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     Machinery Fault & Rotor Dynamics Simulator (MFS-RDS)

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An innovative tool to study oil lubricated journal bearings
 Spectra Quest’s Machinery Fault & Rotor Dynamics Simulator (MFS-RDS) is an innovative tool to study the dynamic behavior for rotor supported by oil lubricated journal bearings, as well as other common machinery faults, such as balancing and resonance study. An oil pump is provided with the simulator to drive the lubrication fluid. In addition, it provides different bearing clearance selection and controllable lubrication oil pressure for rotor dynamics whirl and whip phenomena.

Numerous Experiment Possibilities
  • The MFS-RDS fitted with a resonance kit is the perfect tool to gain practical experience in rotating machinery resonance and learn resonance mitigation methods.

  • With different number of rotor disks installed at various locations on the main shaft, resonances up to the third mode can be excited. The bode plot of the main shaft vibration during a coast down test is illustrated in the right figure. Three resonances can be identified clearly.

  • Oil whirl and whip are important instability phenomena associated with rotors supported fluid film bearings. With proper selection of the bearing load (the number of rotor disk), bearing clearance (the selection of bearing cartridge) and oil pressure (adjusting the oil supply valve), the oil whirl and whip can be simulated using the MFS-RDS. The waterfall plot on the right illustrates the oil whirl and whip observed on this simulator. The first critical speed of the main shaft (1X), oil whirl and oil whip are all identified in this waterfall plot. In order to observe oil whirl and whip, the simulator must be running at more than twice of the first critical speed of the main rotor shaft.

  • One key concept in rotor dynamics is the heavy and high spots. With the MFS-RDS and the optional kits supplied by Spectra Quest, the phase relationship between these two spots can be demonstrated.
    		•
    Features
  • Rotor shaft specially designed for fluid film bearing rotor dynamics simulation
  • Different bearing clearance selection and controllable lubrication oil pressure for rotor dynamics study
  • Convenient installation of proximity probes
  • Rigid, slippage-free operation
  • Split bracket bearing housing for easy rotor assembly interchanges
  • Specialized bearings and rotors with split collar ends for easy replacement and installation
  • Rotor shaft slides without removing mounted components for easy changes
  • Couplings, rotors, bearings, and shaft can be changed without removing bearing housings
  • Convenient alignment with jackscrew
    • Electrical
    Motor 3 Phase, 1/2 HP motor, pre-wired self-aligning mounting system for easy installation/removal
    Drive 1/2 HP variable frequency AC drive with multi-featured front panel programmable controller
    RPM range 0 to 6000 rpm (short duration) variable speed
    Tachometer Built-in tachometer with LCD display and one pulse per revolution analog TTL output for DAQ purposes
    Voltage 115/230 VAC, Single phase, 60/50 Hz
    Mechanical
    Shaft Diameter 1/2” diameter; Turned, Ground, & Polished (TGP) steel
    Rotor Base 30” long, completely movable using jack bolts for easy horizontal misalignment and standard shims for vertical misalignment. Pinned for easy realignment.
    Bearing Two full fluid film bearings with multiple oil inlet prots, provisions to mount proximity probes at any angle. Bearing mounts can be mounted in nine different position for variable rotor span
    Oil Distribution System Pump, pressure gage, stainless steel oil tank, back flow safety switch, pressure interlock gauge.
    Rotors Two 6” aluminum with 36 threaded holes at 10 degree intervals for introducing unbalance
    Safety Cover Lockable clear, impact resistant hinged plastic cover with motor interlock switch to shut down motor when cover is raised
    Foundation 1/2” die cast aluminum base, base stiffener and eight rubber isolators
    Physical
    Weight Approximately 125 lb
    Dimensions L=50” (125cm), W=14” (36cm) , H=25” (65cm)

    Basic Machinery Fault Simulator-Rotor Dynamics Simulator Includes:


