- Will you perform routine health monitoring of machinery at my facility?
- Will you perform seismic measurements?
- Can you help me establish a Preventive Maintenance (PM) program?
- Can you help me establish a Predictive Maintenance (PdM) program?
Machinery Fault Simulator (MFS) Questions
- What is the Machinery Fault Simulator, or MFS?
- How can it help me and what are its benefits?
- What are some of its special features?
- How does it simulate real world machinery and how do I scale the data?
- Why do I need different option kits for it?
- What experiments can I run with each kit?
- Can I learn to perform shaft alignment?
- Can I learn to perform balancing below and above the critical speed?
- Can I perform (operating deflection shape) and learn how to handle a real life situation?
- What do I do with baseline data?
- Can I learn rotor dynamics modeling and experiments?
- What DAQ (data acquisition) system will I need with it?
- Can I use it for certification?
- Can I enhance my balancing skills and develop general guidelines for real machines?
- How do I present the justification to my boss?
- Will I need training to operate and do different experiments?
- Can I perform damage studies?
- What upgrades/mods are available?
- What kits are available?
- What are GDS and MFS-Max?
- What accessories do I need to optimize my benefit of an MFS?
- How does your training program differ from others?
- What does your training software contain and how does it help me?
- Can I get a full training system?
- Can SpectraQuest set up a training program at my facility?
- What are some special features of VibraQuest?
- What is AlignmentQuest?
- Compare it with a high-end laser system.
- What can I do with it that I cannot do with a laser system?
- Is it a better way to learn shaft alignment?
Will you perform routine health monitoring of machinery at my facility?
Although capable, SpectraQuest is not presently involved in this type of activity. We prefer to address specific machinery problems as brought to our attention on a consulting basis.
Will you perform seismic measurements?
Although capable, SpectraQuest is not presently involved in this type of activity.
Can you help me establish a Preventive Maintenance (PM) program?
Yes, SpectraQuest provides advice/assistance in establishing PM programs.
Can you help me establish a Predictive Maintenance (PdM) program?
Yes, SpectraQuest can assist you to organize, train your personnel, and implement your Predictive Maintenance program.
What is the Machinery Fault Simulator, or MFS?
The MFS is a portable machine that can be quickly and easily configured to simulate most typical machinery problems or faults. Some examples are resonance, shaft misalignment, rolling element bearing defects, rotor unbalance, bent shaft, etc. Kits can be fitted to simulate special issues such as gearing defects, centrifugal pump wear, etc.
How can it help me and what are its benefits?
The primary advantage of the machine is that problems can be studied one at a time or in combinations to enhance learning, particularly signal conditioning and vibration analysis. Typical applications include the following:
- Training of engineers and vibration analysts.
- Evaluation and certification of vibration analysts.
- Modeling for R&D development of vibration technology and interpretation.
- Evaluation of signal conditioning techniques.
- Platform for modal analysis development and training.
- Demonstration of fundamental key machine design issues such as resonance and torsional vibration.
The primary benefit of the MFS is that it can cost effectively enable the user to perform activities to improve equipment reliability and develop new technology. From a corporate perspective, cost reduction and/or success in developing and marketing new ideas/products is the ultimate result.
What are some of its special features?
The single, most important feature is that the Machinery Fault Simulator is robust and has been totally designed to reflect the real world as closely as possible, making it an excellent platform for mechanical studies. Additional features are as follows:
How does it simulate real world machinery and how do I scale the data?
- Full technical support from SpectraQuest’s engineering team.
- Thorough manuals and explanations.
- A proven line of cost effective kits to enhance the capability of the MFS to meet customer requirements.
- Custom designs to support specific issues.
- Vibration training and consultation.
The MFS simulates real world machinery by using full-sized commercial components and conventional design methodology. The machine is assembled on a solid, rigid foundation to minimize the introduction of undesirable issues. Quantitative scaling of data while modeling tends to be a unique and sometimes complex issue. Without testing, SpectraQuest cannot predict each case in advance. However, the MFS will generate identical motion to larger or smaller machines.
Why do I need different option kits for it?
The basic Machinery Fault Simulator is a “variable speed rotor kit” configured to permit controlled misalignment and balance studies. Where the user is interested in studying specific issues, “kits” can be fitted to the machine to demonstrate clearly the desired phenomena. For example, typical kits include resonance, rub, gearbox, belt drive, centrifugal pump, reciprocating mechanism, motor misalignment, etc.
What experiments can I run with each kit?
SpectraQuest provides a manual that addresses the experiments in detail to support laboratory exercises. Typical subjects include shaft alignment, sheave/sprocket alignment, resonance, eccentric rotor, cocked rotor, unbalance, defective bearings, phase relationship, reciprocating motion, gearing issues, belt drives, foundation stiffness, centrifugal pumps, motors, etc. The user is encouraged to consult with SpectraQuest engineers regarding the particular application.
Can I learn to perform shaft alignment?
