Views: 0 Author: Site Editor Publish Time: 2025-12-22 Origin: Site
The pump system is a fundamental facility in industrial production processes, and equipment maintenance will be an important task in improving productivity. In order to effectively manage and maintain pump equipment, studying pump system failures and predicting their states is crucial for reducing downtime. This will require a significant amount of time and effort to study the dynamics of the pump system and gain experience in troubleshooting without affecting the factory's production or profits. VPTS (Pump Vibration Test Simulator) is an innovative device designed to study the symptoms of mechanical and fluid faults in pumps, equivalent to an on-site pump system.
Two systems are installed in parallel, one running normally and the other designed to reproduce various faults, making it easier for the laboratory to understand fault symptoms and conduct pump diagnosis research.
Due to the fact that users can implant various faults individually or in combination in a fully controlled testing environment, it is a research and experience testing device that can solve fault analysis in a short period of time.
1. PT585 configuration
The system is configured in parallel with a three-phase induction motor that drives a water pump coupling centrifugal water pump pipeline water tank. These two systems can be independently separated and operated, but running them simultaneously allows one system to operate normally while the other operates with faulty components installed, making direct comparative testing between faulty and normal conditions a significant advantage. When the pipeline is connected to the pump or water tank, install expansion joints to ensure that the tension of the pipeline does not affect the pump, preventing misalignment or structural problems in the system.
For the installation of sensors, 4 pressure sensors, 4 temperature sensors, 2 flow sensors, and 4 vibration sensors are firmly installed in the pipeline system.
In addition, the two pump sets are each equipped with a control box that includes a built-in speed controller, signal controller, and data collector. There are two VVF drivers inside the box, equipped with pressure, temperature, and vibration sensor transmitters. The signal output is connected to a multi-channel DAQ to save data. By collecting real-time data and post-processing data based on the speed of the pump system, the fluid and vibration phenomena of the pump can be analyzed.
Install a high-performance CT on the three-phase power line of the motor to output a signal proportional to the change in motor current, which can be used for motor current spectrum analysis (MCSA). When collecting data, connect the laptop to the USB output of the controller, and all experiments are ready.
2. Characteristics
·The system is stable and has many years of work experience.
Visualize water flow using transparent materials from the water tank.
Compare the fault phenomenon immediately through parallel operation of normal and faulty systems.
Modular supply of faulty components.
Easy to replace parts.
Install all sensors for dynamic research (pressure, temperature, flow rate, vibration, current).
The built-in DAQ does not require a separate analyzer.
3. Use of simulators
The VPTS series test bench can be widely used to study various mechanical and fluid failure phenomena in pump systems and develop preventive maintenance techniques.
·Research on the Impact of Unbalanced Learning
Research on the Effects of Axis Misalignment
Research on Signal Processing Methods Based on Bearing Faults
·Research on Coupling Effect
Research on Mechanical Loosening and Soft Feet
Cavitation and wasp phenomenon
Research on Defect Detection Based on Pump Impeller Damage
Root Cause Analysis (RCA)
Technologies for installing sensors and selecting the optimal measurement location
Vibration analysis and measurement technology
Research on Machine Health Monitoring
Analysis of Electric Motor Current Signal
4. The main fault phenomena that occur in the pump unit and how to implement them in the simulator
1. Imbalance
Imbalance in pump systems is usually caused by the following reasons:
Uneven wear of the impeller (such as deformation or blade fracture).
Poor coupling, jumping, and deformation
·Poor motor rotor.
In PT585, the following faulty components are provided to achieve imbalance.
Impeller fracture and missing
Install unbalanced mass on flange coupling (M6 threaded hole on flange coupling)
Unbalanced rotor motor
2. Incorrect
The misalignment of the pump system is usually caused by one of the following reasons:
The homework method is incorrect.
Pipeline stress.
·Soft feet.
The thermal expansion of the pump itself or inside the pump. Chinese
With the help of the centering mechanism in PT585, the impact of misalignment can be studied in depth.
The shaft alignment of the pump system is achieved using laser alignment equipment to provide perfect conditions, but an alignment mechanism is installed to allow for experiments with shaft misalignment
Install the jack bolt mechanism and dial gauge, and conduct vibration tests by moving the motor base in various ways such as side, up, down, left, and right due to shaft misalignment. By using a percentage table, the degree of misalignment can be determined, and after studying the misalignment effect, it can be used to accurately return to the alignment condition.
For the misalignment test, simply loosen the motor fixing bolts, use the alignment control knob to perform parallel or angular misalignment tests according to the indicated values on the scale, and then return to the perfect alignment state
In addition to analyzing vibrations caused by misalignment, data from pressure, flow, temperature sensors on pipelines and current sensors (CT) installed on motor power lines can also be used to study physical changes such as increased power consumption.
