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.產品描述機械故障模擬試驗臺——PT700旋轉機械綜合故障診斷模擬試驗臺可模擬多級變速箱缺齒、斷齒、磨損、裂紋等缺陷。PT700試驗臺可模擬多種常見的轉動機械故障，包括故障電機、包括多級變速器齒輪和單級變速器行星齒輪箱在內的齒輪變速器故障以及軸承故障、故障皮帶驅動系統、油循環系統、轉子動平衡試驗模塊、啟停試驗、軸摩擦試驗以及壽命預測。結合負載、轉速、潤滑等工況變化，支持變速箱動態分析、振動診斷和故障擴展機理研究，為健康監測算法提供驗證數據。PT700試驗臺主要由設備底板平臺、三相異步變頻電機、變頻器、皮帶驅動系統、軸承轉子系統、動平衡轉子盤總成、兩級驅動直齒輪箱、行星齒輪箱、磁粉制動器、油循環系統、磁粉加載控制單元、安全防護裝置等組成。-模擬電機故障：轉子不平衡電機、轉子偏心電機、軸彎電機、軸承故障電機、轉子排故障電機、定子繞組故障電機、電壓不平衡單相電機。-故障軸承模擬：軸承內圈故障、軸承外圈故障、軸承滾動體故障、軸承保持架故障、軸承綜合故障-多級齒輪故障模擬：缺齒、斷齒、磨損、裂紋。行星齒輪故障模擬：缺、齒、磨損、開裂。-常見機械故障：機械松動、摩擦、對中試驗、轉子動平衡試驗。-在不同速度下：識別軸承故障頻率和齒輪故障頻率。-不同工況下的振動特性研究、啟停試驗。不同載荷下振動研究。•振動測量實踐•時域波形、頻率分析•振動傳感器位置的選擇•相位測量、轉速脈沖信號應用•質量不平衡的影響•多面動平衡•軸未對準的影響•多級軸對準的實踐•軟腳校正•啟停測試•軸臨界轉速研究•MODAL分析、ODS測量•軸承故障研究•故障軸承的時域和頻率分析•齒輪故障分析•齒輪間隙的影響•斜齒輪問題分析•油分析和摩擦晶粒分析•低速機械振動分析•低速檢測故障軸承的方法研究•機械條件監測實踐•振動測量實踐通過加載裝置對輸出軸施加不同大小的載荷，模擬變速箱在實際運行中所承受的各種載荷，從而模擬不同的載荷工況。同時，結合電機調速功能，可以模擬負載組合不同轉速、不同扭矩的復雜工況，使實驗更符合實際運行場景。變速箱在輸入軸上有三個25齒齒輪，中間軸上有58齒和28齒齒輪，輸出軸上有兩個60齒齒輪。插入中間軸的齒輪可左右滑動，與正?；蛴腥毕莸凝X輪嚙合。PT700具有一個變速比為10:1的行星變速箱，其設計工作方式與風機中的齒輪變速器相似。當測試臺的電機轉速為1800 RPM時，平行齒輪箱的傳動比4.97:1減小到360 RPM，并且行星齒輪的傳動比10:1再次減小到36 RPM。這允許您在高速、中速和低速下測試振動和電流信號癥狀。通過更換有缺陷的行星齒輪部件，可以深入研究缺陷導致的行星齒輪振動現象。有缺陷的行星齒輪可作為選購件訂購平臺裝有兩個軸承箱，每個軸承箱有一個正常的軸承，可通過更換故障軸承進行測試。故障軸承模擬：軸承內圈故障、軸承外圈故障、軸承滾動體故障、軸承保持架故障、綜合軸承故障（也可選擇不同的故障類型和嚴重程度）機械松動介質測試錯位跛行問題轉軸摩擦單邊、多邊動平衡變速箱設有潤滑油循環口，并設有單獨的開關裝置和油顯示裝置，實時監測潤滑油的水分、金屬粒徑等。，電機研究（可選）1.轉子不平衡交流電機（RUM-1）2。轉子偏心交流電機（RMM-1）3。軸彎曲交流電機（BRM-1）4。軸承故障交流電機（FBM-1）5。