Bearing Vibration Test Rig

Water Pump Bearing Vibration Analysis system was developed to modify design and develop “On Line Noise/Vibration Testing Unit”.

• Design Test System where different types of Bearings Manufacturing Unit can be tested in production line.

• The test system will be used for on line testing each bearing for the following parameters.
  • Characteristic Frequency & Order measurement for both bearing constant and variable speed (RPM).
  1. Fundamental Train Order / Freq
  2. Ball Spin order / Freq
  3. Outer race order / Freq
  4. Inner race order / Freq
• Orbit Plot of shaft – to indicate the clearances. The above definitions and technical meaning will be explained to you with their significance during the project execution. We will ensure your understanding on the subject.
• Power spectrum (X & Y axis) over operating rpm range vs Freq.
• Spectrum envelope generation with tolerance band for good bearing.
• Statistical analysis for parameters like:
  • Max & Min values ( Accl, Vel & Displ )
  • Std deviation for each ( Accl, Velo & displ )
  • Kurtosis
  • Any other basic analysis as relevant.
• Off Line bearing fault analysis tools for typical bearing defects.
• The typical cycle time will be 12 secs max per piece. Please note the above cycle time is arrived based on assumption. Actual cycle time we need to arrive during trials with system and samples.
• The Test System will be robust and designed to accommodate different bearing assemblies based on specs given above.
• The system shall show Green & Red signals for OK & NOT OK bearings respectively.
• The system will also have buzzer for not OK bearing along with Red indication on LCD Panel.
• This will also have the calibration system with master bearings for all measurements.
• Also provision of noise data to be filtered in following frequencies:
  • Low Band – 50 ~ 300 Hz-OK
  • Medium Band – 300~1800 Hz-OK
  • High Band – 1800~ 10000 Hz

• Bearings are loaded on chute by manually and they roll down in chute by gravitational force.
• Indexing V-block with pneumatic cylinders:- Indexing v-block is proposed for transferring the bearing from chute to Test Station.
• Testing:- After Placing of bearing at test block, upper holding block will come and hold the bearing having accelerometer in X direction. Then Magnetic coupling will actuate forward and to be grip the bearing shaft, then after test will be start for 5 Sec, max. Rpm would be 3000 max. As discussed with you, run-out of coupler after mounting on shaft should be max 0.05mm. Also movement of chuck should be free.- But the run-out value may change up to 0.1 mm.
• In the holding condition, we can change the clamping load by the pressure change of Cyl.
• Vibration probe mounted with radial load system will measure vibrations and data will be forwarded to DAQ system for processing. (Measurement unit of vibration is g/mm per sec.)
• To hold the bearing sleeve there will be proper support for both ends.
• After the testing, there is a manipulator that is having pneumatic centric gripper with rotary and Z axis Actuator for Placing the Bearing in the Bin.
• If bearing is ok then manipulator place the bearing on ok conveyor and if the bearing is not ok, flap will actuate for not ok bin which is placed below conveyor.
• We are considering the cycle time would be 12 max Sec.
• Whether the vibration results (Peak to Peak / RMS) will be based on acceleration and displacement.
• This will also have the calibration system with master bearings for all measurements.
• "Time series plot for acceleration, velocity & displacement" or " 1/3 Octave analysis & Plot" or "Spectrum plots & analysis.
• This will also have the calibration system with master bearings for all measurements.
• The methodology to adjust the pressure of vibration sensor on the outer diameter of bearing.
• For NOT OK bearings, we need buzzer along with red indication on LCD panel, We need counter for the measurement of output of ok bearings & its linkage to PC.
• We need linkage of rejected bearings to the rejection bin so as to ensure that if the rejected bearing doesn't reach rejection bin, next operation will not be started.
• The equipment should have calibration system with master bearings.
• UPS and Control Panel would be mounted under the table top.
• To avoid a vibration of mechanical system (servo motor, drive etc.) we are using magnetic chuck between motor drive and pneumatic chuck. Function:-
  Servo motor (Panasonic make) will give the drive to magnetic chuck & magnetic chuck will give the drive to pneumatic chuck without any mechanical attachment, so that gripper will rotate the bearing without any mechanical vibration.-Ok
• Machine will be supplied with anti vibration pads.