Vibration Training, Vibration Diagnosis and Analysis

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     Machinery Fault Simulator - Lite (MFS-LT)

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A Valuable Tool for Learning Machinery Diagnosis
 To gain an in-depth understanding of different vibration signatures, controlled experiments on a device that emulates real world machinery are needed. While analysis of a single machinery fault may be beneficial, there are many occasions when the analysis of the interaction between dynamic stiffness, resonance, and speed is essential in order to gain an understanding of real world vibration spectra. With the MFS, the expertise required to diagnose industrial machinery problems in well controlled experiments can be developed and enhanced. With a plant running at full production, it is virtually impractical to gain an understanding of the kinetics and dynamics of machinery without adversely affecting production and profits: The MFS-LT enables offline training and experimentation which in turn will minimize production downtime.

Features
  • Simple methods for introducing controlled and calibrated faults.
  • Study the vibration spectra of common faults, learn fault signatures and validate rules provided in training courses.
  • Bench top machine for hands-on training and skill sharpening.
  • Learn machine condition monitoring and predictive maintenance.
  • Manual with exercises for individually paced study.
  • Learn resonance and variable speed diagnostics.
  • Learn to determine vibration transmission path and perform root-cause analysis.
  • Validate balancing procedures above and below the first critical resonance.
    • 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 5/8” diameter; Turned, Ground, & Polished (TGP) steel
    Bearing Two sealed rolling element in aluminum horizontally split bracket housing for easy changes, tapped for transducer mount. Bearing mounts can be mounted in five different position for variable rotor span
    Rotor Base 15” long, completely movable using jack bolts for easy horizontal misalignment and standard shims for vertical misalignment. Pinned for easy realignment.
    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” (12.7 mm) die cast aluminum base, base stiffener and six rubber isolators
    Physical
    Weight Approximately 100lb (45kg)
    Dimensions L=32” (80cm), W=14” (36cm) , H=22” (55cm)

    The MFS-LT provides a basic setup for performing experiments and learning vibration signatures of different machine malfunctions. However, a detailed investigation of particular and more advance vibration phenomena or machinery fault will require additional attachments and fixtures which are available through optional kits.