交流電機（BBM-1）轉子排故障6。交流電機（WFM-1）定子繞組故障7。電壓不平衡和單相交流電機（SPM-1）開展軸承磨損發展過程基礎研究滾動軸承和潤滑油軸承的損傷和劣化趨勢建模分析了解軸承故障機理與軸承負載和速度之間的關系基于滾動軸承損傷、運行速度、負載類型和負載尺寸的發展建立軸承剩余壽命預測模型研究用于監測軸承狀態的傳感器類型和信號處理技術用于監測壽命預測振動、電機電流、負載、摩擦和噪聲譜之間的關聯結構設計，為傳感器位置預留足夠的空間，可根據不同類型的傳感器采用多種方式（如加速度、渦流、噪聲、溫度、轉速、應變、電流、電壓、油等）進行安裝，可任意設置安裝位置（如電機、軸承、轉子系統、變速箱系統上），配合采集系統（如DC24聲學振動采集器）可實現多通道同步信號采集和頻譜分析，并可導出原始數據進行二次開發。供大學科研人員研究使用大專院校教學培訓各系統內科研院所模擬實驗企業工廠對設備狀態監測進行振動訓練技術公司研發檢測部門驗證使用經過十多年的積累，VALENIAN教學設備擁有一個經驗豐富的售后團隊。Valenian教學設備公司非常重視用戶的實驗安全和操作經驗，并保證無論用戶購買了多少年，只要與我們的售后團隊聯系，就可以在實驗室工作臺上享受免費的操作指導。項目名稱性能參數及技術要求基本部件單元由三相異步電機、兩級平行軸變速箱、皮帶傳動系統、油循環單元、雙支撐試驗軸承箱單元、行星齒輪箱、磁粉制動器、調速及轉速顯示模塊、負載顯示調節模塊、轉速脈沖輸出模塊、安全保護磁吸斷電保護開關系統、RUZ變頻器通訊模塊等組成。驅動電機高效ABB三相交流電機，功率2HP，25°C時電纜電阻6.0Ω，36個定子槽，28個轉子排，電機功率因數76%電源輸入模塊額定電流10A，帶過電流保險，帶電源濾波功能。電機電源快速插頭3P帶接地快速接頭，便于電機更換，ABS塑料用于高壓保護。交流變頻器變頻器頻率范圍：0-599Hz，額定輸入：200-240V，50/60Hz，18.5A，額定輸出：3PH 0-230V 8.5A，3.2KVA 1.5KW速度調整模式通過旋轉TOCOS精密電位計以及高電阻和低電阻速度控制旋鈕精確調整速度每分鐘1轉時的轉速控制精度1RPM轉速調整范圍0-1750轉/分可調（短時運行時可達6000轉/分）潤滑油循環系統配備直流24V齒輪循環油泵，出口流量：12L/min，揚程：3m，出口壓力：3bar，管徑12.7mm轉速測量模塊使用漫反射激光轉速計進行脈沖信號采集，最大采集距離為130mm，最小檢測目標直徑為0.04mm。激光信號傳輸器電源電壓：12-24VDC，響應時間：小于0.5ms，絕緣阻抗：大于20兆歐轉速顯示模塊傳感器電源：12VDC±10%，80mA，絕緣阻抗：100兆歐以上，數字實時顯示，可切換Hz，RPM，顯示范圍0-99999，測量精度誤差小于0.05%。項目名稱性能參數及技術要求電機驅動控制接口NEUTRIK針腳1:+15V針腳2:GNDP針腳3:SG針腳4:SG針腳5:NC針腳6:通訊磁安全開關觸點形式：SPST，觸點類型：磁觸點，觸點額定值：10VAt200V，磁吸類型：Alnico 5。開關1控制電機啟停開關開關2控制變速箱油循環系統輸出油泵開關鋁片帶減震底座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