TMFS: A Tool for Learning Machinery Fault Signatures

Condition monitoring (CM) is the practice of monitoring a condition parameter in equipment (vibration, temperature, etc.) in order to detect a significant change that indicates the development of a fault. It is an essential component of predictive maintenance. It enables maintenance to be scheduled or other steps to be done to prevent failure and its consequences. It offers the distinct advantage of addressing issues that might otherwise limit normal lifespan before they evolve into a significant failure.

Condition monitoring techniques are normally used on rotating equipment and other machinery (pumps, electric motors, internal combustion engines, presses), whereas stationary plant equipment such as steam boilers, piping, and heat exchangers are subjected to periodic inspection using non-destructive testing techniques and fit for service (FFS) evaluation.

Condition-based predictive maintenance (PdM) is a dependable, cost-effective technique for monitoring and diagnosing machinery defects before they create irreversible damage and failures that endanger product quality, delivery, and overall customer service.

Furthermore, it can be used as a primary input for beginning proactive strategies. The effectiveness of any PdM programme is ultimately determined by the accuracy and ease with which vibration spectra, waveforms, and phase correlations can be studied and comprehended. The Machinery Fault Simulator (MFS) from TIERA is a cutting-edge instrument for studying the characteristics of typical machinery problems without affecting production schedules or revenues.

The bench-top system has a large modular design that is versatile, easy to use, and strong. The MFS is the best tool available for learning machinery diagnostics since various defects can be introduced either singly or jointly in a completely controlled environment.

List of Experiments

1. Static and dynamic unbalance simulation
2. Study of unbalance of the multi-rotor system and over-hanging rotors.
3. Study of Single-plane and two-plane balancing techniques.
4. Misalignment studies
5. Study of Rotor Rub
6. Study of Bearing Fault
7. Study of Fin Hitting
8. Study of Bent Shaft
9. Study of Foundation looseness
10. Rigid and Flexible Coupling Studies

Specifications

  • 0.25 HP three-phase induction motor with VFD drive for speed control.

  • Maximum speed of 3000RPM

  • Two bearing blocks (aluminum alloy) with drilled holes for varying the rotor span

  • Deep groove double row concealed bearings are used. 2 nos of faulty bearings will be supplied. Also, two numbers of metal bearings will be supplied. Lubrication ports and oil seals are provided.

  • Shims to induce Misalignment

  • 20 mm diameter ground and polished stainless steel shaft.

  • Two Anodized Aluminum discs (150mm dia with 30mm thick) with evenly spaced holes at the sides for adding weights for simulating and correcting unbalance. EDM slots with clamping screws are provided to add fins (3 nos) to facilitate blade-pass frequency and blade rub studies.

  • Mounting pads for the magnetic base at bearing and motor housing.

    Slotted plates for placing tachometer and proximity probes

    200*500*20 mm, powder-coated aluminum-alloy base plate. Mounting holes fitted with Helicoil® inserts for repeated mounting/unmounting. Alternate holes are provided for adjusting the effective distance between bearing mounts. Proper damping pads are provided for isolation. Stiffening is provided to avoid resonances.

  • Stringed/rubberized supports to resist excessive vibrations during whirling.

    Acrylic cover (2 fold) with metallic frame and swivel joint for safety.

    Rugged carrying case for balance weights (grub screws), Allen keys, Bearing mounts, rotors, and accessories.

  • Operating manual with finite element results for verifying the experimental data shall be supplied.

  • Motor Controller Unit

  • Emergency stop button for extra safety.

Related Articles