A New Experimental Platform for Bearing Fault Prediction Research - BPS

SpectraQuest has developed a new bearing fault prediction experimental platform (BPS) for studying bearing wear and bearing damage processes. A prominent feature of BPS is the use of sensors designed by SpectraQuest to measure bearing friction torque, axial and radial loads. This experimental platform can operate in three optional modes: (1) constant speed, (2) pure oscillation, and (3) oscillation and rotational superposition motion. Research can be conducted on rolling bearings, oil film lubricated bearings, and grease sliding bearings. Obtain unique data of the current bearing through friction torque sensors and pressure sensors, study bearing fault characteristics, and establish a bearing fault prediction model. This experimental platform can establish a prediction model for the remaining life of bearings by routine monitoring of their operating status. This torque sensor measures several thousand pounds of axial and radial loads under low friction torque and has high sensitivity. This experimental platform minimizes noise as much as possible through oil film lubrication, and can also provide a higher speed and larger load experimental platform.

Intelligent experimental platform for accelerating bearing failure experiments

Bearings are important components of rotating machinery. Unexpected bearing failures can cause production shutdowns, resulting in significant economic losses and irreparable damage. Most state monitoring programs regularly detect bearing vibration and analyze fault characteristics to assess its health status, i.e. estimate its degree of damage. Strict evaluation based on historical data or statistical analysis leads to misjudgment and premature replacement of bearings, resulting in production losses. At present, it is difficult to establish a bearing health prediction model, possibly due to the lack of an accelerated testing platform for bearing faults and sensors for detecting key parameters. SpectraQuest's BPS fills these gaps.

advantage:

·Basic research on bearing wear process

·Study the deepening mechanism of damage in rolling bearings, oil film sliding bearings, and grease lubricated bearings

·Understand the relationship between bearing failure mechanism and load, speed, and bearing oscillation

·Research on the Remaining Life Prediction Model of Bearings Based on Damage Development, Speed, Amplitude, and Loading Type

·Research signal processing technology and sensing technology for state monitoring of bearing fault prediction

·Study the relationship between vibration, motor current, load, friction, and noise

·Validate model-based fault diagnosis and prediction algorithms

A bearing fault prediction experimental platform equipped with rolling bearings and stepper motors

Features:

·Modular, robust, and multifunctional experimental platform for bearing fault prediction research

·Simultaneously measure radial and axial loads as well as friction torque of bearings

·The designed intelligent friction torque sensor is used to measure the small friction torque of bearings under heavy loads

·Programmable motors can input parameters for constant speed and oscillatory motion with and without rotational speed

·Equipped with rolling bearings for testing, grease lubricated bearings, and oil film sliding bearings

·Interchangeable variable speed AC motors and servo motors for different types of loads

·Easy to operate hydraulic bearing loading system

·Easy to install and remove test bearings

Measurable force bearing loading system

The bearing fault prediction simulation test bench (BPS) of SpectraQuest's company uses hydraulic methods to achieve axial and radial loading of bearings. Conduct tests to observe the occurrence and propagation of different types of bearing damage. This experimental platform can operate in three different modes: (1) constant speed, (2) oscillatory motion, and (3) combined oscillatory and rotational motion. A PC programmable variable frequency AC asynchronous motor is used to provide speeds up to 6000 revolutions per minute (higher speeds can be provided according to requirements), while a programmable stepper motor can be used for oscillating motion or low speeds (10-180 revolutions per minute). These two types of motors can be interchanged and easily installed on the BPS experimental platform.

Test the cantilever installation of bearings, with two heavy-duty rolling bearings used for support. We can provide oil film bearing systems according to customer requirements. Choosing cantilever installation facilitates bearing loading and measurement of friction torque during testing. The hydraulic loading system can be used for axial and radial loading of bearings. The hydraulic system consists of oil cylinders, valves, hand pumps, pressure gauges, pressure sensors, and loading cylinders. This loading system can provide a radial load of 6000 pounds (approximately 27KN) to the bearing seat. The pressure sensor is installed between the loading cylinder and the test bearing seat to measure the force applied by the system.

