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Machinery Fault Simulator Option Kits
The Machinery Fault Simulator Series provide 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 thought carefully
about various applications of the MFS systems. This brochure describes Option
Kits to be used with the simulator series for performing different in-depth studies.
Each Option Kit provides you with a wealth of information to increase your knowledge
of rotor dynamics and machinery fault diagnostics. It is important to note that
all the simulators very versatile and it can be configured in many more ways
than those associated with the standard Option Kits.
Training Curriculum Manual
- Learn machinery conditioning monitoring and vibration basics through
upper intermediate level.
- Use prescribed laboratory exercises specifically prepared for the MFS
to enhance learning through hands-on experimentation
- Use as a basis for accelerated course preparation and the development
of vibration training programs.
The SpectraQuest machinery vibration-training manual consists of two volumes.
Volume 1 is a textbook that provides basic classroom training in the fundamentals
of machinery vibration, transducers, monitoring, signal processing, analysis,
etc., from beginner to upper intermediate levels. It is both hands-on and
mathematically oriented, making it appropriate for technicians and engineers.
Volume 2 contains laboratory exercises to be conducted on the MFS to provide
a truly experiential learning environment.
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Eccentric Rotor
- 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 bore and one clamp collar.
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Cocked Rotor
- 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 and one clamp collar.
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Set of Four Coupling Types
- The spectral pattern for shaft misalignment is a strong function of coupling stiffness.
- Learn the effects of coupling stiffness on rotor dynamics and vibration signature of various defects.
- Clarify the complexities of machinery shaft misalignment problems.
Each kit consists of one gear, one LoveJoy, one rubber, and one rigid steel coupling.
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Centrally Bent Shaft
- Demonstrate the signature of a bent shaft.
- Observe the difficulty associated
with attempting to balance a rotor with a bent shaft.
- Learn to cope with
the alignment issues due to a bent shaft.
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Coupling End Bent Shaft
- The coupling end bent shaft reveals a complicated vibration signature due to gyroscopic effects.
- Observe the difficulty associated with attempting to balance an overhung rotor with a bent shaft.
- Learn to cope with the alignment issues due to a bent shaft.
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Resonance/Critical
Study Kit*
- Designed for in-depth study of resonance and critical speed phenomena.
- Critical speeds below 2000 RPM simulate real world operating conditions and improve safety.
- Relocate rotors and supports to study the 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 modes.
- Study non-linear dynamics for chaos modeling.
The standard shaft system is
designed for controlled experiments and exhibits a high resonance
frequency (7,000 RPM or more depending on rotor positions), which is
too high for safe resonance study. The resonance kit contains: one
special shaft, three rotors, two rolling element bearings, and one
coupling.
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5/8" Shaft Bearing Fault Kit
- Deliberately faulted bearings to 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 while increasing the severity of defects.
- Determine why ultra-high resolution spectrum is
needed to diagnose a bearing fault when fault frequencies are located
close to multiples of RPM.
- Learn how a large signal can mask adjoining low amplitude signals due to spectral leakage.
The kit consists of one inner race defect, one outer
race defect, one with ball defect, and one combination of defects. The
fault frequencies are very close to the multiples of shaft RPM.
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1" Shaft
Bearing Study Kit
This
system is designed to exhibit bearing fault frequencies further away
from multiples of the shaft rotational speed (RPM). The standard MFS
bearings exhibit fault frequencies close to multiples of shaft RPM
requiring ultra high-resolution spectra to clearly identify bearing
fault frequencies. This kit is essential for a more complete study of
rolling element-bearing faults because real world applications include
both types of bearings, one with fault frequencies close to multiples
of RPM and one with fault frequencies away from the multiples of
rotational speed.
- Identify bearing fault frequencies in the presence of defects at multiples of shaft RPM without using high resolution spectra.
- Understand signal processing issues such as averaging, spectral resolution and leakage phenomena.
- Perform experiments while increasing severity of defects.
The kit includes two precision-machined split bearing housings,
two 1" diameter ID bearings, one 1" diameter shaft, and one coupling.
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1" Shaft
Bearing Fault Kit
The
kit provides deliberately faulted bearings to learn waveform and
spectra of classic bearing defects when bearing fault frequencies are
not close to multiples of the shaft running speed (RPM). The kit
includes four faulted bearings: one outer race, one ball, one inner
race, and one combination defect.
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1" Shaft Bearing Loader
- Demonstrate how rotor loading affects bearing vibration amplitude.
- Location can be adjusted axially.