    - 1/2 HP variable frequency AC drive with multi-featured front panel programmable controller
    - 3 Phase, 1/2 HP motor, pre-wired self-aligning mounting system for easy installation/removal
    - Built-in tachometer with LCD display and one pulse per revolution analog TTL output for DAQ purposes
    - Pressurized fluid film bearings with features to change bearing clearance, length, and type.
    - Includes two full sleeve bearings with multiple oil inlet prots, tapped holes for mounting two proximity probes at 90 degrees, ability to rotate probe at any angle.
    - Oil distribution and pressure adjustment system including of pump, pressure gage, stainless steel oil tank, back flow safety switch, pressure interlock gauge.
    - Bearing inserts with 0.002" clearance
    - Extended 30" rotor base to allow for rotor dynamics experiments up to three critical speeds and whirl/whip phenomena investigation, and five bearing mounting positions for shaft span reconfiguration
    - Vibration isolators mounts and base stiffener
    - Three steel disks with one row of holes
    - Alignment system with calibrated reference dials and jack bolts
    - One 1/2" TGP straight steel shaft
    - Impact resistant clear safety cover with safety interlock
    - Balance weight kit
    - Allen wrench set
    - 24V Power supply
    - Cover support
    - Comprehensive operations manual

    The MFS-RDS provides you with a basic setup for performing rotor dynamics experiments and learning vibration signatures of different machine malfunctions. However, a detailed investigation of a particular phenomenon will require additional attachments and fixtures. SpectraQuest has designed option kits for performing different in-depth studies on the MFS-RDS.

