Multifunctional Mechanical Failure Simulator

Product DescriptionMechanical failure simulation test bench-The PT700 Rotating Machinery Comprehensive Fault Diagnosis simulation test bench can simulate defects such as missing teeth, broken teeth, wear, and cracks in multi-stage gearboxes.The PT700 test bench can simulate a variety of common rotating machinery failures, including faulty motors, gear transmission failures including multi-stage transmission gears and single-stage transmission planetary gearboxes and bearing failures, faulty belt drive systems, oil circulation systems, rotor dynamic balance test modules, start-stop tests, shaft friction tests, and life prediction. Combined with changes in load, speed, lubrication and other working conditions, it supports dynamic analysis of gearboxes, vibration diagnosis and study of fault expansion mechanisms, and provides validation data for health monitoring algorithms.The PT700 test bench is mainly composed of equipment base plate platform, three-phase asynchronous variable frequency motor, frequency converter, belt drive system, bearing rotor system, dynamic balance rotor disk assembly, two-stage drive straight gearbox, planetary gearbox, magnetic powder brake, oil circulation system, magnetic powder loading control unit, safety guard, etc.- Simulate motor faults: rotor unbalanced motor, rotor eccentric motor, shaft bent motor, bearing faulty motor, rotor bar faulty motor, stator winding faulty motor, voltage unbalanced and single-phase motor. - Faulty bearing simulation: Inner ring failure of bearing, outer ring failure of bearing, rolling element failure of bearing, cage failure of bearing, comprehensive failure of bearing. - Multi-stage gear fault simulation: missing teeth, broken teeth, wear, cracks. Planetary gear fault simulation: missing teeth, broken teeth, wear, crack. - Common mechanical faults: mechanical loosening, friction, misalignment test, rotor dynamic balance test. - At different speeds: identification of bearing failure frequency and gear failure frequency. - Vibration characteristics study, start-stop test under different working conditions. Study on vibration characteristics under different torque loads.• Practice of vibration measurement• Time-domain waveforms, frequency analysis• Best choice for the position of the vibration sensor• Phase measurement, rotational speed pulse signal application• Effects of mass imbalance• Multi-faceted dynamic balance• Effects of axis misalignment• Practice of multilevel axis alignment• Soft foot correction• Start-stop test• Research on the critical speed of the shaft• MODAL analysis, ODS measurement• Bearing failure study• Time-domain & frequency analysis of faulty bearings• Gear failure analysis• The influence of gear clearance• Analysis of helical gear problems• Oil analysis & Friction grain analysis• Low-speed mechanical vibration analysis• Research on methods for detecting faulty bearings at low speeds• Mechanical condition monitoring practice • Practice of vibration measurementIt can simulate different load conditions by applying loads of different magnitudes to the output shaft through the loading device, simulating the various loads that the gearbox is subjected to in actual operation. At the same time, combined with the motor speed adjustment function, it can simulate complex conditions with different speeds and different torques of load combinations, making the experiment more in line with the actual operating scenarios.