Force measured under oscillating load

Pressure sensors are based on strain gauges and are independently developed to measure the force applied by the system and analyze the impact of increased wear on bearing signals. This sensor ensures that the force is applied to the bearing centerline by adjusting the direction and point of application of the system loading force, which is the most important aspect of loading.

Ideal tool for studying the friction torque characteristics of bearings

As bearing damage progresses, the friction characteristics between the rotating and stationary parts of the bearing will change. The bearing friction torque sensor system is designed to complete characteristic research. This new type of sensor can eliminate torque related to bending forces and minimize the influence of supporting structures. It can also be used for on-site adjustment to eliminate the impact of increased lateral loads on support deformation. This clever design can obtain information on the friction torque as the bearing damage intensifies. Information can be used to characterize bearing failure mechanisms and develop fault prediction models.

Easy to assemble and durable bearing fault prediction experimental platform

The bearing fault prediction experimental platform is easy to dismantle and install for testing bearings. This device is suitable for installing different types of bearings such as rolling bearings, oil film bearings, and grease lubricated bearings. A complete oil circulation system includes a pump that provides oil pressure for testing bearings. This experimental platform has powerful functions and high lateral stiffness, and will not yield when thousands of pounds of force are applied to the test bearings. The test bearing seat is easy to install and remove bearings. Provided the necessary accessories for installing sensors. The bearing fault prediction experimental platform is installed on the isolation block to minimize vibration transmission in the surrounding environment.

Sensors and data collection

The acceleration sensor is installed on the bearing seat to measure vibrations in three directions. Temperature sensors can also be used for temperature monitoring and analysis of bearing outer rings, and residual lubricating oil can be collected for lubrication and bearing condition analysis. Other sensors can also be installed according to customer requirements. Spectra Quest provides data acquisition hardware and software for time-domain and frequency-domain signal analysis.

Structure and optional kits of bearing fault prediction experimental platform

The bearing fault prediction experimental platform provides the basic configuration for conducting experiments and studying the vibration characteristics of bearing faults. Detailed fault prediction research requires obtaining the required accessories and devices through optional kits.

Lateral pressure sensor (BP-TFT)

·Measure the lateral force applied to the test bearing

·Study on the fluctuation of lateral force during the rotation of worn bearings

·Study the response of lateral force to oscillatory torsional load

·Signal analysis of intensified bearing wear

·This kit includes an axial pressure sensor and a signal conditioner

Friction torque sensor (BP-FTT)

·Study the characteristics of friction between rotating and stationary components

·Study the Evolution of Friction Bearing Wear

·This kit includes a friction torque sensor, a torque frame, and a signal conditioner

Oil lubricated bearings (BP-GR)

·Basic research on the wear evolution of grease lubricated bearings

·Establish a model for damage propagation mechanism

·Validate model-based diagnostic and predictive algorithms

·This kit includes grease lubricated bearings, wheel hubs, and installation accessories

Stepper Motor (BP-STEP)

·Study on the Mode of Bearing Wear under Oscillatory Load

·Study the response of bearings to fluctuating loads

·This kit includes a stepper motor, a controller, and an encoder

Axial Force Loader (BP-AXL)

·Research and modeling of bearing wear under axial load

·This kit includes an axial loader and installation accessories

Axial force sensor (BP-AFT)

·Measure the axial load of the spindle under dynamic excitation

·Study the phase relationship between force and vibration spectrum

·Study the response of axial force to rotational speed and axial load

·Validate and improve rotor dynamics models to enhance modeling capabilities

·This kit includes an axial force sensor and a signal conditioner

·Should be used in conjunction with BP-AXL

Oil film lubricated bearings (BP-OIL)

·Reduce the vibration signal of the supporting bearings on the experimental platform and improve the signal quality of the tested bearings

·This kit includes oil film lubricated bearings, installation accessories, oil system with pump, pressure gauge, stainless steel oil tank, reflux safety switch, pressure gauge, and pressure interlock

Impact resistant transparent protective cover (BP-COV)

·In order to improve safety, the impact resistant transparent protective cover with lock is equipped with an electric motor interlock switch. When the protective cover is opened, the electric motor automatically stops

·This kit includes a polycarbonate safety cover