Design of Machine Fault Simulator for

Different Mechanical Operations

Presented by:
Nabeel Maqsood
(F15PWMEC019)
 Introduction

The aim of this project to design and fabricate

economical MFS apparatus for controlled experiments
on a device that emulates real world machinery
diagnosis simulation.
Most comprehensive device of its kind on the market,
the MFS meets the needs of a broad range of vibration
analysts, from novice to experience.
Effective tool for introducing the concepts and
methodologies of predictive maintenance and design
considerations to engineering community.
Introduction
During the survey and interactions with the customers, we
came to know that the customers are having severe problem in
misalignment of shafts
Couplings
Unbalancing
belt drive performance
mechanical rubbing
gearbox faults
resonance bearing
rotor dynamics
crack shaft
reciprocating mechanism
induction motor and pump in different Mechanical applications.
 Project Objectives

The objective of the project is to design and

manufacture, assemble, test bench performance
evaluation and obtain results from the market of the
test lot of new machinery fault simulator which perform
different mechanical operations from a single machine
following the systematic approach of the product design
and development process.
 Mission Statement
Mission Statement: To make Machinery fault simulator which perform
different mechanical operations for the maintenance of
various mechanical components
Product Description: The machine should be able to perform
misalignment, misbalancing, rotors balancing and vibration
analysis. It should be deign to perform analysis on two rotors at a
time.
Primary Market: Company dealers
Secondary Market: Mechanical parts manufacturing companies,
Engineering Universities
Stakeholders: Company workers, drivers, company dealers, Spectra
Quest Inc.
Motivations for Design

There are two prime features i.e. performing different

mechanical operations and maintaining different mechanical
components, which the customers wanted to be in this machine,
however, the key and important features that motivate our team
members to include in the product, are as under:

a. The Machine should be capable of performing misalignment,

misbalancing, rotors balancing and vibration analysis.

b. Proper material should be selected for the machine

manufacturing and assembly.
Identifying the Customers Requirement
S.No Customer Statement Interpreted Need
1 What type of operations should performed? Maximum possible operations
2 What type of rotors should be used? Eccentric and cocked rotors
3 What type of result display needed? Built-in tachometer LCD
display
4 Which process is used in manufacturing? Machining and drilling,
assembly
5 What should be the maximum speed of the 6000 rpm (maximum)
motor?
6 What is procedure to reduce failures in By designing good quality
components? machine
7 Which type of sensors should be used? Accelerometer & DAQ card
8 What should be the operating voltage? 200V 220V
9 What should be the dimensions of the L=40, W=25, H=22
machine?
10 What should be the maximum weight of 175lb (80Kg)
the machine?
Customer Needs & Relative
Importance
S.No Machine Design Needs Importance

1 Machine Design Perform max operations 4

2 Machine Design High quality machine 5

3 Machine Design Maximum operating 4

speed
4 Machine Design Machine Dimensions 4

5 Machine Design Machine material 4

6 Machine Design Assembly 3

7 Machine Design Sensors used 4

The Unit Metrics
S.No Need No. Metric Importanc Units
e
1 1,2,3,4,6,7 Machine Installation 4 Foot (ft)
dimensions
2 2,3,6 Max operating speed 4 rpm

3 2,5,6 Weight (mass) of the machine 5 N (Kg)

4 1,2,3,4,5,6,7 Machine Vibrations 5 Hertz (Hz)

5 6 Machine cycle time 2 Sec

6 1,2,3,4,5,6,7 After sale rejection 4 %

Concept Generation

Fig. CAD Assembly

Concept Generation

Fig. CAD Exploded View

Rotational Analysis on ANSYS

Fig. Rotational analysis on ANSYS