The COMPACS-RPP system for vibration analysis of rolling bearings
The COMPACS®-RPP system for vibration analysis of rolling bearings
The COMPACS®-RPP system for vibration analysis of rolling bearings is a modification of the computer monitoring system COMPACS® and serves for an objective evaluation of rolling bearings health and detection of defects, influencing their service life.
The COMPACS®-RPP stand system is designed for rolling bearings vibration analysis and provides bearings sorting to three quality categories:
recommended for application on the equipment of the 1st hazard category with rotation frequency up to 3000 rpm and more;
recommended for application on the equipment of the 2nd hazard category with rotation frequency not more than 1500 rpm;
recommended for application on the equipment of the 3rd hazard category with rotation frequency not more than 1000 rpm.
The COMPACS®-RPP system structure
The system consists of a diagnostic station (control panel section, diagnostic controller, monitor, keyboard, UPS, laser printer), the COMPACS®-RPP software, bearing test stands (drive unit for bearing running), a set of bearing mandrels, a spark marker and a set of special keys.
Diagnostic station is connected to the monophase power supply network with a voltage of 220±22V, 50 Hz frequency and power consumption not more than 200 Wt.
Time of bearing diagnostics with a test report printing on the system printer does not exceed 3 minutes, excluding time for bearing preparation and mounting on and dismantling from the stand, marking and packing.
The COMPACS®-RPP system can be equipped with any of 3 bearing stands or their combination: 1602, 1607, 1608.
drive 1608 – provides vibration analysis of bearings with an inner diameter from 7 to 35 mm, an outer diameter not more than 100 mm; the drive is completed with 11 mandrels;
drive 1602 – provides vibration analysis of bearings with an inner diameter from 40 to 120 mm, an outer diameter not more than 310 mm; the drive is completed with 16 mandrels;
drive 1607 – provides vibration analysis of bearings with an inner diameter from 130 to 300 mm, an outer diameter not more than 500 mm; the drive is completed with 14 mandrels;
The drives control is carried out by means of the diagnostic station on the basis of an industrial controller with an automatic control circuit and the built-in COMPACS®-RPP software package, providing an automatic vibration analysis of bearings, as well as archiving and printing of results.
Bearings acceptance tests area
Rolling bearings acceptance test
In order to achieve reliability, repetition and safety of bearings diagnostics results, it is required to provide the following conditions: pre-washing (for depreservation), finishing washing and drying of bearings, pre-visual-measuring control with magnetization measuring, bearings preservation after the acceptance tests. These conditions are provided by bearings acceptance test area, which in addition to the COMPACS®-RPP system includes:
tanks with heating for preliminary and finishing washing, drying and preservation of bearings;
malfunctions detection and demagnetization desk, with a demagnetizing device and magnetization measuring device, illuminated magnifier, indicators for micromeasurements (radial clearance, radial runout) with a magnetic holder;
Bearings acceptance tests area features:
stainless steel tanks;
support of operation fluids temperature;
completeness and flexibility of kitting.
A partial delivery of the system with a set of necessary technical means is possible on the Customer’s request.
The COMPACS®-RPP system features
The system operation does not require the highly qualified personnel – it is usually carried out by metalworkers of 4-5 categories.
Bearing quality is evaluated according to velocity and vibration acceleration in 4 frequency bands. The expert system for bearings defects diagnostics is based on vibration signal envelope spectrum analysis and automatically indicates particular bearings defects: of inner and outer races, rolling and separator elements, higher radial clearance and others. An original method of rolling bearings vibration control is implemented in the system, and vibration level rates are set for the following types of bearings: radial ball bearings, angular ball bearings, radial roller bearings with short cylindrical rollers, radial spherical double-row roller bearings and conical roller bearings.
Bearings database includes information on each bearing number, its inner and outer diameters, quantity of rolling elements, their diameters and contact angles. The software allows to correct the information according to bearings parameters from the operator’s panel. Bearing frequencies calculation considering rotation frequency is carried out automatically. Moreover, there is a possibility to collect information on tested bearings signals in the special archive.
The COMPACS®-RPP rolling bearings vibration analysis system meets the requirements of GOST 520, GOST 24955, GOST 24346, ISO 2041, ISO 15242, including GOST 53563-2009, GOST 53564-2009, GOST 53565-2009, developed by SPC "Dynamics", patented methods of SPC "Dynamics", using А_S, A_F1, A_F2, A_F3, V_S, V_F1, V_F2, V_F3, and a powerful analytical software complex for measurement of vibroacoustic signals noise components. The system has a certificate of approval for measuring devices types as a set of components, which determine the system metrological characteristics.