产品描述机械故障模拟试验台——PT700旋转机械综合故障诊断模拟试验台可模拟多级变速箱缺齿、断齿、磨损、裂纹等缺陷。PT700试验台可模拟多种常见的转动机械故障，包括故障电机、包括多级变速器齿轮和单级变速器行星齿轮箱在内的齿轮变速器故障以及轴承故障、故障皮带驱动系统、油循环系统、转子动平衡试验模块、启停试验、轴摩擦试验以及寿命预测。结合负载、转速、润滑等工况变化，支持变速箱动态分析、振动诊断和故障扩展机理研究，为健康监测算法提供验证数据。PT700试验台主要由设备底板平台、三相异步变频电机、变频器、皮带驱动系统、轴承转子系统、动平衡转子盘总成、两级驱动直齿轮箱、行星齿轮箱、磁粉制动器、油循环系统、磁粉加载控制单元、安全防护装置等组成。-模拟电机故障：转子不平衡电机、转子偏心电机、轴弯电机、轴承故障电机、转子排故障电机、定子绕组故障电机、电压不平衡单相电机。-故障轴承模拟：轴承内圈故障、轴承外圈故障、轴承滚动体故障、轴承保持架故障、轴承综合故障-多级齿轮故障模拟：缺齿、断齿、磨损、裂纹。行星齿轮故障模拟：缺、齿、磨损、开裂。-常见机械故障：机械松动、摩擦、对中试验、转子动平衡试验。-在不同速度下：识别轴承故障频率和齿轮故障频率。-不同工况下的振动特性研究、启停试验。不同载荷下振动研究。•振动测量实践•时域波形、频率分析•振动传感器位置的选择•相位测量、转速脉冲信号应用•质量不平衡的影响•多面动平衡•轴未对准的影响•多级轴对准的实践•软脚校正•启停测试•轴临界转速研究•MODAL分析、ODS测量•轴承故障研究•故障轴承的时域和频率分析•齿轮故障分析•齿轮间隙的影响•斜齿轮问题分析•油分析和摩擦晶粒分析•低速机械振动分析•低速检测故障轴承的方法研究•机械条件监测实践•振动测量实践通过加载装置对输出轴施加不同大小的载荷，模拟变速箱在实际运行中所承受的各种载荷，从而模拟不同的载荷工况。同时，结合电机调速功能，可以模拟负载组合不同转速、不同扭矩的复杂工况，使实验更符合实际运行场景。变速箱在输入轴上有三个25齿齿轮，中间轴上有58齿和28齿齿轮，输出轴上有两个60齿齿轮。插入中间轴的齿轮可左右滑动，与正常或有缺陷的齿轮啮合。PT700具有一个变速比为10:1的行星变速箱，其设计工作方式与风机中的齿轮变速器相似。当测试台的电机转速为1800 RPM时，平行齿轮箱的传动比4.97:1减小到360 RPM，并且行星齿轮的传动比10:1再次减小到36 RPM。这允许您在高速、中速和低速下测试振动和电流信号症状。通过更换有缺陷的行星齿轮部件，可以深入研究缺陷导致的行星齿轮振动现象。有缺陷的行星齿轮可作为选购件订购平台装有两个轴承箱，每个轴承箱有一个正常的轴承，可通过更换故障轴承进行测试。故障轴承模拟：轴承内圈故障、轴承外圈故障、轴承滚动体故障、轴承保持架故障、综合轴承故障（也可选择不同的故障类型和严重程度）机械松动介质测试错位跛行问题转轴摩擦单边、多边动平衡变速箱设有润滑油循环口，并设有单独的开关装置和油显示装置，实时监测润滑油的水分、金属粒径等。，电机研究（可选）1.转子不平衡交流电机（RUM-1）2。转子偏心交流电机（RMM-1）3。轴弯曲交流电机（BRM-1）4。轴承故障交流电机（FBM-1）5。交流电机（BBM-1）转子排故障6。交流电机（WFM-1）定子绕组故障7。电压不平衡和单相交流电机（SPM-1）开展轴承磨损发展过程基础研究滚动轴承和润滑油轴承的损伤和劣化趋势建模分析了解轴承故障机理与轴承负载和速度之间的关系基于滚动轴承损伤、运行速度、负载类型和负载尺寸的发展建立轴承剩余寿命预测模型研究用于监测轴承状态的传感器类型和信号处理技术用于监测寿命预测振动、电机电流、负载、摩擦和噪声谱之间的关联结构设计，为传感器位置预留足够的空间，可根据不同类型的传感器采用多种方式（如加速度、涡流、噪声、温度、转速、应变、电流、电压、油等）进行安装，可任意设置安装位置（如电机、轴承、转子系统、变速箱系统上），配合采集系统（如DC24声学振动采集器）可实现多通道同步信号采集和频谱分析，并可导出原始数据进行二次开发。供大学科研人员研究使用大专院校教学培训各系统内科研院所模拟实验企业工厂对设备状态监测进行振动训练技术公司研发检测部门验证使用经过十多年的积累，VALENIAN教学设备拥有一个经验丰富的售后团队。Valenian教学设备公司非常重视用户的实验安全和操作经验，并保证无论用户购买了多少年，只要与我们的售后团队联系，就可以在实验室工作台上享受免费的操作指导。项目名称性能参数及技术要求基本部件单元由三相异步电机、两级平行轴变速箱、皮带传动系统、油循环单元、双支撑试验轴承箱单元、行星齿轮箱、磁粉制动器、调速及转速显示模块、负载显示调节模块、转速脉冲输出模块、安全保护磁吸断电保护开关系统、RUZ变频器通讯模块等组成。驱动电机高效ABB三相交流电机，功率2HP，25°C时电缆电阻6.0Ω，36个定子槽，28个转子排，电机功率因数76%电源输入模块额定电流10A，带过电流保险，带电源滤波功能。电机电源快速插头3P带接地快速接头，便于电机更换，ABS塑料用于高压保护。交流变频器变频器频率范围：0-599Hz，额定输入：200-240V，50/60Hz，18.5A，额定输出：3PH 0-230V 8.5A，3.2KVA 1.5KW速度调整模式通过旋转TOCOS精密电位计以及高电阻和低电阻速度控制旋钮精确调整速度每分钟1转时的转速控制精度1RPM转速调整范围0-1750转/分可调（短时运行时可达6000转/分）润滑油循环系统配备直流24V齿轮循环油泵，出口流量：12L/min，扬程：3m，出口压力：3bar，管径12.7mm转速测量模块使用漫反射激光转速计进行脉冲信号采集，最大采集距离为130mm，最小检测目标直径为0.04mm。激光信号传输器电源电压：12-24VDC，响应时间：小于0.5ms，绝缘阻抗：大于20兆欧转速显示模块传感器电源：12VDC±10%，80mA，绝缘阻抗：100兆欧以上，数字实时显示，可切换Hz，RPM，显示范围0-99999，测量精度误差小于0.05%。项目名称性能参数及技术要求电机驱动控制接口NEUTRIK针脚1:+15V针脚2:GNDP针脚3:SG针脚4:SG针脚5:NC针脚6:通讯磁安全开关触点形式：SPST，触点类型：磁触点，触点额定值：10VAt200V，磁吸类型：Alnico 5。