Machinery Fault Simulator
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Why MFS
Features
Specifications
Basic MFS
Option Kits
Packages
The Best Tool Available 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 enables offline training and experimentation which in turn will minimize production downtime.Applications
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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.
- Modular, versatile, robust, and comprehensive.
- Simultaneous reciprocating and rotating mechanisms.
- Learn resonance, variable speed, gearbox, and belt drive diagnostics.
- Learn to determine vibration transmission path and perform root-cause analysis.
- Study correlation among vibration, motor current, and noise spectra.
- Model rotor dynamics and its effects on fault signatures.
- Validate balancing procedures above and below the first critical resonance.
Smart Design Makes the Simulator Robust and Easy to Use
The MFS is designed to be both versatile and easy to operate. The simulator is constructed with a split bracket bearing housing, a sliding shaft, rotors with split collar ends, couplings, pulleys, a multiple belt tensioning and gearbox mounting mechanism, and reciprocating system; all of which are designed to be easily removed and replaced between various experiments.Electrical | |
Motor | 3 Phase, 1 HP motor, pre-wired self-aligning mounting system for easy installation/removal |
Drive | 1 HP variable frequency AC drive with multi-featured front panel programmable controller |
RPM range | 0 to 6000 rpm (short duration) variable speed |
Current Measurement | Power leads accessible for current measurements |
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 | 3/4″ 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 | 18″ 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 |
Belt Mechanism | Two double groove “V” belt with one set screw mounting and one bush/key mounting. Positive displacement lever with turnbuckle plus adjustable gearbox platform |
Gearbox and Brake | Accessible three-way straight cut bevel gearbox with 1.5:1 ratio (20 gear input). Manually adjustable magnetic brake 0.5 – 10 lb.-in |
Reciprocating Mechanism | Adjustable spring engagement timing and two stroke settings. |
Centrifugal Pump | 1/2 HP, 27psi at 0gpm, 25gpm at 0psi with water at 4000rpm |
Reciprocating Compressor | 1/2 HP, 2.6cfm, 120psi belt driven with 5-gallon air tank |
Instrumentation Connectors | 16 BNC connector plate under the rotor base linked to BNC connector panel mounted on the edge for the base plate for direct connection to data collectors |
Safety Cover | Lockable clear, impact resistant hinged plastic cover with motor interlock switch to shut down motor when cover is raised |
Foundation | 1/2″ die cast aluminum base, base stiffener and eight rubber isolators |
Physical | |
Weight | Approximately 130 lb |
Dimensions | L=39″ (100cm), W=25″ (63cm) , H=21″ (53cm) |
Basic Machinery Fault Simulator System includes:
- 1 HP variable frequency AC drive with multi-featured front panel programmable controller
- 3 Phase, 1 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
- Split bracket bearing housings
- 18″ rotor deck with five mounting positions for shaft span reconfiguration
- Two rolling element ball bearings with squeeze lock type
- Vibration isolators mounts and base stiffener
- Two balance rotors with two rows of holes
- Alignment system with calibrated reference dials and jack bolts
- One 3/4″ TGP straight steel shaft
- 16 BNC connector plate under the rotor base linked to BNC connector panel mounted on the edge for the base plate for direct connection to data collectors
- Power leads accessible for current measurements.
- Impact resistant clear safety cover with safety interlock
- Balance weight kit
- Allen wrench set
- 24V Power supply
- Cover support
- Comprehensive operations manual
The MFS 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) | |
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Eccentric Rotor (Requires MR-SCK-3/4) (M-ER-3/4) | |
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Cocked Rotor (Requires MR-SCK-3/4) (M-CR-3/4) | |
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Coupling Type Set (Requires MR-SCK-3/4) (M-CK-3/4) | |
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Centrally Bent Rotor Shaft for Balance Studies (Requires MR-SCK-3/4) (M-BRS-3/4) | |
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Coupling-end bent rotor shaft for alignment studies (Requires MR-SCK -3/4) (M-CBRS-3/4) | |
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Rolling Bearing Resonance/Critical Study Kit (M-RSK-1/2) | |
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Sleeve Bearing Resonance Study Kit (M-SBK-1/2) | |
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3/4″ shaft bearing loader (Requires MR-SCK -3/4) (M-BL-3/4) | |
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3/4″ Bearing Fault Kit (Requires MR-SCK -3/4) (M-BFK-3/4) | |
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1″ Shaft Bearing Study Kit (M-BSK-1) | |
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1″ shaft Bearing Loader (Requires MR-BSK-1) (M-BL-1) | |
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1″ shaft bearing fault kit (Requires MR-BSK-1) (M-BFK-1) | |
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Cocked Bearing Housing (M-CBM-3/4) | |
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3/4″ Shaft Sleeve Bearing (grease lubricated) kit (M-SBK-3/4) | |
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Multi-Belt Drive, Straight Tooth Gearbox, and Adjustable Particle Magnetic Brake System (M-BDGB) | |
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Defective Straight Tooth Gearbox Pinions (Requires M-BDGB) (M-DGPA) | |
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Worn Straight Tooth Gearbox (Requires M-BDGB) (M-WGB) | |
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Eccentric Sheave (Requires M-BDGB) (M-ES-3/4) | |
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Belt-Drive Mounting Block (Requires M-BDGB) (M-BDB) | |
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Direct Driven Gearbox Mounting Kit (Requires M-BDGB) (M-DGBB) | |
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Reciprocating Mechanism (Requires M-BDGB) (M-RMS) | |
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Direct Driven Reciprocating Mechanism Mounting Kit (Requires M-RMS and M-BDGB) (M-DRMB) | |
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Fan Vibration Kit (M-FVK-3/4) | |
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Crack Shaft Study Kit (M-CSRK-3/4) | |
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Mechanical Rub Kit (M-MRK) | |
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Damped Bearing Housing Kit (Requires MR-SCK -3/4) (M-DBHK-1/2) | |
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Centrifugal Pump with Clear Cover to Visualize Cavitation (Requires M-BDGB) (M-CFPK) | |
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Centrifugal Pump With Worn Impeller (Requires M-BDGB and M-CFPK) (M-CFPFI) | |
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Direct Driven Centrifugal Pump Mounting Kit (M-CFPK) (M-DCPK) | |
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Reciprocating Compressor Kit (Requires M-BDGB) (M-RCK) | |
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Reciprocating Compressor Fault Kit (Requires M-BDGB and M-RCK) (M-RCFK) | |
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Direct Driven Reciprocating Compressor Mounting Kit (M-RCK) (M-DRCK) | |
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AC Motor With Built-In Rotor Unbalance (M-UBM) | |
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AC Motor With Built-In Rotor Misalignment System (M-MAM) | |
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AC Motor With Built-In Bowed Rotor (M-BRM) | |
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AC Motor With Built-In Faulted Bearings (M-FBM) | |
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AC Motor With Built-In Broken Rotor Bars (M-BRBM) | |
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AC Motor With Stator Winding Faults (M-SSTM) | |
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AC Motor With Voltage Unbalance & Single Phasing (M-VUSM) | |
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PC Motor Control Kit (M-PCK) | |
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Shaft Alignment Kit (M-ATK) | |
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Mechanically Operated Bearing Loader (M-MBL-3/4) | |
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Bearing Loader Force Transducer (Requires M-MBL-3/4) (M-BLFT) | |
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Vertical and Horizontal Bearing Force Transducer for 1/2″ to 1″ Shafts (M-FTVH) | |
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Axial Bearing Force Transducer for 1/2″ to 1″ shafts (M-FTA) | |
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High Value Combination Packages
The MFS 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 12% discount over separately purchased items.Package # 1 : | Basic MFS+ Kits for in-depth studies of alignment, balancing and resonance issues |
Package # 2 : | Basic MFS+ Kits in-depth studies of alignment, balancing, resonance, and bearing defects issues |
Package # 3 : | Basic MFS+ Kits for in-depth studies of alignment, balancing, resonance, bearing defect, and gearbox & belt drive issues |
Package # 4 : | Basic MFS+ Kits for in-depth studies of alignment, balancing, resonance, bearing defect, gearbox & belt drive fault, reciprocating mechanism, mechanical rub, shaft/rotor crack and damping issues |
Package # 5F : | asic MFS+ Kits for in-depth studies of alignment, balancing, resonance, bearing defect, gearbox and belt drive fault, reciprocating mechanism, mechanical rub, shaft crack, damping, and fan issues |
Package # 5P : | Basic MFS+ Kits for in-depth studies of alignment, balancing, resonance, bearing defect, gearbox and belt drive fault, reciprocating mechanism, mechanical rub, shaft crack, damping, and pump issues |
Package # 5C : | Basic MFS+ Kits for in-depth studies of alignment, balancing, resonance, bearing defect, gearbox and belt drive fault, reciprocating mechanism, mechanical rub, shaft crack, damping, and reciprocating compressor issues |
Package # 5M : | Basic MFS+ Kits for in-depth studies of alignment, balancing, resonance, bearing defect, gearbox & belt drive fault, reciprocating mechanism, mechanical rub, shaft crack, damping, and induction motor electro-mechanical defects issues |
Package # 6 : | Basic MFS+ Kits for in-depth studies of alignment, balancing, resonance, bearing defect, gearbox & belt drive fault, reciprocating mechanism, mechanical rub, shaft crack, damping, induction motor electro-mechanical defects, pump, fan, and reciprocrating compressor issues |
Package # 7 : | Basic MFS+ Kits for in-depth studies of alignment, balancing, resonance, bearing defect, gearbox and belt drive fault, reciprocating mechanism, mechanical rub, shaft crack, damping, induction motor electro-mechanical defects, pump, fan, and reciprocrating compressor issues; plus PC operation, shaft alignment kit and bearing loader with force transducer |
Package # 8 : | Basic MFS+ Kits for in-depth studies of alignment, balancing, resonance, bearing defect, gearbox & belt drive fault, reciprocating mechanism, mechanical rub, shaft crack, damping, induction motor electro-mechanical defects, pump, fan, and reciprocrating compressor issues plus PC operation, shaft alignment kit, tri-axial force measurement of both bearing supports, bearing loader issues; and extra set of direct drive mechanisms for an alternate loading of induction motor electro-mechanical defects |
Option kit | PKG 1 | PKG 2 | PKG 3 | PKG 4 | PKG 5F | PKG 5P | PKG 5C | PKG 5M | PKG 6 | PKG 7 | PKG 8 | |
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Training Curriculum Manual | SQI-TRCM | x | x | x | x | x | x | x | x | x | x | x |
Eccentric Rotor (Requires MR-SCK-3/4) | M-ER-3/4 | x | x | x | x | x | x | x | x | x | x | x |
Cocked Rotor (Requires MR-SCK-3/4) | M-CR-3/4 | x | x | x | x | x | x | x | x | x | x | x |
Centrally Bent Rotor Shaft for Balance Studies (Requires MR-SCK-3/4) | M-BRS-3/4 | x | x | x | x | x | x | x | x | x | x | x |
Coupling Type Set (Requires MR-SCK-3/4) | M-CK-3/4 | x | x | x | x | x | x | x | x | x | x | x |
Coupling-end bent rotor shaft for alignment studies (Requires MR-SCK -3/4) | M-CBRS-3/4 | x | x | x | x | x | x | x | x | x | x | x |
Rolling Bearing Resonance/Critical Study Kit | M-RSK-1/2 | x | x | x | x | x | x | x | x | x | x | x |
Sleeve Bearing Resonance Study Kit | M-SBK-1/2 | x | x | x | x | x | x | x | x | x | x | x |
3/4″ Bearing Fault Kit (Requires MR-SCK -3/4) | M-BFK-3/4 | x | x | x | x | x | x | x | x | x | x | |
3/4″ shaft bearing loader (Requires MR-SCK -3/4) | M-BL-3/4 | x | x | x | x | x | x | x | x | x | x | |
1″ Shaft Bearing Study Kit | M-BSK-1 | x | x | x | x | x | x | x | x | x | x | |
1″ shaft bearing fault kit (Requires MR-BSK-1) | M-BFK-1 | x | x | x | x | x | x | x | x | x | x | |
1″ shaft Bearing Loader (Requires MR-BSK-1) | M-BL-1 | x | x | x | x | x | x | x | x | x | x | |
Cocked Bearing Housing | M-CBM-3/4 | x | x | x | x | x | x | x | x | x | x | |
3/4″ Shaft Sleeve Bearing (grease lubricated) kit | M-SBK-3/4 | x | x | x | x | x | x | x | x | x | x | |
Multi-Belt Drive, Straight Tooth Gearbox, and Adjustable Particle Magnetic Brake System | M-BDGB | x | x | x | x | x | x | x | x | x | ||
Belt-Drive Mounting Block (Requires M-BDGB) | M-BDB | x | x | x | x | x | x | x | x | x | ||
Defective Straight Tooth Gearbox Pinions (Requires M-BDGB) | M-DGPA | x | x | x | x | x | x | x | x | x | ||
Worn Straight Tooth Gearbox (Requires M-BDGB) | M-WGB | x | x | x | x | x | x | x | x | x | ||
Eccentric Sheave (Requires M-BDGB) | M-ES-3/4 | x | x | x | x | x | x | x | x | x | ||
Direct Driven Gearbox Mounting Kit (Requires M-BDGB) | M-DGBB | x | x | x | x | x | x | x | x | x | ||
Reciprocating Mechanism (Requires M-BDGB) | M-RMS | x | x | x | x | x | x | x | x | |||
Direct Driven Reciprocating Mechanism Mounting Kit (Requires M-RMS and M-BDGB) | M-DRMB | x | x | x | x | x | x | x | x | |||
Mechanical Rub Kit | M-MRK | x | x | x | x | x | x | x | x | |||
Damped Bearing Housing Kit (Requires MR-SCK -3/4) | M-DBHK-1/2 | x | x | x | x | x | x | x | x | |||
Crack Shaft Study Kit | M-CSRK-3/4 | x | x | x | x | x | x | x | x | |||
Reciprocating Compressor Kit (Requires M-BDGB) | M-RCK | x | x | x | x | |||||||
AC Motor With Built-In Rotor Unbalance | M-UBM | x | x | x | x | |||||||
Fan Vibration Kit | M-FVK-3/4 | x | x | x | x | |||||||
Reciprocating Compressor Fault Kit (Requires M-BDGB and M-RCK) | M-RCFK | x | x | x | x | |||||||
AC Motor With Built-In Rotor Misalignment System | M-MAM | x | x | x | x | |||||||
Centrifugal Pump with Clear Cover to Visualize Cavitation (Requires M-BDGB) | M-CFPK | x | x | x | x | |||||||
Direct Driven Reciprocating Compressor Mounting Kit (M-RCK) | M-DRCK | x | x | x | x | |||||||
AC Motor With Built-In Bowed Rotor | M-BRM | x | x | x | x | |||||||
Centrifugal Pump With Worn Impeller (Requires M-BDGB and M-CFPK) | M-CFPFI | x | x | x | x | |||||||
AC Motor With Built-In Faulted Bearings | M-FBM | x | x | x | x | |||||||
Direct Driven Centrifugal Pump Mounting Kit (M-CFPK) | M-DCPK | x | x | x | x | |||||||
AC Motor With Built-In Broken Rotor Bars | M-BRBM | x | x | x | x | |||||||
AC Motor With Stator Winding Faults | M-SSTM | x | x | x | x | |||||||
AC Motor With Voltage Unbalance & Single Phasing | M-VUSM | x | x | x | x | |||||||
PC Motor Control Kit | M-PCK | x | x | |||||||||
Shaft Alignment Kit | M-ATK | x | x | |||||||||
Mechanically Operated Bearing Loader | M-MBL-3/4 | x | x | |||||||||
Bearing Loader Force Transducer (Requires M-MBL-3/4) | M-BLFT | x | x | |||||||||
Axial Bearing Force Transducer for 1/2″ to 1″ shafts | M-FTA | x | ||||||||||
Vertical and Horizontal Bearing Force Transducer for 1/2″ to 1″ Shafts | M-FTVH | x |
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About Us
Spectra Quest, Inc. is dedicated to providing state-of-the-art systems for enhancing product reliability and quality assurance. We develop and manufacture training and diagnostic systems for industrial maintenance and vibration analysis. Our flagship Machinery Fault Simulator (MFS) has been sold in over 50 countries [ Read More About Us]