- A radial load on bearings shows the effects of loading and enhances the spectral amplitude.
The kit consists of one 1" bore loader and two clamp collars.
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Cocked Bearing Housing Due
to improper seating, bearings are sometimes not installed uniformly in
the cavity, creating a cocked situation. Recognizing the signature of a
cocked bearing is beneficial in that corrective action can be taken long
before failure occurs. The kit consists of one bearing housing designed
to exhibit this condition. |
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5/8" Sleeve
Bearing Kit
- Waveform and spectral recognition of worn or loose fitting bearings.
- Fits the standard rotor shaft with grease lubricated, babbitt lined, sleeve bearings.
- Bearings are split so that plastic shims may be used to open the clearance to simulate increased looseness.
- Shaft orbital analysis.
The kit consists of two customized pillow block sleeve bearings, two bearing pedestals, and mounting hardware.
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Multiple
Belt Drive, Gearbox, and Braking System**
- Learn the misalignment effects of improper belt tightening and belt fault frequencies.
- Learn the effects of load, backlash, and tooth
faults on the amplitudes and distribution of the gear mesh and side
band frequencies.
- Develop advanced signal processing techniques
such as time synchronous averaging, wavelet analysis, short time
Fourier transform, etc., for gearbox fault diagnosis.
- Develop expertise to diagnose a gearbox problem under variable loading (or speed) conditions.
- Learn the effects of the frequency and amplitude modulation on vibration spectra.
The double V-belt drive system features industrial quality sheaves
and belts. The oil lubricated gearbox is three-way with straight cut bevel gears,
producing a distinct gearmesh frequency and sidebands. The pinion assembly can
be easily removed for examination, backlash adjustment, and fault introduction.
The bearings are ball roller style. The braking system can be used to apply different
levels of torque to load the gearbox. The optional reciprocating mechanism can
be attached to excite backlash and simulate gearing defects. The kit consists
of one gearbox, one adjustment platform, one brake, two double groove sheaves,
and two v-belts. |
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| Defective
Gear Assembly**
The defective gear assemblies consist of two complete pinion
subassemblies ready for installation. Backlash between mating gears can
be varied easily. The kit consists of one simulated missing tooth and
one simulated chipped tooth pinion. |
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Worn
Straight Tooth Gearbox**
The
gearbox study kit comes with a new gearbox. It will take a
long time to wear it using the MFS. The "worn" gearbox is created by
accelerating wear within the gearbox to simulate the bearing and gear
characteristics
of a gearbox that has been in service for a considerable period
of time. The unit will display additional backlash, bearing looseness,
and tooth
surface polishing and imprint. Compare the spectrum of a worn
gearbox
to a good gearbox. The kit provides an opportunity to develop
practical techniques to diagnose gearbox faults. |
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Eccentric
Sheave**
Eccentric
sheaves are all too common in industry. The eccentricity not only mimics
unbalance but also excites belt resonance, which contributes to unwanted
vibration and noise. The kit consists of one eccentric sheave to be
mounted on the end of the rotor shaft.
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Multiple
Spring/Stroke Reciprocating Mechanism**
This
reciprocating mechanism features locations for four springs with
independent stops to permit the timing of the spring engagement to be
adjusted. The design also includes two different stroke adjustments.
The combination of using a variety of spring constants with different
stroke and timing generates a complex loading on the system to yield
unusual speed variations and signatures.
- Learn how to monitor and diagnose reciprocation and load varying machinery.
- Study torsional vibration measurement techniques.
- Demonstrate the effectiveness of commercial analyzers at tracking speed variation and displaying the results.
The kit consists of one reciprocating assembly, one connecting rod, and one crank
wheel. |
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Mechanical Rub Kit
- This kit permits the evaluation of typical rub phenomena
associated with a variety of materials under different angle, loading,
and lubricant conditions.
- Experiments can be performed on the shaft
or rotor.
- Easy to install different materials for rubbing experiments.
The kit consists of an adjustable tool holder for the rub material, a vertical
post, a horizontal bar, and clamping mechanism. |
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Damped Bearing Housing Kit This
kit provides a 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. This item will enable you to add
damping to a standard rolling element bearing housing. The amplitude
of the resonance of a structure (or critical speed of rotors) is primarily
controlled by its damping. A typical rotor resonance amplitude tends
to be high, creating violent vibration. This kit can be used to demonstrate
the reduction in rotor resonance amplitude due to the installation
of damping. This approach can be used in real life situations where the
other common techniques such as mass and/or stiffness variation cannot
be applied or is cost prohibitive. In many situations, damping is the
most cost effective and appropriate means to attenuate resonant vibration.
