Basic Info.
Product Description
The VALENIAN test bench can support the experimental testing of feature extraction models for resonance signals of multiple vibration sources in electromechanical systems; Capable of providing modular design and compatible with the installation of other test bench specimens; Vibration isolation design, including a reinforced base design; The maximum power of the test bench shall not exceed 2KW; We can provide typical fault kits for simulating shaft misalignment, imbalance, critical speed, oil film vortex and oscillation, mechanical friction, shaft cracks, mechanical looseness, induction motor faults, pump cavitation phenomena, fan blade vibration, reciprocating compressor faults, etc; Typical fault data can be provided, including: unbalance, misalignment, ball bearing failure, gear failure, shaft failure, fan, water pump cavitation test, motor failure, compressor failure, oil film bearing failure, generator failure, torsional vibration, pulley failure
Introduction:
PT300 is designed to learn detailed knowledge of various vibration characteristics, and it is necessary to conduct simulation experiments in the same device as actual machines to improve the analysis ability of very complex vibration spectra. At the same time, precision vibration analysis and detailed fault diagnosis can be carried out for various defects. Each part of the PT mechanical fault diagnosis teaching simulation experiment can be precisely machined, with high tolerances, and can operate under low vibration. Based on the specific fault characteristics you want to analyze, experiments can be conducted separately or in combination with various defects in a safe and controllable environment. As an innovative experimental platform for studying the characteristics of machine defects, it fully meets the extensive needs of vibration analysis engineers and teaching simulation users.
Function Description:
Function Description:
This simulation platform is designed to learn dynamic balance, misalignment, equipment looseness, rolling bearing faults (inner ring, outer ring, ball, cage, comprehensive faults), rotor friction, and vibration characteristic frequencies at different speeds.
This simulation platform generates vibrations based on the degree of defects and can simulate vibration phenomena caused by imbalance and misalignment. In addition, it is an ideal choice for training balance and axis alignment methods to correct imbalance and misalignment faults, looseness, and bearing defects.
Product features:
To achieve imbalance, 36 holes were drilled in the disc, each with an angle of 10 °, allowing any unbalanced mass to be added at the desired location.
The misalignment mechanism is designed to move the motor back and forth freely, allowing it to set defects without disassembling the machine.
PT100 and PT300 are suitable educational training simulation platforms for learning imbalance, misalignment, and bearing faults.
Precision dynamic balance simulation
Central support rotor
High precision axis centering component
Move the top screw bolt left and right
Various defective bearings can be pre installed
Research on Signal Processing Technology
Single or multi-level balance training
Fault simulation of mechanical looseness
Diagnosis of bearing problems
Analysis of characteristic frequencies of bearing faults at different rotational speeds
Product features:
To achieve imbalance, 36 holes were drilled in the disc, each with an angle of 10 °, allowing any unbalanced mass to be added at the desired location.
The misalignment mechanism is designed to move the motor back and forth freely, allowing it to set defects without disassembling the machine.
PT300 is the best educational simulation platform for learning imbalance and misalignment, as well as calibration methods.
Basic layout of experimental platform
The impact of imbalance on the normal operation of equipment
Poor dynamic balance or malfunction of equipment usually refers to abnormal vibration caused by the eccentricity of the rotor components of rotating machinery relative to the axis of the rotating shaft. On site dynamic balancing refers to the direct dynamic balancing correction of rotor components without dismantling the equipment (usually requiring specialized instruments). Before discussing how to achieve dynamic balance, let's first understand the characteristics of poor dynamic balance and its impact on equipment:
1, The adverse effects of abnormal dynamic balance on equipment:
1. Reduce the expected service life of equipment, especially in the early damage of bearings;
2. Shorten the maintenance cycle of equipment;
3. Increase equipment maintenance costs;
4. Affects product quality;
5. Deterioration of working environment, etc.
2, Characteristics of poor dynamic balance and some precautions for analysis:
Since poor dynamic balance has such a serious impact on equipment, it is necessary to carry out dynamic balance correction when the equipment has poor dynamic balance. However, before dynamic balance correction, analyzing and identifying the causes of poor dynamic balance is the most essential and primary step in our dynamic balance correction. The following is a discussion on how to identify unbalanced vibration characteristics and some validated analysis techniques:
1. Unbalanced vibration characteristics:
The basic characteristics of imbalance are intuitive and easy to understand. When a rotor with uneven mass distribution rotates, the rotational characteristics of the imbalance are reflected through vibration characteristics;
a. The periodicity of vibration is at the same frequency as the working speed, and the main vibration energy is concentrated at twice the rotational speed of the equipment;
b. The degree of vibration intensity is highly sensitive to changes in working speed;
c. The amplitude of radial vibration is the highest;
d. The amplitude and phase angle of vibration have stability and repeatability;
e. The phase angle of vibration differs by about 90 degrees in the horizontal and vertical directions.