Yes. Learning the basics of shaft alignment on the MFS is much more comfortable and conducive to information exchange than learning in the field. Field experience is important after mastering the fundamentals of alignment. You will need alignment tooling to support this task.
Can I learn to perform balancing below and above the critical speed?
Yes. When configured properly, the MFS is capable of operating above the first critical. You will need the appropriate balancing hardware and software.
Can I perform ODS (operating deflection shape) and learn how to handle a real life situation?
Yes. Due to the wide variety of attachments that simulate a multitude of motions, the MFS is a great platform for operating deflection shape training. You will need the appropriate hardware and software.
What do I do with baseline data?
No dynamic machine is free of vibration. There will always be some movement, even if very small. Baseline data is typically the vibratory performance of a healthy machine under normal operating conditions. This data reflects the normal and expected movement and is the “signature” of the machine. When a new and/or unusual peak occurs, the analyst must look for the root cause. Hence, baseline data is the unique standard for that particular machine and is maintained as a reference for comparison.
Can I learn rotor dynamics modeling and experiments?
Yes. Academic institutions frequently use the MFS for this purpose. You will need the appropriate hardware and software.
What DAQ (data acquisition) system will I need with it?
Since the Machinery Fault Simulator creates the desired disturbances, you can apply the DAQ system of your choice. For those who do not have such a system, SpectraQuest can provide the necessary software and hardware.
Can I use it for certification?
Yes. The Machinery Fault Simulator is ideal for this application because faults can be introduced on a controlled and repeatable basis. Some customers have training programs that presently use the MFS as evidence of skill level.
Can I enhance my balancing skills and develop general guidelines for real machines?
Yes. Please keep in mind that the MFS is a real machine and exhibits the same behavior, but in a much safer environment.
How do I present the justification to my boss?
Predictive Maintenance Programs
Purchasing hardware and software for PdM programs is relatively simple. The problem is what you do with the equipment once you have completed the purchase. The equipment suppliers tend to oversimplify vibration analysis in order to encourage sales. As a result, much of the training on vibration analysis tends to be somewhat superficial, “cook book,” and not really effective. It is SpectraQuest’s contention that a fundamental understanding of the kinematics of machinery is required to develop the most successful analysts. The Machinery Fault Simulator is a proven, excellent platform to support this training. The justification must be tailored to the business requirements of each organization. After discussing the particular situation with you, SpectraQuest will gladly provide assistance in wording of the project justification.
Research projects typically require a mechanical “test bed” of sorts to evaluate and study various scenarios. The basic MFS is an economical and relatively quick approach to developing the desired facility. By arranging for the services of SpectraQuest in the early stages of the project, the chances of success are greatly enhanced because of the contribution of experienced engineers who are not only interested in your work but also knowledgeable in how to modify the MFS to suit your circumstances. The net result is that you can concentrate on the issues that are most important to you and allow SpectraQuest to provide the necessary support at a competitive price.
The Machinery Fault Simulator is the hands-on laboratory device used in SpectraQuest’s unique turnkey vibration training program. If you are assigned the responsibility of developing a vibration training program in a quick and economical manner, consider this package as the benchmark.
Will I need training to operate and do different experiments?
The manuals are written to be self-explanatory, reducing the necessity of formal training. However, since our customers come from a wide variety of backgrounds, SpectraQuest provides an optional training seminar specifically on the use of the MFS to assure a hands-on comfort level.
Can I perform damage studies?
The Machinery Fault Simulator, as designed, is not intended for destructive testing. It is recommended that the customer contact SpectraQuest for consultation before considering damage studies.
What upgrades/mods are available?
Since the options are numerous/continuously increasing and some are not openly marketed, it is recommended that the customer discuss needs with appropriate SpectraQuest personnel to determine what is available. The most common upgrade/mod options (standard kits not listed) are as follows:
What kits are available?
- 2 hp. and 3 hp., 3 phase AC motor and inverter
- 1 hp. DC motor and SCR controller
- 5/8″ bore balance rotor with one row of holes
- 5/8″ bore balance rotor with two rows of holes
- 1″ diameter bore balance rotor with one row of holes
- Resonance rotor
- Split bearing housings for 5/8″ shaft
- 5/8″ diameter steel shaft
- 1″ diameter steel shaft
- 5/8″ diameter bearing loader
- Set of standard 5/8″ rotor bearings
- Set of 1″ diameter rotor bearings
- Set of standard 5/8″ rotor bearings with pillow blocks
- Straight tooth gearbox
- Straight tooth pinion assemblies
- Set of gearbox backlash adjustment shims
- Belts for multiple belt drive system
- Trig pulse notched collar for 5/8″ diameter steel shaft
- Heavy-duty 1/4″ thick LEXAN safety cover
- Pre-drilled 1/2″ machined base plate for stiffer/heavier foundation
Since the kits are numerous and continuously increasing, and some are not openly marketed, it is recommended that the customer discuss the needs with appropriate SpectraQuest personnel to determine what is available. The most common kits are as follows:
What are GDS and MFS-Max?