    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.
    Eccentric Rotor (M-ER-5/8)
    • 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.
    Cocked Rotor (M-CR-5/8)
    • 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.
    Coupling Type Set (M-CK-5/8)
    • 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.
    Centrally Bent Rotor Shaft for Balance Studies (ML-BRS-5/8)
    • 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 5/8” shaft centrally bent ~0.020”
    Coupling-End Bent Rotor Shaft for Balance Studies (ML-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 5/8” shaft coupling-end bent ~0.010”
    Rolling Bearing Resonance/Critical Study Kit (ML-RSK-1/2)
    • Study resonance and critical speed phenomena, at speeds below 2000 RPM to simulate real world operating conditions while improving safety. The standard ¾” shaft has a high resonance frequency, 7000 RPM or more depending on rotor positions.
    • Study damaging effects of resonance and develop control methods.
    • Relocate rotors and supports to study the effects of mass and stiffness on resonance frequencies and mode shapes.
    • Study beating due to closely spaced modes.
    • Study non-linear dynamics for chaos modeling.
    • The kit consists of one ½” shaft, three rotors, two rolling element bearings, and one coupling.
    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
    • Requires ML-RSK-1/2
    5/8” Bearing Loader (M-BL-5/8 )
    • Investigate bearing radial loading effects.
    • Enhance the spectral amplitude of system.
    • The kit consists of one 5/8” bore loader weighting 11lb (5kg) and two clamp collars.
    5/8” Bearing Fault Kit (M-BFK-5/8 )
    • 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.
    1" Shaft Bearing Study Kit (M-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, two 6” aluminum rotors with 36 threaded holes, 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.
    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.
    Cocked Bearing Housing (M-CBM-5/8)
    • Recognize the signature of a cocked bearing due to improper seating or due to inconsistent installation.
    • The kit consists of one cocked bearing housing.
    5/8" Sleeve Bearing Resonance Study Kit (M-SBK-5/8)
    • 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.
    Crack Shaft Study Kit (ML-CSRK-5/8)
    • 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.
    Fan Vibration Kit (M-FVK-5/8)
    • 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
    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.
    • Requires M-RSK-1/2
    Vertical and Horizontal Bearing Force Transducer for 1/2" to 1" Shafts (M-FTVH)
    • Measure forces exerted on bearings due to coupling misalignment, rotor unbalance, belt misalignment, and belt tension.
    • Establish quantitative tensions for drive belt studies.
    • Learn to relate the vibration signature to forces associated with common malfunctions such as resonance and bearing faults. Learn phase relationship between force and vibration spectrum.
    • Learn nature of rotor dynamic forces due to common defects.
    • Witness 180 degree phase shift between heavy and high spots when rotor goes through a critical speed. Demonstrate how mass unbalance force quadruples when the speed is doubled, but vibration amplitude does not follow the same trend.
    • Verify and refine your rotor dynamic models and enhance modeling skills.
    • The kit consists of one transducer simultaneously measuring vertical and horizontal force and one matching signal conditioner.
    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-Lite provides a basic setup for performing experiments and learning vibration signatures of different machine malfunctions. However, a detailed investigation of particular and more advance vibration phenomena or machinery fault 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: Kits for in-depth studies of alignment, balancing and resonance issues
    Package No. 2: Kits for in-depth studies of alignment, balancing, resonance, and bearing defects issues
    Package No. 3: Kits for in-depth studies of alignment, balancing, resonance, bearing defect, crack shaft, fan vibrations, mechanical rub & damping issues
    Package No. 4: Kits for in-depth studies of alignment, balancing, resonance, bearing defect, crack shaft, fan vibrations, mechanical rub, damping issues; plus PC Operation, shaft alignment, and both bearing horizontal and vertical forced measurements

     Option kit
    		  
    PKG 1
    PKG 2
    PKG 3
    PKG 4
     Training curriculum manual
    SQI-TRCM
    x
    x
    x
    x
     Eccentric rotor
    M-ER-5/8
    x
    x
    x
    x
     Cocked rotor
    M-CR-5/8
    x
    x
    x
    x
     Coupling type set
    M-BRS-5/8
    x
    x
    x
    x
     Centrally bent rotor shaft for balance studies
    M-CK-5/8
    x
    x
    x
    x
     Coupling-end bent rotor shaft for alignment studies
    M-CBRS-5/8
    x
    x
    x
    x
     Rolling bearing resonance/critical study kit
    M-RSK-1/2
    x
    x
    x
    x
     Sleeve bearing resonance study kit (Requires ML-RSK-1/2)
    M-SBK-1/2
    x
    x
    x
    x
     5/8" shaft bearing fault kit
    M-BFK-5/8
    x
    x
    x
     5/8" shaft bearing loader
    M-BL-5/8
    x
    x
    x
     1" shaft bearing study kit
    M-BSK-1
    x
    x
    x
     1" shaft bearing fault kit (Requires ML-BSK-1)
    M-BFK-1
    x
    x
    x
     1" shaft bearing loader (Requires ML-BSK-1)
    M-BL-1
    		  
    x
    x
    x
     Cocked bearing housing
    M-CBM-5/8
    x
    x
    x
     5/8" shaft sleeve bearing (grease lubricated) kit
    M-SBK-5/8
    x
    x
    x
     Mechanical rub kit
    M-MRK
    x
    x
     Damped bearing housing kit (Requires ML-RSK-1/2)
    M-DBHK-1/2
    x
    x
     Crack shaft study kit
    M-CSRK-5/8
    x
    x
     Fan vibration kit
    M-FVK-5/8
    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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