During my work experience in PHC Pile machine maintenance, I realized that effective maintenance is not only about repairing faults—it often demands engineering design decisions to improve machine reliability and performance. One such critical responsibility was the design and modification of bearing couplings for spinning machines used in PHC pile production.
 

Spinning machines in PHC pile plants operate under high rotational speed, heavy load, continuous duty cycles, and harsh site conditions. Over time, issues such as bearing failure, shaft misalignment, excessive vibration, and abnormal noise were frequently observed. These problems directly affected production quality and increased downtime.

To address these challenges, I had to design and modify bearing coupling arrangements rather than relying solely on standard replacements. The objective was to:

• Improve load distribution

• Accommodate misalignment

• Reduce vibration and shock

• Extend bearing and shaft life

The design process involved analyzing shaft diameters, torque transmission, rotational speed, bearing type selection, coupling geometry, and mounting constraints within the existing machine layout. Special attention was given to ease of installation and maintenance, as the machines required quick servicing without long shutdowns.

By redesigning the bearing couplings, the spinning machines achieved:
✔ Smoother rotation
✔ Reduced bearing overheating
✔ Lower vibration levels
✔ Improved alignment stability
✔ Increased operational life of components

This experience strengthened my understanding that maintenance engineering and design engineering are deeply interconnected. Practical field problems often become the foundation for meaningful design improvements. Designing bearing couplings in a real industrial environment not only enhanced machine performance but also optimized maintenance efficiency and production reliability.

 After Full Assembly, my Coupling Modifications look like these: