Drivetrain Diagnostics Simulator

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Advanced Signal Processing Course for Machinery Fault Diagnosis -

This is a Practical Course on Advanced Vibration Analysis & Condition Monitoring taught by world recognized expert: Professor Bob Randall, University of New South Wales, Australia and assisted by Dr. Suri Ganeriwala President of SpectraQuest, Inc. on November 4 – 8, 2013 at 8227 Hermitage Road, Rihcmond VA 23228.

The objective is to provide tools to prepare you to become an expert in analyzing machinery faults. Topics include overview of condition monitoring techniques, basic vibration theory, and advanced signal processing principles like FFT methods, Hilbert methods via FFT and related amplitude, phase and frequency demodulation, cepstrum, order tracking and time synchronous averaging.

Rather than giving pure theory, it will be illustrated at all stages with diagnostic examples and demonstrations using SpectraQuest Machinery Fault Simulators and Drivetrain Diagnostics Simulators. The concept of cyclostationarity with principal application to bearing diagnostics will be presented. The course will cover a range of techniques for bearing diagnostics, as well as for gear diagnostics. It will also cover IC engines, and other reciprocating machines, by a number of techniques, including simple torsional vibration analysis by frequency demodulation of shaft encoder signals and will use SpectraQuest bearing wear and gearbox dynamics simulators, and a reciprocating compressor.

Kindly Register at: http://spectraquest.com/events/courses/

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Drivetrain Diagnostics Simulator

  1. 1. Drivetrain Diagnostics Simulator The Perfect Tool for Gearbox and Bearing Diagnostics and Dynamics Studies
  2. 2. 28201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Drivetrain Diagnostics Simulator Designed to simulate industrial drivetrains for experimental and educational purposes Drivetrain consists of a 2 stage planetary gearbox, a 2 stage parallel shaft gearbox with rolling or sleeve bearings, a bearing loader, and a programmable magnetic brake. Designed to maximize the number of drivetrain configurations to investigate gearbox dynamics and acoustic behavior, health monitoring, vibration based diagnostic techniques, lubricant conditioning or wear particle analysis. Robust enough to handle heavy loads and spacious enough for easy gear placement, setup, and installation of monitoring devices. Can be configured to reduce or increase the gear ratio. Planetary gear train, sun, planet and ring gears, the carrier, and bearings are all easily accessible.
  3. 3. 38201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Drivetrain Diagnosis Simulator Torque transducer and encoder 2 stage planetary gearbox Parallel shaft gearbox Programmable magnetic brake Radial bearing loaderVariable speed drive
  4. 4. 48201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com DDS Benefits Faults like surface wear, crack tooth, chipped tooth and missing tooth can be demonstrated on either spur gears or helical gears. Rolling element bearing faults like inner race, outer race, ball damage can also be incorporated. Adjustable clearance to study backlash is possible: increasing the amount of backlash is without major consequence (other than increased noise and rotational play), and reducing backlash can result in binding and/or excessive operating temperatures. Misalignment can also be introduced intentionally Any of these faults can be added to the drivetrain one at a time, or simultaneously to study fault interactions. Both torsional and radial loadings can be applied to study damage signature or propagation in gears and/or bearings Torsional load is applied via a 3 HP variable frequency AC drive with a programmable, user-defined speed profiles Radial load is applied to a shaft in the parallel gearbox.
  5. 5. 58201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com DDS Features 2-stage planetary gearbox and 2-stage oil-lubricated parallel shaft gearbox Gears can slide along the shafts to alter system stiffness and make room for additional devices. Adaptable to spur or helical gears. Intentionally damaged or worn gearing can be fitted to study the effects on vibration signature. Alterable backlash by replacing bearing mounting hubs to provide the desired clearance. 2 stage, 27:1 gear ratio planetary gear with 4 planet stage1 and 3 planet stage 2
  6. 6. 68201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Versatility Modular design makes the introduction of faulted bearing and/or faulted gears an easy task. Multiple mounting locations provided for installation of various transducers. Develop diagnosis techniques and advanced signal processing methods. Torsional and radial variable speed loading PC controlled magnetic brake connected directly to output shaft to provide loading
  7. 7. 78201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Transducers and DAQ Designed to accommodate different types of sensors easily. Accelerometers can be installed on the gearboxes and on the bearing housing to measure the vibrations in all three directions. Torque meter enables precise load measurement. Input and output shafts can be fitted with encoder or tachometer to measure the transmission error or for time synchronize averaging. Other transducers can also be installed as per customer’s request. Data acquisition hardware and software are also available from Spectra Quest and ready to do time domain and frequency domain signal analysis.
  8. 8. 88201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Basic DDS 3 HP variable frequency AC drive with multi-featured front panel programmable controller 3 Phase 3 HP motor, pre-wired self-aligning mounting system for easy installation/removal Built-in Tachometer with LCD Display and analog output for DAQ purposes Three in-line parallel shafts configurable as single or two stage reducer/increaser 2 stage planetary gearbox Four spur gears to obtain two gear mesh frequencies Six rolling element bearings Magnetic break for gearbox loading Precision machined bearing housings at both ends of the gearbox with mountings for direct measurements of bearing vibrations Gearbox oil level gauge Vibration isolators mounts and base stiffener
  9. 9. 98201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Option Kits SpectraQuest offers a complete array of option kits enabling detailed investigations of particular and more advance vibration phenomena or machinery faults. G-ENCShaft encoder G-TORTorque transducer with built encoder on input shaft G-RBFTRadial bearing loader force transducer (Requires W- RBL) G-PCBPC controlled brake G-PCKPC motor control kit G-PDGDefective planatary gears G-HDGDefective helical gears G-HGHelical gears set G-ESGEccentric Spur Gear G-SDGDefective spur gears G-RBLRadial bearing loader G-SBHParallel gearbox oil-impregnated sleeve bearing G-BFK-PPlanetary gearbox bearing fault kit G-BFK-1Parallel gearbox bearing fault kit
  10. 10. 108201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Parallel Gearbox Bearing Fault Kit (G-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.
  11. 11. 118201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Planetary Gearbox Bearing Fault Kit (G-BFK-P) Study bearing faults in planetary gearbox The kit consists of one inner race defect, one outer race defect, one with ball defect, and one combination of defects.
  12. 12. 128201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Radial Bearing Loader (G-RBL) Investigate bearing radial loading effects. Understand bearing failure signature as a function of load and rotational speed. Compare vibration signature between loaded and unloaded bearings. Study outer race bearing fault signature as a function of load location. The kit consists of one mechanical bearing loader
  13. 13. 138201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Defective Spur Gears (G-SDG) Study the effect of damaged tooth in gearboxes. Apply phase demodulation signal analysis to detect gear damage. Investigate backlash between mating gears. The kit consists of one missing tooth gear, one chipped tooth gear, one root
  14. 14. 148201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Eccentric Spur Gear (G-ESG) Study the effects of eccentric spur gear. Measure the vibration signature of eccentric gears. The kit consists of one eccentric spur gear.
  15. 15. 158201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Helical Gears Set (G-HG) Study the helical gears parallel shaft gearbox. Compare vibration signature between spur and helical gears. The kit consists of four helical gears to replace standard spur gears in gearbox
  16. 16. 168201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Defective Helical Gears (G-HDG) Study the effect of damaged helical gears. Apply phase demodulation signal analysis to detect gear damage. The kit consists of one gear with chipped tooth and one gear with missing tooth
  17. 17. 178201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Defective Planetary Gears (G-PDG) Study the effect of damaged planetary gears. Apply phase demodulation signal analysis to detect gear damage. The kit consists of one missing tooth gear, one chipped tooth gear, one root crack gear, and one surface wear gear
  18. 18. 188201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com PC Motor Control Kit (G-PCK) Operate DDS 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.
  19. 19. 198201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com PC Controlled Brake (G-PCB) Operate magnetic brake from remote location. Pre-program load profiles of run to meet exact requirements. The kit consists of PC software, one interface module to magnetic brake and cables.
  20. 20. 208201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Radial Bearing Loader Force Transducer (G-RBFT) Measure the radial load applied by the mechanically operated bearing loader. The kit consists of one transducer measuring radial force and one matching signal conditioner.
  21. 21. 218201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Torque Transducer with Built Encoder on Input Shaft (G-TOR) Measure the torque on the input shaft. Study torque variation through full rotation cycle. Track shaft position in signal analysis. The kit consists of one 20 N.m torque meter with built-in 360 pulse encoder
  22. 22. 228201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Shaft Encoder (G-ENC) Measure transmission error in the gearbox by comparing input and output rotation. The kit consists of one 360 pulse per revolution encoder and once per revolution index
  23. 23. 238201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Value Packages The DDS is also available in high value combination packages Diagostics Instrumentation PKG 1 x PKG 2 x x G-BFK-1 W-BFK-P G-SBH G-RBL G-SDG G-ESG G-HG G-HDG G-PDG G-PCK G-PCB G-BPC G-RBFT G-TOR G-ENC PKG 1 x x x x x x x x x PKG 2 x x x x x x x x x x x x x x x
  24. 24. 248201 Hermitage Rd, Richmond, VA 23228 1-804-261-3300 www.spectraquest.com Specifications L=56” (142cm), W=76” (190cm), H=96” (220cm)Dimensions Approximately 250 lbWeight Physical 1/2” (12.7 mm) die cast aluminum base, base stiffener and eight rubber isolatorsFoundation 1.5 to 32 lb.ft capacity heavy duty magnetic particle brakeMagnetic Brake 3000lb capacity with available force transducerBearing Loader Up to 20N.m with built-in 360 pulse encoderTorque meter Deep groove ball bearing or oil-impregnated bronze sleeve bearingBearing 2 stage, 2.5 maximum ratio per stage, spur or helical gearsParallel Shaft Gearbox 2 stage, 27:1 gear ratio planetary gear with 4 planet stage1 and 3 planet stage 2Planetary Gearbox 1” diameter; Turned, Ground, & Polished (TGP) steelShaft Diameter Mechanical 230 VAC, Single phase, 60/50 HzVoltage Built-in tachometer with LCD display and one pulse per revolution analog TTL output for DAQ purposesTachometer 0 to 5000 rpm variable speedRPM range 3 HP variable frequency AC drive with multi-featured front panel programmable controllerDrive 3 Phase, 3 HP motor, pre-wired self-aligning mounting system for easy installation/removalMotor Electrical

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