SpectraQuest has unique expertise in damping technology. The kit consists
of two special bearing housings and two " bearings fitted with isolators.
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Induction
AC Motor Defects Kits**
SpectraQuest
offers the following internally faulted induction AC motors:
1.
Rotor Misalignment (Static Air Gap Eccentricity)
- A new motor is taken apart
and fitted with custom machined end bells. Innovative design allows for
easy introduction of known misalignment at either end of the motor. It
is simple to bring the motor back to original no-fault condition.
- Introduce known parallel and/or
angular misalignment in the horizontal plane to study the effect of
variable air gap (or electrodynamic forces) on vibration and motor
current spectra.
- Determine the effect of misalignment on power consumption.
- Study the effects of amount/type of misalignment and rotor speed on vibration/current spectra.
- Study the effect of temperature rise on non-linear characteristics of induction motors.
2.
Bowed
Rotor (Dynamic Air Gap Eccentricity)
- A new motor is taken apart and the rotor carefully bent in the center.
- Study the effects of rotor bow on vibration and/or current signature.
- Study the effect of bowed rotor on power consumption.
3. Faulted Bearings
- Both good bearings are
removed from a new motor and then fitted with one inner race faulted
bearing and one outer race faulted bearing. User can specify the types
of bearing faults.
- Study the effects of bearing faults on vibration and/or current signature.
- Study the effect of bearing faults on power consumption.
4. Unbalanced Rotor
- A new motor is taken apart and some material is removed from the rotor to create an unbalanced condition
- Study the effects of unbalanced rotor on vibration and/or current signature.
- Study the effect of unbalanced rotor on power consumption.
- Study the effect of temperature rise on non-linear characteristics of induction motors.
5. Broken Rotor Bars
- A new motor is taken apart and the rotor bars are carefully broken and fitted back in the motor.
- Study the effects of broken rotor bars on motor current signature/vibration as a function of speed/load.
- Study the effect of broken rotor bars on power quality and consumption.
- Study the effect of temperature rise on non-linear characteristics of induction motors.
6. Shorted Turn Stator Winding
- A new motor is taken apart
and stator winding turns are shorted. Leads are brought out for user to
vary motor current by adjusting short conditions.
- Study the effects of turn-to-turn short in stator windings on vibration and/or current signature.
- Study the effect of turn-to-turn short in stator windings on power quality and consumption.
- Study the effect of temperature rise on non-linear characteristics of induction motors.
7. Single Phasing and Voltage Unbalance
- A new motor is taken apart and rewired for easy introduction of voltage and unbalance and disconnecting one phase.
- Study the effects of voltage unbalance and one phase loss on motor current/vibration signatures
- Study the effect of voltage unbalance and one phase loss on power quality and consumption.
- Study the effect of temperature rise on non-linear characteristics of induction motors.
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Pump System Kit for the Machinery Fault Simulator**
- Study vibration spectra due to cavitation.
- Determine the damaging effect of
the cavitation.
- Visualize cavitation using the clear pump cover.
- Study the effect of turbulence on vibration signature.
- Study the effect of pump loading on motor and other components.
- Study the effect of different head and valve restriction on suction and/or discharge sides on the flow dynamics of the pump.
- Investigate the effect of speed and load variation on pump vibration spectra.
- Study the effect of clearance between the impeller and the suction portion of the pump.
- Conduct similar studies using other non-hazardous liquids of different viscosity and specific gravity.
The pump kit consists of a single
stage centrifugal pump, two pressure gauges, flow meter, water tank, an extra
LEXAN cover for visualizing cavitation, valves, hoses, mounting brackets,
and other
required hardware to install on the MFS gearbox platform.
It is driven by a double groove sheave. A user needs to simply remove the gearbox assembly and mount the pump.
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Worn
Pump**
To
assist in recognizing vibration and hydraulic issues associated with a
worn pump, a pump with simulated cavitation damage to the head and
impeller has been developed.
The kit consists on one worn centrifugal pump assembly less the sheave.
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PC Motor Control Kit
- Operate MFS from remote location.
- Preprogram speed acceleration, deceleration, and length of run to meet exact requirements.
This kit permits speed control of
the MFS through a personal computer. The user enters the essential data in a
user-friendly program resident on the PC. The PC is connected to an interface
module that communicates through an external
port on the inverter drive.
The kit consists of PC software, one interface module, and cables.
