The Best Experimental Platform for Reliability Research of Power Transmission System

SpectraQuest has specially designed a power transmission fault diagnosis comprehensive experimental platform (DDS) that can simulate industrial power transmission, which can be used for experiments and teaching. The power transmission system consists of a two-stage planetary gearbox, a two-stage parallel shaft gearbox supported by rolling bearings or sleeve bearings, a bearing load, and a programmable magnetic brake. This experimental platform includes all the necessary configurations for power transmission and is suitable for studying the dynamics and noise characteristics, health monitoring, and vibration characteristics of gearboxes based on diagnostic techniques, lubrication conditions, and wear particle analysis. The experimental platform has stable performance, can withstand strong load impacts, and has sufficient space for gear replacement, installation, and monitoring device installation. This two-stage parallel axis transmission gearbox facilitates the change of gear transmission ratio. The planetary gear system, sun gear, planetary and ring gears, brackets, and bearings are all easy to disassemble and assemble.

Fault diagnosis of flexible power transmission

This experimental platform can simulate faults such as tooth surface wear, tooth cracks, tooth surface pitting, and missing teeth of straight and helical teeth. It can also simulate faults in the inner and outer rings, rolling elements, and their coupling faults of rolling bearings. The effect of backlash can be studied by adjusting the backlash: increasing backlash does not result in serious consequences (except for increased noise and rotational play), while reducing backlash may lead to tooth surface adhesion and increased operating temperature. Power transmission misalignment can also be introduced. It is possible to introduce a single fault or multiple faults simultaneously and study their coupling effects. The damage and expansion characteristics of gears and bearings are studied by loading torsional and radial loads. The torsional load can be loaded by programming a custom speed using a 3-horsepower AC variable frequency drive motor, while the radial load can be loaded on the axis of a parallel gearbox. By using programmable magnetic brakes, it is possible to simulate the rapid fluctuation effect of actual loads on site.

Features:

● 2nd stage planetary gearbox and 2nd stage oil lubricated parallel shaft gearbox.

Gears can slide along parallel axes to change the stiffness of the system and provide sufficient space for other devices.

Suitable for spur gears and helical gears.

Damaged or worn faulty gears can be used for the study of vibration characteristics.

● You can choose between rolling bearings or sleeve bearings.

Obtain the required tooth clearance for the study by replacing the bearing mounting plate.

Modular design can better introduce bearing faults and gear faults.

Composite installation positioning components facilitate the installation of various sensors.

● Facilitate the research of fault diagnosis technology and advanced signal processing methods.

● Variable speed loading for torsional and radial loads.

The PC controls the magnetic brake connected to the output shaft to provide load.

The brake can be replaced with an additional device.

Easy to assemble heavy-duty equipment

DDS can quickly and conveniently replace gearbox and bearing components, suitable for spur and helical gears. Modular design can better introduce gear faults. Composite installation positioning components facilitate the installation of various sensors. The motor, gearbox, and magnetic brake are installed on a half inch thick aluminum base with reinforcing plates and isolation blocks to reduce vibration.

Sensors and data acquisition systems

The design of the power transmission system facilitates the installation of various sensors. The accelerometer can be installed on the gearbox and bearing seat to measure vibration signals in three directions. Torque sensors can accurately measure torsional loads. The input and output shafts are matched with encoders and tachometers for measuring transmission errors and time-domain synchronization averages. Other sensors can also be installed according to customer needs. The data acquisition software and hardware system designed by Spectra Quest can be used for signal acquisition and time-domain/frequency-domain analysis.

Basic configuration and optional kits

This experimental platform provides a basic configuration for conducting power transmission experiments and studying the vibration characteristics of gearbox and bearing faults. SpectraQuest also offers optional kits for in-depth study of vibration phenomena.

Basic configuration of DDS (DDS2010)

·A 3-horsepower variable frequency AC drive with a multifunctional programmable control panel.

·A 3-phase electric motor with 3 horsepower and a pre wired self straightening system that is easy to disassemble and replace.

·Built in tachometer with LCD digital display and an analog output for data acquisition.

·Three parallel axes can form a single-stage or two-stage variable speed transmission.

·2nd stage planetary gearbox.

·Four spur gears can obtain two gear meshing frequencies.

·6 rolling bearings.

·Magnetic brake that can provide gearbox load.

·The bearing vibration can be directly measured on the precision bearing seats at both ends of the gearbox.

·The 5mm displacement sensor installation hole is used for measuring in both directions of the shaft.

·Gearbox oil label.

·Isolation block and base reinforcement plate.

Bearing Failure Kit (G-BFK-1)

·Study the vibration characteristics of typical bearing faults.

·Learn signal processing knowledge such as mean processing, spectrum leakage, frequency resolution, and their applications in bearing fault diagnosis.

·Experiments can be conducted to intensify the degree of damage.

·Understand why a very high spectral resolution is required to identify bearing faults when the fault frequency approaches the frequency doubling of the rotational frequency.

·Study how a strong signal can mask weaker signals around it due to spectrum leakage.

·This kit includes one inner ring faulty bearing, one outer ring faulty bearing, one ball faulty bearing, and one hybrid faulty bearing.

Planetary gearbox faulty bearing kit (G-BFK-P)

·Study the bearing faults of planetary gearboxes.

·This kit includes one bearing each with inner ring failure, outer ring failure, rolling element failure, and hybrid failure.

Gearbox sleeve bearing (G-SBH)

·Compare the vibration characteristics of rolling bearings and sleeve bearings.

·Study the vibration characteristics of bearing wear and looseness.