开关1控制电机启停开关开关2控制变速箱油循环系统输出油泵开关铝片带减震底座h*高度The gearbox is equipped with three 25-tooth gears on the input shaft, 58-tooth and 28-tooth gears on the intermediate shaft, and two 60-tooth gears on the output shaft. The gears inserted into the intermediate shaft can slide left or right to engage with normal or defective gears.The PT700 has a planetary gearbox with a transmission ratio of 10:1, which is designed to work in a similar way to gear transmission in wind turbines. When the test bench's motor speed is 1800 RPM, the ratio of the parallel gearbox, 4.97:1, is reduced to 360 RPM, and the ratio of the planetary gear, 10:1, is reduced again to 36 RPM. This allows you to test vibration and current signal symptoms at high, medium, and low speeds. By replacing the defective planetary gear component, you can delve into the phenomenon of planetary gear vibration caused by the defect. Defective planetary gears can be ordered as an optionThe platform is fitted with two bearing housings, each with a normal bearing. It can be tested by replacing the faulty bearing.Faulty bearing simulations: faulty inner ring of the bearing, faulty outer ring of the bearing, faulty rolling elements of the bearing, faulty bearing cage, faulty comprehensive bearing. (Different fault types and severity of the bearings can also be selected)Mechanical loosening Misaligned medium test Limp problems Rotating shaft friction Single-sided, multi-sided dynamic balanceThe gearbox is equipped with a lubricating oil circulation port, along with a separate switch device and an oil display device for real-time monitoring of the lubricating oil moisture, metal particle size, etc.,Motor research (optional)1. Rotor unbalanced AC motor (RUM-1) 2. Rotor eccentric AC motor (RMM-1) 3. Shaft bending AC motor (BRM-1) 4. Bearing failure AC motor (FBM-1) 5. Rotor bar fault AC motor (BBM-1) 6. Stator winding fault AC motor (WFM-1) 7. Voltage imbalance and single-phase AC motor (SPM-1)Conduct fundamental research on the development process of bearing wear Modeling and analysis of damage and deterioration trends of rolling bearings and grease-lubricated bearings Understand the relationship between the bearing failure mechanism and the bearing load and speed Develop a bearing remaining life prediction model based on the development of rolling bearing damage, operating speed, type of load, and load size Research on sensor types and signal processing techniques for bearing condition monitoring life prediction Correlation between vibration, motor current, load, friction and noise spectraStructural design with sufficient space reserved for sensor positions, which can be installed in various ways (such as acceleration, eddy current, noise, temperature, speed, strain, current, voltage, oil, etc.) according to different types of sensors, The installation position can be set at will (such as on the motor, bearing, rotor system, gearbox system), and in conjunction with the acquisition system (such as the DC24 acoustic vibration collector), multi-channel synchronous signal acquisition and spectral analysis can be achieved, and the original data can be exported for secondary development.For research use by university researchers Teaching and training in colleges and universities Research institute simulation experiments within each system The enterprise factory conducts vibration training for equipment condition monitoring Technology companies' R&D testing departments verify the useAfter more than a decade of accumulation, VALENIAN Teaching Equipment has an experienced after-sales team. Valenian Teaching Equipment Company attaches great importance to users' experimental safety and operation experience, and guarantees that no matter how many years