    Training Curriculum Manual (SQI-TRCM)
    • The training curriculum manual begins with textbook and basic classroom training in the fundamentals of classic machinery vibration, transducers, monitoring, signal processing, analysis, etc; from beginner to upper intermediate levels. It is both hands-on and mathematically oriented, being appropriate for both technicians and engineers.
    • A wide array of laboratory exercises to be conducted on the MFS to provide a truly experiential learning environment.
    • Use as a basis for accelerated course preparation and the development of vibration training program.
    Oil whirl/whip in-depth study kit for 1/2" shaft (MR-OWSK-1/2)
    • Study effects of bearing clearance, L/D ratio, and rotor loading effects on oil induced instability, and to understand whirl/whip phenomena and how to avoid it.
    • The kit consists total of four sleeve bearing pairs to give bearing clearances of 6 mils (0.001') for two different lengths(2 pairs), 2 mils for one length (1 pair) and elliptical bearings (1 pair) to avoid whirl/whip instability, and one shaft centering device.
    Oil whirl/whip in-depth study kit for 3/4" shaft (MR-OWSK-3/4)
    • Study the effect of stiffer rotor on oil induced instability and understand whirl/whip phenomena and how to avoid it. The idea is to understand and control the whirl/whip phenomena. 3/4” shaft provides not only stiffer rotor but also lighter balance, eccentric and cocked disks for more investigation to enhance the understanding.
    • The kit consists total of five sleeve bearing pairs to give bearing clearances of 2 and 6 mils (0.001') for two different lengths(4 pairs) and elliptical bearings (1 pair) to avoid whirl/whip instability, and one shaft centering device insert.
    • Requires MR-BSK-3/4 and MR-OWSK-1/2
    3/4" Shaft Conversion Kit (MR-SCK-3/4)
    • Study bearing fault frequencies away from multiples rotational speed. The standard 1/2” shaft exhibit fault frequencies close to multiples rotational speed, requiring ultra high resolution spectra to clearly identify bearing fault frequencies.
    • Identify bearing fault frequencies in the presence of defects at multiples of shaft speed without using high-resolution spectra.
    • The kit consists of two 3/4" bearings with mounting housings, two 6” aluminum rotors with 36 threaded holes, one 3/4” diameter shaft, and one coupling.
    3/4” Bearing Loader (M-BL-3/4 )
    • Investigate bearing radial loading effects.
    • Enhance the spectral amplitude of system.
    • The kit consists of one 3/4” bore loader weighting 11lb (5kg) and two clamp collars.
    • Requires MR-SCK-3/4
    3/4” Bearing Fault Kit (M-BFK-3/4 )
    • Learn waveform and spectra of classic bearing defects.
    • Learn about signal processing issues such as averaging techniques, leakage, and spectral resolution on determining bearing faults.
    • Perform experiments with increasing severity of defects.
    • Determine why an ultra-high resolution spectrum is needed to diagnose a bearing fault when fault frequencies are located close to multiples rotational speed.
    • Learn how a large signal can mask adjoining low amplitude signal due to spectra leakage.
    • The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
    • Requires MR-SCK-3/4
    Eccentric Rotor (M-ER-3/4)
    • Learn the effects of rotor eccentricity on vibration spectra.
    • Determine relationships between eccentricity and unbalance.
    • Develop techniques to locate and correct the effects of eccentricity.
    • Learn the effect of varying the mass moment of inertia on vibration amplitude.
    • The kit consists of one aluminum rotor with an asymmetrically located center and one clamp collar.
    • Requires MR-SCK-3/4.
    Cocked Rotor (M-CR-3/4)
    • Learn the effects of a sheave that has not been fitted to the shaft properly.
    • Learn vibration signature of a cocked rotor.
    • Develop methods to correct cocked rotor problems.
    • Learn the effect of varying the mass moment of inertia on vibration amplitude.
    • The kit consists of a cocked aluminum rotor (0.5 degree off-axis) and one clamp collar.
    • Requires MR-SCK-3/4.
    Coupling Type Set (M-CK-3/4)
    • Learn the effects of coupling stiffness on rotor dynamics and vibration signature.
    • Clarify the complexities of machinery shaft misalignment problems (spectral pattern for shaft misalignment is a strong function of coupling stiffness).
    • The kit consists of one gear, one LoveJoy, one rubber, and one rigid steel coupling.
    • Requires MR-SCK-3/4.
    Centrally Bent Rotor Shaft for Balance Studies (MR-BRS-3/4)
    • Demonstrate the signature of a bent shaft.
    • Observe the difficulty associated with attempting to balance a rotor mounted on a bent shaft.
    • Learn to cope with the alignment issues due to a bent shaft.
    • The kit consists of one 3/4” shaft centrally bent ~0.020”
    • Requires MR-SCK-3/4.
    Coupling-End Bent Rotor Shaft for Balance Studies (MR-CBRS-5/8)
    • Investigate complicated vibration signature due to gyroscopic effects.
    • Observe the difficulty associated with attempting to balance an overhung rotor on a bent shaft.
    • Learn to cope with the alignment issues due to a bent shaft.