·This kit includes six 1-inch oil lubricated bronze sleeve bearings.

Radial bearing load (G-RBL)

·Study the influence of radial load on bearings.

·Study the influence of load and speed on bearing fault signals.

·Compare the vibration characteristics of bearings under loaded and unloaded conditions.

·Study the influence of load position on the fault characteristics of bearing outer rings.

·This kit includes a mechanical bearing load.

Faulty spur gear (G-SDG)

·Study the characteristics of tooth damage in gearboxes.

·Apply phase demodulation analysis method to diagnose gear damage.

·Study the backlash between meshing gears.

·This kit includes a gear with missing teeth, a gear with pitting corrosion, a gear with cracked tooth roots, and a gear with worn surface.

Fault planetary gear (G-PDG)

·Study the damage characteristics of planetary gears.

·Apply phase demodulation analysis method to diagnose gear damage.

·This kit includes a gear with missing teeth, a gear with pitting corrosion, a gear with cracked tooth roots, and a gear with worn surface.

Eccentric spur gear (G-ESG)

·Study the characteristics of eccentric spur gears.

·Collect vibration signals of eccentric gears.

·This kit includes an eccentric spur gear.

Helical gear kit (G-HG)

·Study helical gears in parallel axis gearboxes.

·Compare the vibration characteristics of spur gears and helical gears.

·This kit includes four helical gears that can replace the spur gears in the basic configuration.

Fault helical gear (G-HDG)

·Study the damage characteristics of faulty helical gears.

·Apply phase demodulation analysis method to diagnose gear damage.

·This kit includes a corroded gear and a missing gear.

·It needs to be used in conjunction with G-HG.

G-TOR torque sensor with built-in encoder on input shaft

·Measure the input shaft torque.

·Study the torque variation throughout the entire rotation cycle.

·Axis trajectory analysis.

·This kit includes a 20 N.m torque meter with a built-in 360 pulse encoder.

Axis encoder (G-ENC)

·Measure transmission error by comparing input and output speeds.

·This kit includes a 360 pulse encoder and a pointer disk that records every rotation.

PC based Motor Control Kit (G-PCK)

·Remote Control Mechanical Fault Comprehensive Simulation Experiment Platform (MFS).

·Programmable implementation of control requirements for acceleration, deceleration, and running time.

·This kit includes PC software and hardware interface modules.

Based on PC controlled brake (G-PCB)

·Remote control of magnetic brake.

·Pre programmable operation enables precise control.

·This kit includes PC software, a magnetic brake interface module, and cables.

Bearing Radial Load Pressure Sensor (G-RBFT)

·Measure the radial load loaded on the bearing.

·This kit includes a pressure sensor for measuring radial loads and a matching signal conditioner.

·It needs to be used in conjunction with G-RBL.

3-horsepower faulty AC motor with built-in unbalanced rotor (G-UBM-3)

·Study the influence of unbalanced rotors on vibration and current characteristics.

·Study the impact of unbalanced rotors on power quality and losses.

·Study the effect of temperature rise on the nonlinear characteristics of asynchronous motors.

·This kit includes a faulty 3 horsepower AC motor with an unbalanced rotor.

3-horsepower faulty AC motor with internally warped rotor (G-BRM-3)

·Study the influence of rotor bending on vibration and current characteristics.

·Study the impact of warped rotors on power quality and losses.

·This kit includes a faulty AC motor with a 3-horsepower center bent rotor.

3-horsepower faulty AC motor with built-in faulty bearings (G-FBM-3)

·Study the impact of bearing faults on vibration and current characteristics.

·Study the impact of bearing failures on power quality and losses.

·This kit includes a 3 horsepower AC motor with bearing inner and outer ring faults. Users can choose the desired type of bearing failure.

3-horsepower AC motor with built-in misaligned rotor system (G-MAM-3)

·Study the influence of air gap changes on vibration and current characteristics.

·Study the effects of misalignment, type, and rotor speed on vibration and current characteristics.

·Study the impact of rotor misalignment on power quality and losses.

·Study the effect of temperature rise on the nonlinear characteristics of asynchronous motors.

·This kit includes a 3-horsepower AC motor with an adjustable misalignment bell shaped end cap, making it easy to introduce pre-set misalignment at either end of the motor.

3-horsepower faulty AC motor with built-in rotor bar breakage (G-BRBM-3)

·Study the influence of rotor bar breakage fault on the vibration and current characteristics of electric motors at different speeds and loads.

·Study the impact of rotor bar breakage faults on power quality and losses.

·Study the effect of temperature rise on the nonlinear characteristics of asynchronous motors.

·This kit includes a 3-horsepower AC motor with rotor bar breakage fault.

Three horsepower AC motor (G-SSTM-3) with stator winding failure

·Study the influence of inter turn short circuit in stator winding on vibration and current characteristics.

·Study the impact of inter turn short circuits in stator windings on power quality and losses.

·Study the effect of temperature rise on the nonlinear characteristics of asynchronous motors.

·This kit includes a faulty AC motor with stator winding inter turn short circuit and a controller that can adjust the short circuit condition.

Voltage imbalance and phase loss fault 3 horsepower AC motor (G-VUSM-3)

·Study the effects of voltage imbalance and phase loss faults on current and vibration characteristics.

·Study the impact of voltage imbalance and phase loss faults on power quality and losses.

·Study the effect of temperature rise on the nonlinear characteristics of asynchronous motors.

·This kit includes a 1 horsepower faulty AC motor and a controller for adjusting voltage balance and phase loss.