- Eccentric rotor
- Eccentric sheave
- Cocked rotor
- Centrally bent shaft
- Coupling end bent shaft
- Set of different style couplings
- Resonance study
- Set of faulted bearings for 5/8″ shaft
- 1″ diameter shaft bearings
- Set of faulted bearings for 1″ shaft
- 1″ diameter bearing loader
- Set of sleeve bearings
- Multi-belt drive, straight tooth gearbox, and magnetic brake
- Set of defective pinions to fit gearbox
- Worn gearbox
- Multiple spring/stroke reciprocating mechanism
- Mechanical rub
- Damped bearing housing
- Centrifugal pump system
- Worn centrifugal pump
- Unbalanced motor armature
- Misaligned motor armature (adjustable)
- Bent motor armature
- Motor with inner and outer race defects
GDS is short for Gearbox Dynamics Simulator. It is a machine specifically designed to support studies of gearing issues such as typical gear defects, backlash, and the effects of lubrication. It can be configured with rolling element or sleeve bearings. MFS-Max is short for Machinery Fault Simulator — Maximum. This is an extended MFS designed to support research in fault detection techniques of motors driving different types of loads including an MFS rotor deck, gearbox, centrifugal pump, and turbine blades/disks assembly.
What accessories do I need to optimize my benefit of an MFS?
Typical accessories for data acquisition and analysis (accelerometers, proximity probes, power supplies, mounting devices, cabling, DAQ, analysis software, strobe, tachometer, trigger pulse generator, etc.) are essential. If one wishes to learn more, specialized software such as balancing and modal programs become useful
How does your training program differ from others?
SpectraQuest vibration training is unique in that a totally different approach is employed to assure a solid understanding of machinery behavior and basic issues. As with competitive courses, the curriculum is presented in a logical and systematic manner although SpectraQuest tends to dwell more on addressing fundamental concepts and signal processing. The primary differences are as follows:
- SpectraQuest relies heavily on hands-on laboratory exercises using the Machinery Fault Simulator to bring the student into intimate contact with typical mechanisms, data collection issues, and analysis. In short, the lectures and text material are not only supported by observation but also driven home by the process of performing the work personally. This approach tends to increase understanding, confidence, and creativity.
- Although case histories are examined to some extent to reveal useful information or highlight an issue, the emphasis is really placed on coaching the student to develop a systematic approach using the tools of the trade, experience, skill, and brainpower to troubleshoot any vibration related problem.
- Students are encouraged to think for themselves and to openly question/challenge the published diagnostic rules/guidelines and norms.
- Considerable emphasis is placed on understanding data acquisition and signal processing issues to enable the student to better grasp the importance of collecting the information and manipulating it properly to reveal machinery defects.
- Some aspects of machine design are examined and evaluated for possible improvement or caution. The intent is to encourage the student to be not only alert to problem areas on existing equipment but also to be prudent in the selection of new machinery.
SpectraQuest does not endorse any particular brand of vibration monitoring/analysis equipment. Students are encouraged to bring personal instrumentation and to use it in conjunction with VibraQuest if so desired.
What does your training software contain and how does it help me?
VibraQuest Educational Software is specifically designed with training in mind and operates on a fully functional four to sixteen-channel data acquisition and rotational analysis software package. The features of the program are similar to competitive systems. VibraQuest Educational software provides additional benefit as follows:
- Demonstration programs to illustrate various signal processing issues such as aliasing, windowing, leakage, averaging, signal operation, and signal modulation.
- Simulation of a single degree of freedom (DOF) system to illustrate the fundamental principles of vibration.
The software is helpful in that it coaches the student in areas critical to achieving success.
Can I get a full training system?
Yes. The SpectraQuest Turnkey training package is a complete system consisting of simulators, sensors, training curriculum, custom data analysis software and a National Instruments’ data acquisition system.
Can SpectraQuest set up a training program at my facility?
Yes. The program will be tailored to your requirements.
What are some special features of VibraQuest?
VibraQuest, a fully functional open-architecture data acquisition and rotational analysis software package, is a cost effective high performance PC based system assembled from the National Instruments product line. The approach makes tailoring a program for particular customer requirements and hardware installation in a variety of packages from laptops and desktops to rugged shop floor cabinets relatively easy and affordable. Some special features are as follows:
- Windows based graphical HMI with intuitive layout for easy operation.
- Standard test configuration retrieval.
- Options to save raw or processed data to a file such as ASCII, Excel, etc.
- User-friendly experimental program set-up for coaching/assistance.
- Automatic data rendering and report generation to Excel and Word.
- Eight channel simultaneous sampling.
- Software configurable ICP® conditioning for accelerometers and microphones.
- Hammer test set-up for quick modal testing.
- Educational prompting and help messages.