    • The kit consists of one 3/4” shaft coupling-end bent ~0.010”
    • Requires MR-SCK-3/4.
    Sleeve Bearing Resonance Study Kit (M-SBK-1/2)
    • Study resonance and critical speed phenomena in sleeve bearings.
    • The kit consists of two customized grease-lubricated, babbitt lined sleeve bearings, two bearing pedestals, and various thickness plastic shims
    Rolling Bearing Resonance Study Kit (M-RBK-1/2)
    • Study rolling element bearings on the MFS-RDS.
    • The kit consists of two 1/2" squeeze lock bearings.
    Higher Resonance Study Kit (M-RDK-1/2)
    • Study rolling element bearings on the MFS-RDS.
    • The kit consists of three steel disks.
    3/4" Shaft Sleeve Bearing Kit (M-SBK-3/4)
    • Investigate waveform and spectral recognition of worn or loose fitting bearings.
    • Modify the clearance of the split bearings with plastic shims.
    • Perform shaft orbital analysis.
    • The kit consists of two customized grease-lubricated, babbitt lined sleeve bearings, two bearing pedestals, and various thickness plastic shims.
    • Requires MR-SCK-3/4.
    Cocked Bearing Housing (M-CBM-3/4)
    • Recognize the signature of a cocked bearing due to improper seating or due to inconsistent installation.
    • The kit consists of one cocked bearing housing.
    • Requires MR-SCK-3/4.
    1" Shaft Bearing Study Kit (MR-BSK-1)
    • Study bearing fault frequencies away from multiples rotational speed. The standard 5/8” shaft exhibit fault frequencies close to multiples rotational speed, requiring ultra high resolution spectra to clearly identify bearing fault frequencies.
    • Identify bearing fault frequencies in the presence of defects at multiples of shaft speed without using high-resolution spectra.
    • Understand the signal processing issues such as averaging, spectral resolution, and leakage phenomena.
    • The kit consists of two split bearing housings, two 1” inside diameter bearings, one 1” diameter shaft, and one coupling.
    1” Bearing Loader ( M-BL-1)
    • Investigate bearing radial loading effects.
    • Enhance the spectral amplitude of system.
    • The kit consists of one 1” bore loader weighting 11lb (5kg) and two clamp collars.
    • Requires MR-BSK-1
    1” Bearing Fault Kit ( M-BFK-1)
    • Learn waveform and spectra of classic bearing defects.
    • Learn about signal processing issues such as averaging techniques, leakage, and spectral resolution on determining bearing faults.
    • Perform experiments with increasing severity of defects.
    • Determine why an ultra-high resolution spectrum is needed to diagnose a bearing fault when fault frequencies are located close to multiples rotational speed.
    • Learn how a large signal can mask adjoining low amplitude signal due to spectra leakage.
    • The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
    • Requires MR-BSK-1.
    Crack Shaft Study Kit (MR-CSRK-3/4)
    • Study the effects of crack on the natural frequencies and vibration behavior.
    • Develop diagnostic technique to detect crack at early stage.
    • Study crack propagation and breathing.
    • Apply advanced signal processing techniques, such as wavelet, joint time-frequency analysis, time series analysis, to study the vibration caused by crack.
    • The kit consists of one shaft with a 4 ½’’ 4-bolt flange connection to simulate crack, one shaft with slit crack and filler, and one shaft with a deep V-notch crack.
    • Requires MR-SCK-3/4.
    Fan Vibration Kit (M-FVK-3/4)
    • Learn the sound and vibration signatures of fans.
    • Study the effects of volumetric flow rate on pressure rise and fan vibration.
    • Develop the noise and vibration control methods on fans.
    • The kit consists of one six-blade paddle fan, one ten-blade paddle fan, one 12-blade axial fan, and one axial fan obstruction
    • Requires MR-SCK-3/4.
    Mechanical Rub Kit (M-MRK)
    • Evaluate typical rub phenomena associated with a variety of materials under different angle, loading, and lubricant conditions.
    • Experiment rubs on shaft or rotor.
    • The kit consists of an adjustable spring-loader rub material holder and four different rub materials.
    Damped Bearing Housing Kit (M-DBHK-1/2)
    • Study bearing housing with a higher damping factor than the standard housing. Typical rolling element bearing systems are an all-metal structure with virtually no damping.
    • Add damping to a standard rolling element bearing housing.
    • Demonstrate the reduction in rotor resonance amplitude due to the installation of damping.
    • The kit consists of two bearing housings and two ½” bearings fitted with isolators.
    PC Motor Control Kit (M-PCK)
    • Operate MFS from remote location.
    • Pre-program speed acceleration, deceleration, and length of run to meet exact requirements.
    • The kit consists of PC software, one interface module to motor drive and cables.
    Shaft Alignment Kit (M-ATK)
    • Align shafts precisely with convenient and simple Windows alignment software.
    • Accommodates ½” to 1 ¼” diameter shafts.
    • The kit consists of two precision dial indicators, two mounting brackets/bars, one mirror, one set of feeler gauges, and instructions packaged in a rugged plastic case.