2. Analysis and confirmation of imbalance:
a. The amplitude of the frequency spectrum is twice the speed and the harmonics are very small;
b. No other peaks are included in the significant amplitude;
c. Using high-resolution magnification or time synchronized averaging methods to confirm accurate double speed characteristics;
d. There is no significant difference in amplitude between the horizontal and vertical directions at a frequency of one speed, unless there are asymmetric steel characteristics in the structure;
e. The vibration intensity of axial frequency doubling is less than that of radial frequency doubling
f. Generate a symmetrical waveform once per rotation cycle, without any trimming or interruption at the top;
g. In phase analysis, the horizontal and vertical differences of the same bearing seat are about 90 degrees;
3. The main factors causing equipment imbalance (correctable) are:
1. The machining tolerance and installation tolerance are incorrect;
2. Manufacturing errors (eccentricity of rotating parts, etc.);
3. Uneven material (such as voids in castings);
4. Component defects (corrosion or wear of rotating components, etc.);
5. There is thermal deformation or mechanical deformation, etc;
6. Bending of rotating components;
7. Mass eccentricity caused by foreign object attachment;
4. Other factors that cannot be corrected through dynamic balance:
1. The equipment is severely loose (including increased bearing clearance);
2. The device triggers resonance near the operating speed;
3. Shaft rupture;
4. Bearing damage;
5. Wear of transmission components leads to torque imbalance;
6. The device is not functioning properly;
7. Equipment installation tilt (such as equipment foundation settlement, equipment installation adjustment pad damage, etc.);
Tip: The factors that cause poor dynamic balance are complex and intricate, so we must carefully analyze the true cause of abnormal equipment vibration before dynamic balance. If the equipment has the above uncorrectable reasons, we must handle these issues before dynamic balance, otherwise dynamic balance correction will not achieve the expected effect.
Experimental title: Rotor dynamic balance correction
Experimental objective: Poor dynamic balance or malfunction of equipment usually refers to abnormal vibration caused by the eccentricity of the rotor components of rotating machinery relative to the axis of the rotating shaft. On site dynamic balancing refers to the direct dynamic balancing calibration of rotor components without dismantling the equipment. Before discussing how to achieve dynamic balancing, let us first understand the characteristics of poor dynamic balancing and its impact on the equipment
1. Reduce the expected service life of equipment, especially in the early damage of bearings;
2. Shorten the maintenance cycle of equipment;
3. Increase equipment maintenance costs;
4. Affects product quality;
5. Deterioration of working environment, etc
Experimental equipment:
1. PT300 dynamic balance shaft centering simulation platform;
2. VALENIAN multi-channel vibration acquisition system;
3. Weight bolts and weight washers;
4. Precision electronic scale;
5. One set of hexagonal wrenches;
Experimental process:
Firstly, power off the experimental platform;
2. Open the acrylic safety cover;
3. Choose the testing position on the bearing seat to install the acceleration sensor;
4. Open the vibration analyzer and run the vibration analysis software;
5. Power on the equipment, turn on the power switch, and run the experimental bench at a fixed speed;
6. Collect current vibration data, and real-time vibration spectra will appear;
7. Stop the experimental platform and turn off the power to the experimental platform;
8. Install M5 bolt counterweights on the rotor disc for fast installation of unbalanced mass.
9. Open the vibration analyzer and run the vibration analysis software;
10. Power on the equipment, turn on the power switch, and run the experimental bench at a fixed speed;
11. Collect current vibration data, and real-time vibration spectra will appear;
12. Use VALENIAN multi-channel vibration analyzer and software dynamic balance calculation function to perform dynamic balance correction on the rotor disk;
Experimental precautions:
1. Keep the emergency stop button and red power button in the pop-up mode. At this time, the frequency converter has been powered on and will display the current motor operating frequency.