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Force Transducer
- Measure forces exerted on bearings due to coupling misalignment, rotor unbalance, belt misalignment, belt tension
- Demonstrate how mass unbalance force quadruples
when the speed is doubled, but vibration amplitude does not follow the
same trend
- Establish quantitative tensions for drive belt studies
- Learn to relate the vibration signature to
forces associated with common malfunctions such as resonance, bearing
faults, and more
- Witness 180 degree phase shift between heavy and high spots when rotor goes through a critical speed
- Verify and refine your rotor dynamic models and enhance modeling skills
- Learn phase relationship between force and vibration spectrum
- Learn nature of rotor dynamic forces due to common defects
There are three options available depending on the customer requirements:
- Vertical
force transducer for 5/8" and diameter shaft
- Horizontal force transducer
for 5/8" and shaft
- Combined horizontal and
vertical force transducer for 5/8" and diameter shaft
The kit consists of one appropriate force transducer with cables and one matching signal conditioner and power supply.
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Fault
Kits for Rotor Dynamics Studies***
1.
Oil Whirl/Whip in-Depth Study Kit for 1/2" Diameter
Shaft
- Study effects of bearing clearance, L/D ratio,
and rotor loading effects on oil induced instability.
- Understand whirl/whip
phenomena and how to avoid it.
The kit includes:
Six sleeve bearings to give bearing clearances of 2, 4, and 6 mils (0.001") for two different lengths with
a 1/2" diameter shaft,
two elliptical bearings to avoid whirl/whip instability, for the 1/2" diameter
shaft.
2. Oil
Whirl/Whip in-Depth Study Kit for 5/8” Diameter Shaft
- Study effects of bearing clearance, L/D ratio,
and rotor loading effects on oil induced instability.
- Understand whirl/whip
phenomena and how to avoid it.
The kit includes:
Six sleeve bearings to give bearing clearances of one 2, 4, and 6 mils
(0.001") for two different lengths with
a 5/8" diameter
shaft, and two elliptical bearings to avoid whirl/whip instability for the
5.8" diameter shaft.
3. 5/8” Diameter
SHhaft System for Whirl/Whip Study Kit
This kit is designed to study effects of bearing clearance, L/D ratio,
and rotor loading effects on oil induced
instability and understand whirl/whip phenomena and how to avoid
it.
The kit includes: Six sleeve bearings to give bearing
clearances of one 2, 4, and 6 mils (0.001") for two different
lengths with a 5/8" diameter shaft, and two elliptical
bearings
to avoid whirl/whip instability for the 5.8" diameter
shaft.
4.
ROLLING ELEMENT BEARING STUDY CONVERSION
KIT
This kit is designed to convert MFS-RDS for studies with rolling
element bearings. The user will be able to use
option kits applicable to MFS-Lite.
The kit includes: Split bracket rolling element bearing
conversion kit with two 5/8" or 1/2" bearing mounting
housings, 5/8" TGP steel shaft, two 5/8" squeeze
lock bearings, two row hole balance rotors (2),
one helical beam
coupling, one 5/8" bearing loader.
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Crack
Shaft/Rotor Study Kit
- 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.
This option kit includes one 5/8" shaft
with 4 1/2" 4-bolt flange connection to simulate crack, and one 5/8"
shaft with a deep V-notch crack.
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Fan
Vibration Kit
- 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.
This option kit includes: one six-blade paddle
fan, one ten-blade paddle fan, one 12-blade axial fan, one axial fan obstruction,
and one sheet metal shroud. |
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Reciprocating
Compressor Kit
- Learn the reciprocating compressor performance.
- Study the pressure
pulsation and the effects of discharge pressure on the behavior of
the compressor.
- Learn the sound and vibration signatures of compressor
housing, valves, and other structural components.
- Develop diagnosis
techniques for reciprocating compressors.
This option kit includes: one 1/2 HP compressor
with discharge piping, two mounting bases, one sheave, two V-belt, one
5-gallon air tank with flow controls, one 10-ft length tubing with fittings,
and 5/16-18 hardware set.
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1. The option kits listed in this document
are for the Machinery Fault Simulator (MFS), the MFS Lite, the MFS Magnum,
the Rotor Dynamics Simulator (RDS), and the Bearing Balancing Simulator (BBS).
2. * This option kit does not apply
to BBS.
3. ** This option kit does not apply
to MFS Lite, BBS, or RDS.
4. *** This option kit does not apply
to MFS, MFS Lite, or BBS.
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