Engineering solutions, implemented in the system, are protected by the Russian Federation Patents on various objects of intellectual property and Certificates of official registration for computer programs.
The COMPACS®-RPP-AE system for vibration analysis of rolling bearings
The COMPACS®-RPP-AE system
"MONITOR" mode screen
The COMPACS®-RPP-AE system is a modification of the computer monitoring system COMPACS® and is developed for rolling bearings health monitoring and recourse-influencing defect diagnostics, considering results of vibration and acoustic emission parameters measuring.
Bearing health is evaluated in 4 frequency ranges considering the results of digital processing of acoustic emission sensors signals being displayed in the form of colored pictograms and numerical values of vibration and acoustic emission parameters. The system complies with the requirements of GOST 520-2002, GOST 52545.1-2006, ISO 15242-1:2004.
Application of micrometric measuring devices and form factors has allowed to reduce noise rates of the bearing stand, thus enabling to check bearings with vibration categories up to "Sh9".
In comparison with the COMPACS®-RPP system, the COMPACS®-RPP-AE system allows to check the drive noise rates according to velocity and vibration acceleration together with a channel of vibration measuring in octave and one-third-octave frequency bands.
The COMPACS®-RPP-AE system advantages:
incipient defects diagnostics on acoustic emission parameters;
wider measurement range of RMS vibration parameters (vibration acceleration: 0,03-500 m/s2; velocity: 0,01-50 mm/s);
lower level of the drives noises rates;
bearings diagnostics can be carried out in all the vibration categories: from Sh to Sh9;
wider range of a spindle rotation frequency: 30-3000 rpm;
wider range of loadings: 0-2000 N;
the system completing with extra sensors of temperature, vibration, acoustic emission and motion;
control of temperature and drives units vibration;
application of high-precision units and special equipment.
Operation modes of the COMPACS®-RPP and the COMPACS®-RPP-AE systems
In order to present different types of information, there are several working modes (screens):
"MONITOR" Mode displays information on the controlled unit health.
"ANALYSIS" Mode provides analysis of the signals spectra received from the vibration transducer.
"SYSTEM" Mode displays information on the built-in self-control system.
"OSCILLOGRAPH" Mode provides analysis of the signal form and the system set-up.
"ARCHIVE" Mode provides search, viewing and printing of the electric motor test reports.
Rolling bearings acceptance tests economic benefits
Cost of bearing acceptance tests, according to information from our customers, is 41-47 rubles per month in case of less than 1000 bearings tests, in case of more bearings test - less than 40 rubles. Thus, one can get bearings of a guaranteed high quality at a considerably lower price than high-quality and "Sh" category bearings.
Economic efficiency calculations indicate that the COMPACS®-RPP systems compensation period is less than a year, and a net present value (NPV) is more than 50 million rubles. Besides, general level of the equipment safety increases, and failures quantity significantly reduces.
Engineering solutions, implemented in the system, are protected by the Russian Federation Patents on various objects of intellectual property and Сertificates of official registration for computer programs.
Warranty for supplied equipment - 12 months.
Operation frequency range of vibration acceleration
(velocity) parameters measuring, Hz:
Basic relative error limit of vibration parameters
measuring at basic frequency (f=159,2 Hz),%
vibration acceleration, m/s2
Irregularity of amplitude-frequency characteristic
of measuring vibration parameters using vibration
transducer in operation frequency range, %
vibration acceleration, m/sec2
Maximal measuring time per channel, sec, not exceeding
Time for operation mode establishing, min, not exceeding
Service life, years
Maximal cable length, m:
from sensor to remote module
from portable module to diagnostic station
Bearing Acceptance Test Area
Maximal outside diameter of the washed bearing, mm
Minimal area, m2
Time cycle of bearing passing, min, not exceeding
Temperature range, °С and used liquid:
pre-washing tank (2% water solution) for potash soap;
washing tank (oil of I8..I20 grades according to GOST 20799);
drying tank (petroleum jelly according to GOST 13037);
preservation tank (petroleum jelly according to GOST 13037);
Parameters of the drive unit and diagnostic station power supply:
power input, kW
Operation-temperature range, °С
Specifications can be changed without prior notification