 기본 ·············272
6-2 단계별 전개 방법 ·············274
Part 03. 기계 일반 및 기계 보전
제1장 기계 일반
1. 기계 요소 제도 ···························290
1-1 결합용 기계 요소의 제도 ···290
1-2 축계에 관한 요소의 제도 ···301
1-3 전동 장치의 제도 ·············307
1-4 스프링과 관계 요소 제도 ···315
2. 기계공작법 ··································323
2-1 기계 공작 일반 ·················323
2-2 선반 가공법 ······················326
2-3 밀링 가공법 ······················334
2-4 연삭 가공 ··························344
2-5 기타 범용 기계 가공 ·······354
2-6 정밀 입자 가공 및 특수 가공··369
2-7 수기 가공 ··························377
2-8 용 접 ·································392
2-9 열처리 ·······························419
제2장 기계 보전
1. 보전의 개요 ································428
1-1 측정과 보전용 공기구 ·······428
1-2 보전용 측정 기구 ·············432
1-3 보전용 재료 ·······················433
1-4 설비 보전의 용어 ·············439
2. 기계 요소 보전 ··························449
2-1 체결용 기계 요소 보전 ····449
2-2 축계 기계 요소 보전 ·······451
2-3 전동 장치 보전 ·················458
2-4 제어용 요소의 보전 ·········461
2-5 관계 요소 보전 ·················462
3. 기계 장치 보전 ··························489
3-1 펌 프 ··································489
3-2 통풍기 ································509
3-3 송풍기(blower) ················510
3-4 압축기(compressor) ·······518
3-5 변속기와 감속기 ···············525
3-6 전동기의 정비 ··················531
Part 04. 윤활 관리
제1장 윤활의 개요
1. 윤 활 ···········································536
2. 윤활의 목적과 방법 ···················536
제2장 윤활제의 종류와 선정
1. 윤활 작용 ····································540
2. 원유의 정제 ································541
3. 윤활제 ·········································544
4. 윤활유 성질 ································547
5. 윤활제의 첨가제 ························551
6. 그리스 ·········································552
제3장 윤활제의 급유법
1. 개 요 ···········································563
2. 윤활유 급유법 ····························564
3. 그리스 급유법 ····························568
제4장 윤활유의 열화와 관리
1. 윤활유의 열화 원인 ···················573
2. 윤활유 열화에 미치는 인자 ·····573
3. 첨가제 ·········································574
4. 윤활유의 열화 판정법 ···············575
5. 윤활유의 열화 방지와 사용 한계···576
제5장 현장 윤활 관리
1. 베어링의 윤활 관리 ···················583
2. 베어링의 그리스 윤활 ···············586
3. 압축기의 윤활 ··························587
4. 기어의 윤활 관리 ······················590
5. 유압 작동유 ································592
6. 절삭유제 ·····································593
7. 방청제 ·········································594
8. 현장의 윤활 관리 ······················594
Part 05. 공유압 및 자동화
제1장 공 유 압
1. 공유압 장치의 개요 ···················602
1-1 공유압의 정의 ····················602
1-2 공유압 장치의 구성 및 작동 유체 ······································602
1-3 공유압의 기초 ···················604
2. 공압 기기 ···································614
2-1 공압 발생 장치 ·················614
2-2 공압 밸브 ··························616
2-3 공압 액추에이터 ···············619
2-4 공유압 조합 기기 ···········624
3. 유압 기기 ···································645
3-1 유압 펌프 ··························645
3-2 유압제어 밸브 ·················649
3-3 유압 액추에이터 ···············653
3-4 부속 기기 ··························654
4. 공유압 회로 ································687
4-1 공유압 회로 설계 ·············687
4-2 공압 회로 ··························688
4-3 유압 회로 ··························690
제2장 자동화의 개요
1. 자동화의 개요 ····························719
1-1 자동화의 개념 ····················719
1-2 자동화의 발전과 생산 관리··719
1-3 자동화 도입 절차 ··············720
2. 자동화 시스템 ····························720
2-1 자동화 시스템의 개요 ······720
2-2 자동화의 목표 ···················721
2-3 공장 자동화의 전개 단계 ···721
2-4 공장 자동화의 종류 ·········721
2-5 구 성 ·································723
3. 제어와 자동 제어 ······················726
3-1 제어계 ································726
3-2 제어 시스템의 분류 ·········726
3-3 제어와 자동 제어 ·············728
4. 핸들링 ·········································734
4-1 정 의 ··································734
4-2 개 요 ·································734
4-3 종 류 ·································736
5. 전기 회로 구성 요소와 기초 전기 회로 ···············································740
5-1 전기 회로 구성 요소 ········740
5-2 기초 전기 회로 ·················745
6. 전기 기계 ···································756
6-1 직선 모터 ··························756
6-2 회전 모터 ··························757
제3장 자동화 시스템의 보전
1. 보전의 개요 ································768
1-1 보수 관리의 목적 ··············768
1-2 보수 관리의 용어 ·············768
2. 자동화 시스템 보수 유지 방법 ···770
2-1 공압 시스템 보수 유지 ····770
2-2 유압 시스템의 보수 유지 ···772
2-3 전기 시스템의 보수 유지 ···774
2-4 수치 제어 시스템의 보수 유지 ······································777
부 록
1. 과년도 출제 문제 ·····································790
2. 실기 예상 문제 ·····································975