    High Value Combination Packages
    The MFS-RDS provides a basic setup for performing rotor whirl/whip experiments and learning vibration signatures of different machine malfunctions. However, a detailed investigation of particular and more advance vibration phenomena will require additional attachments and fixtures which are available through optional kits. Depending on the package selected, you get a 6% to 8% discount over separately purchased items.

    Package No. 1: Basic MFS-RDS+ Kits for in-depth studies of rotor whirl/whip phenomena with 1/2" and 3/4" diameter shafts
    Package No. 2: Basic MFS-RDS+ Kits for in-depth studies of oil whirl/whip, alignment, balancing and resonance up to third critical frequency issues
    Package No. 3: Basic MFS-RDS+ Kits for in-depth studies of oil whirl/whip, alignment, balancing, resonance, and bearing defect issues
    Package No. 4: Basic MFS-RDS+ Kits for in-depth studies of oil whirl/whip, alignment, balancing, resonance, bearing defect, shaft crack, fan vibrations, mechanical rub and damping issues
    Package No. 5F: Basic MFS-RDS+ Kits for in-depth studies of oil whirl/whip, alignment, balancing, resonance, bearing defect, shaft crack, fan vibrations, mechanical rub, damping issues; plus PC operation, shaft alignment kit and force measurement of both bearing

     Option kit
    		  
    PKG 1
    PKG 2
    PKG 3
    PKG 4
    PKG 5F
     Training curriculum manual
    SQI-TRCM
    x
    x
    x
    x
    x
     Oil whirl/whip in-depth study kit for 1/2" shaft
    MR-OWSK-1/2
    x
    x
    x
    x
    x
     3/4" shaft conversion kit
    MR-SCK-3/4
    x
    x
    x
    x
    x
     Oil whirl/whip in-depth study kit for 3/4" shaft (Requires MR-SCK-3/4 and MR-OWSK-1/2)
    MR-OWSK-3/4
    x
    x
    x
    x
    x
     Eccentric rotor (Requires MR-SCK-3/4)
    M-ER-3/4
    		  
    x
    x
    x
    x
     Cocked rotor (Requires MR-SCK-3/4)
    M-CR-3/4
    		  
    x
    x
    x
    x
     Coupling type set (Requires MR-SCK-3/4)
    M-CK-3/4
    		  
    x
    x
    x
    x
     Centrally bent rotor shaft for balance studies (Requires MR-SCK-3/4)
    M-BRS-3/4
    		  
    x
    x
    x
    x
     Coupling-end bent rotor shaft for alignment studies (Requires MR-SCK -3/4)
    M-CBRS-3/4
    		  
    x
    x
    x
    x
     Rolling bearing resonance study kit
    MR-RSK-1/2
    		  
    x
    x
    x
    x
     Higher resonance study kit
    M-RDK-1/2
    		  
    x
    x
    x
    x
     Sleeve bearing resonance study kit
    M-SBK-1/2
    		    
    x
    x
    x
     Cocked bearing housing (Requires MR-SCK -3/4)
    M-CBM-3/4
    		    
    x
    x
    x
     3/4" shaft sleeve bearing (grease lubricated) kit (Requires MR-SCK -3/4)
    M-SBK-3/4
    		 
    x
    x
    x
     3/4" shaft bearing fault kit (Requires MR-SCK -3/4)
    M-BFK-3/4
    		 
    x
    x
    x
     3/4" shaft bearing loader (Requires MR-SCK -3/4)
    M-BL-3/4
    		 
    x
    x
    x
     1" shaft bearing study kit
    MR-BSK-1
    		 
    x
    x
    x
     1" shaft bearing fault kit (Requires MR-BSK-1)
    M-BFK-1
    		 
    x
    x
    x
     1" shaft bearing loader (Requires MR-BSK-1)
    M-BL-1
    		    
    x
    x
    x
     Mechanical rub kit
    M-MRK
    x
    x
     Damped bearing housing kit (Requires MR-SCK -3/4)
    M-DBHK-1/2
    x
    x
     Crack shaft study kit (Requires MR-SCK -3/4)
    MR-CSRK-3/4
    x
    x
     Fan vibration kit (Requires MR-SCK -3/4)
    M-FVK-3/4
    x
    x
     PC motor control kit
    M-PCK
    x
     Shaft alignment kit
    M-ATK
    x
     Vertical and horizontal bearing force transducer for 1/2" to 1" shafts
    M-FTVH
    x (2)


     

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