SpectraQuest, Inc. Vibration Training and Diagnosis

APPLICATIONS
Using the Simulator offers you a wide range of benefits in developing your understanding of predictive maintenance and learning to recognize the signatures of various machine faults. Different types of studies can be done with application specific kits. Each kit is designed to fit on the basic simulator. Application notes and exercises provide a cost effective self-paced training program. The following list indicates some of the many ways the simulator can increase your knowledge of machinery diagnosis and vibration analysis.

Balance training

Shaft alignment training

Alignment system assessment

Coupling studies

Bearing Faults and loading effects

"Cocked" rotor

Eccentric rotor

Resonance studies

Sleeve bearing studies

Belt drive performance

Mechanical looseness

Bent shaft

Mechanical rub

Gearbox fault studies

Reciprocating mechanism studies

Foundation studies

Signal processing techniques

Variable speed/load effects

Motor current analysis

Rotor dynamics

Operating Deflect ion Shape and Modal Analysis

Optimize sensor mounting

Sensor types (accelerometer. proximity probes, etc.)

Vibration training

Analyst certification

Customized test bed for rotor dynamics studies and demonstrations

Shaft Alignment Effects
Misalignment between two mating shafts is the most common cause of machinery deterioration. A properly aligned machine can save a factory 20% to 30% in downtime, replacement parts, inventory, and energy consumption. The simulator provides: Calibrated dials to introduce known amounts of parallel and angular misalignment Easy ways to study misalignment effects and methods of correction Learn effects of speed, coupling and rotor stiffness on misalignment signatures

Balancing
Unbalanced rotors are a very common cause of machinery malfunction. An improperly balanced machine has many hidden costs in downtime and parts due to accelerated wear and performance issues. The simulator provides for controlled study of unbalance:

Center and over hung

Single and multi-plane

Eccentric and cocked rotor effects

Critical speed effects

Rolling Element Bearing Fault Signature Analysis
Most common machines are fitted with rolling element bearings. Many malfunctions damage bearings first. It is essential to learn bearing defect signatures in presence of other complicating effects so that malfunctions are detected prior to catastrophic failure.

Deliberately faulted bearings fit the standard rotor shaft

Waveform and spectral recognition of classic bearing defects

Resonance and Critical Speed Studies
A proper understanding of resonance phenomenon is fundamental for minimizing downtime and maintaining the sound health of production machinery. The simulator along with the resonance kit is an ideal tool for an in-depth study of resonance and lateral critical speed phenomena.

Critical speeds below 2000 RPM simulate real world operating conditions and improve safety

Study effects of mass and stiffness on resonance frequencies and mode shapes

Study damaging effects of resonance and develop control methods

Study beating due to closely spaced vibration modes

Study rotor stability and non-linear dynamics for chaos modeling

Sleeve Bearing Effects
Many high speed machines are designed with sleeve bearings. Sleeve bearings are inherently quieter than the rolling element bearings, but they exhibit different rotor dynamics and problems. The modular design of the simulator makes it easy to install grease lubricated sleeve bearings.

Waveform and spectral recognition of worn or loose fitting bearings

Fits the standard rotor shaft with grease lubricated, babbitt lined, sleeve bearings

Bearings split so that plastic shims may be used to open the clearance to simulate real world conditions

Shaft orbital analysis

Examine heat generation as a function of alignment and bearing clearance

Belt Drive Studies
Belt tension can be controlled with an idler lever or by sliding the gearbox. The system can be operated with one or two belts and the two may be mismatched. Parallel and angular belt misalignment can be easily introduced to study the effects on vibration signatures.

Gearbox Study
Gearbox vibration signatures are very complicated. The simulator provides easy methods for introducing typical gearbox defects for study. Straight and spiral gearing problems can be studied with controlled backlash and loading. Missing tooth, chipped tooth and worn gears are available.

Reciprocating Mechanism Effects
The reciprocating mechanism introduces speed variation into the rotor dynamics generating complex vibration signatures. The loading patterns are controlled so that torsional vibration and nonlinear dynamics can be studied effectively.

Motor Current Signature Analysis
Mechanical malfunctions can often be seen in electrical current signatures. The simulator has easy access to all the electrical leads to facilitate motor current signature analysis.

Foundation Effects
Foundations have a profound effect on machinery vibrations and performance. The simulator provides convenient ways to study the relationships among foundation mass and stiffness and the vibration spectra.