users have purchased this platform, as long as they contact our after-sales team, they can enjoy free operation guidance on the laboratory bench.Project namePerformance parameters and technical requirementsBasic component unitsIt consists of three-phase asynchronous motor, two-stage parallel shaft gearbox, belt drive system, oil circulation unit, double support test bearing housing unit, planetary gearbox, magnetic powder brake, speed regulation and speed display module, load display regulation module, speed pulse output module, safety protection magnetic suction power-off protection switch system, RUZ frequency converter communication module.Drive motorHigh-efficiency ABB three-phase AC motor, power 2HP, wireline resistance 6.0 Ω @ 25 ° C, 36 stator slots, 28 rotor bars, motor power factor 76%Power input moduleRated current 10A, with overcurrent fuse, with power filtering function.Motor power quick plug connector3P with ground quick connector for easy motor replacement, ABS plastic for high voltage protection.Ac frequency converterInverter frequency range: 0-599Hz, rated input: 200-240V, 50/60Hz, 18.5A, rated output: 3PH 0-230V 8.5A,3.2KVA 1.5KWSpeed adjustment modeThe speed is precisely adjusted by rotating the TOCOS precision potentiometer in conjunction with high resistance and low resistance speed control knobsSpeed control accuracy1RPM at 1 revolutions per minuteSpeed adjustment range0-1750RPM adjustable (up to 6000RPM for short runs)Lubricating oil circulation systemEquipped with DC 24 v gear circulating oil pump, outlet flow: 12L/min, head: 3 m, outlet pressure: 3bar, piping diameter 12.7mmRotational speed measurement modulePulse signal acquisition was carried out using a diffuse reflection laser tachometer, with a maximum acquisition distance of 130mm and a minimum detection target diameter of 0.04mm.Laser signal transmitterPower supply voltage: 12-24VDC, response time: less than 0.5ms, insulation impedance: more than 20 megohmsRotational speed display moduleSensor power supply: 12VDC±10%, 80mA, insulation impedance: above 100 megohms, numerical real-time display, switchable Hz,RPM, display range 0-99999, measurement accuracy error less than 0.05%.Project namePerformance parameters and technical requirementsMotor drive control interfaceNEUTRIK Pin 1: +15V , Pin 2: GNDPin 3: SG- Pin 4: SG +Pin 5: NC Pin 6: for communicationMagnetic safety switchContact form: SPST, contact type: Magnetic Contact, contact rating: 10Vat 200V, magnetic attraction type: Alnico 5.Switch 1Control the motor start stop switchSwitch 2Control the gear box oil circulation system output oil pump switchSwitch 3Control the magnetic powder brake F switch and load to the same setting as beforeSwitch 4Control whether the magnetic powder cooling fan is on or offInput voltage220 VAC, single-phase, 60/50 HzBase platePrecisely machined 15mm aluminium sheet with a shock-absorbing baseMotor centering mechanismOne end of the motor is equipped with a jack alignment adjustment bolt for convenient shaft alignment adjustmentSafety protectionThe front panel has an emergency stop button, the rotating rotor section has an acrylic shield, and there is also a magnetic switch device to protect against power-off.Environment of Use-10~50°C, 35~85RHDimensions1700mm*500*500 length * width * height