Machinery Fault Rotor Dynamics Simulator

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.

Basic MFS-RDS Configuration (RDS2010)

• 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 nine bearing mounting positions for shaft span reconfiguration
• Vibration isolators mounts and base stiffener
• Three steel resonance rotors 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

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.

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 ¾” bearings with mounting housings, two 6” aluminum rotors with 36 threaded holes, one 3/4” diameter shaft, and one coupling.

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 understands 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-SCK-3/4 and MR-OWSK-1/2

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 Alignment Studies (MR-CBRS-3/4)

• 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 ¾” 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 (MR-RSK-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 higher resonance modes by adding disks to ½” shaft.
• 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 ¾” 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” shaft, and one coupling.

3/4” and 1” Bearing Loader (M-BL-3/4 and M-BL-1)

• Investigate bearing radial loading effects.
• Enhance the spectral amplitude of system.
• The kit consists of one 3/4” or 1” bore loader weighting 11lb (5kg) and two clamp collars.
• Requires MR- SCK -3/4 or Requires MR-BSK-1

3/4” and 1” Bearing Fault Kit (M-BFK-3/4 and 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- SCK -3/4 or 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.

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.