2. To simulate an unbalanced experiment, M5 bolts can be installed on the rotor disk to artificially create an unbalanced amount, which is directly related to the vibration magnitude of the rotor and the amount of unbalanced mass added. (Only sample M5 bolts are provided. Customers can freely add the number and length of bolts according to their desired imbalance, and precise adjustments can be made by adding bolt washers.)
3. The acrylic safety cover must be closed before the equipment can be powered on.
4. The bearing seat provided by our company is equipped with sensor fixing bolt holes, which have been pre-set as M6 fixing bolt holes.
5. After the device is completely powered off and stops running, the setting change operation can be carried out;
6. Be careful of rotating machinery causing injury. When the equipment is started, personnel should maintain a certain safe distance;
7. Vibration data can only be collected when the device's rotational speed is stable;
8. Please collect vibration data at a constant speed to ensure the consistency of experimental data;
The impact of device misalignment on the device
More than 70% of unplanned shutdowns of rotating equipment are caused by shaft misalignment. These unplanned shutdowns have led to increased maintenance costs and production losses. In addition, misalignment of the shaft can increase the vibration and wear of the machine, increase energy consumption, and lead to bearing, seal, and even coupling failures, shortening the mechanical life.
Laser alignment instrument can provide precise spindle alignment during equipment maintenance or installation, eliminating the main source of vibration faults. Compared to traditional dial gauge alignment, laser centering instruments make this task fast and accurate. The high-precision, multifunctional, easy to learn, and user-friendly interface makes it an ideal tool for shaft alignment of rotating equipment such as motors, water pumps, compressors, centrifuges, etc.
Experimental title: Coupling shaft alignment correction
Experimental objective: Over 70% of unplanned shutdowns of rotating equipment are caused by misalignment of the shaft. These unplanned shutdowns have led to increased maintenance costs and production losses. In addition, misalignment of the shaft can increase the vibration and wear of the machine, increase energy consumption, and lead to bearing, seal, and even coupling failures, shortening the mechanical life. Laser alignment instrument can provide precise spindle alignment during equipment maintenance or installation, eliminating the main source of vibration faults.
Experimental equipment:
1. PT300 dynamic balance shaft centering simulation platform;
2. Laser centering device;
3. Different specifications of gaskets such as 0.5mm, 0.3mm, 0.2mm, and 0.1mm;
4. Adjustable wrench;
5. One set of hexagonal wrenches;
Experimental process:
Firstly, power off the experimental platform;
2. Adjust the shafts on both sides of the coupling to a reasonable position;
3. Install the laser alignment device;
4. Complete data measurement according to instrument prompts;
5. Align the equipment according to tolerance standards;
Experimental precautions:
1. After the device is completely powered off and stops running, the setting change operation can be carried out;
2. First, conduct a soft foot test to eliminate any adverse factors that may affect the alignment;
3. Choose an appropriate deviation value based on the operating speed of the equipment;
The comprehensive simulation experimental platform for mechanical motors is designed specifically for simulating industrial gear faults and is used for in-depth research on bearing and gear transmission systems. It consists of a rolling bearing, dynamic balance correction rotor disc, planetary gearbox, magnetic powder brake, and two-stage parallel shaft gearbox. Reserve enough space to place a vibration data collector to collect vibration signals. Its structure is easy to install and replace gears. The two-stage parallel axis gearbox can be designed to switch between good and faulty gears at any time according to experimental needs. And it can test for defects in rolling bearings, such as damage to the inner ring, outer ring, and ball bearings. Visual load control can be performed in gear testing, and gear clearance adjustment can be made to study different gear clearances. Different types of gear faults can be integrated into the gearbox, and tested one by one through various faulty gears, or two types of faulty gears can be placed simultaneously to study the interaction between different gear faults, as well as to study the fault characteristics of planetary gears, such as large ring gear faults, sun gear faults, planetary gear faults, etc.
VALENIAN It was reconstructed in 2018 with 12.00 million RMB registered capital, and has invested more than 100 million RMB, Our company owns 17000 square meter land, with a total of 11000 square meters facility and 2400 square meter 100,000 Grade clean room. 2018,1200,1.17000, 11000,102400.Location:VALENIAN Teaching equipment Locates at KunShan, the most industrialized and developed area in JiangSu Province, just next to Shanghai.VALENIAN Teaching equipment,.Employees:About 300 staff, Marketing department, research and development department, manufacturing department, quality regulation and logistics department
