Test Systems for Rotating Machines

Novator Solutions go beyond automation, crafting reliable test systems that prioritise safety and precision. Our test systems for rotating machines cater to both production and R&D testing needs, ensuring precise measurements and operator safety for all applications.

When developing test systems for rotating machines, Novator Solutions understands the importance of achieving a balance between precision and safety. Our expertise goes beyond creating automated testing setups that deliver high-measurement accuracy. We prioritise the safety of personnel by designing systems that incorporate safeguards and minimise human interaction with potentially hazardous rotating equipment.

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Understanding Test Systems for Rotating Machines

A test system for rotating machines typically involves one or more motors driving various loads, such as:

pumps
compressors
agitators
hydraulic motors
fans

These systems are often anchored on sturdy foundations with intricate connections to the media they transport. Normally, such systems undergo manual testing procedures. Operators manually set speeds and pressures, recording temperature and flow rate readings, which are painstakingly transcribed onto test reports, Excel spreadsheets, or inputted into production databases. These tests are then iterated across different speed and pressure parameters.

Automated Test Systems

This entire test process can be streamlined through automation. A sophisticated test system for rotating machines regulates speed and pressure while meticulously measuring flow and temperature. This cycle continues until all designated tests are executed. Subsequently, the system logs the test data into a production database and generates a comprehensive test report, ready for delivery alongside the product to the end customer.

Safety as the Primary Concern

Given the inherent risks associated with test systems for rotating machines—ranging from formidable forces to rotating components and high pressures—it becomes obligatory to design test systems with operator safety as the primary concern, whether it is for production or research and development (R&D) purposes. Ensuring compliance with safety standards, such as CE marking, is particularly crucial for this category of test systems.

Sensors in Test Systems for Rotating Machines

Speed Sensors

A speed sensor is mounted on the shaft of the motor that drives the rotating machine. When selecting a speed sensor, it is important that it is capable of measuring changes in speed as required by the application. A speed sensor generating one pulse per revolution will detect changes in speed at a slower rate compared to one producing 65,536 pulses per revolution. Some speed sensors are equipped to determine both the direction of rotation and the position along the shaft.

Flow Sensors

When selecting a flow sensor, understanding the necessary accuracy is paramount to meet specific requirements. For instance, a flow sensor might be calibrated within a particular flow and temperature range for a given medium. Achieving the required accuracy across the operational span of your rotating machinery may necessitate employing multiple flow sensors, each calibrated to measure within their respective flow ranges.

Rotating Torque Sensors

To measure the power consumption of a machine, we employ a torque sensor affixed between the motor shaft and the item under examination, such as a pump. By multiplying torque by speed, we derive power (Torque x Speed = Power). Additionally, there are torque sensors equipped with built-in speed sensors for enhanced measurement precision.

Power Meter

Instead of measuring the torque directly, it is possible to measure the power consumed by an electric motor. However, in this approach, the accuracy may be compromised since electric motors experience varying losses, such as friction and heat dissipation, at different speeds and load conditions. This can affect the power consumption readings.

Pressure Sensors

Pressure measurement, combined with flow rate, is essential for calculating the efficiency of a machine at specific speeds. Furthermore, it plays a vital role in monitoring system parameters, like hydraulic oil pressure, which ensures a smooth and reliable operation.

Temperature Sensors

Temperature sensors are used in measuring the temperature of transported media, enabling calculations of factors like viscosity or density. Additionally, they are employed to prevent overheating in test objects. With various types available, the selection of temperature sensors is contingent upon the temperature range in question.

FAQ

How is the safety of personnel and test objects ensured in automated test systems for rotating machines?
As a customer, it is crucial to ensure that the test system is engineered to safeguard staff from harm, regardless of whether it operates manually or automatically. Additionally, the test system should carry the CE mark, indicating compliance with safety standards. Preserving the integrity of the test object is also an economic imperative. Embedding safety considerations from the outset when designing an automated test system is vital. Fortunately, there are numerous proven solutions capable of mitigating risks to both personnel and test objects.
What should I consider when choosing a sensor for my test system?
It is crucial to have a requirement specification for your test system. The requirement specification should explicitly define the accuracy for measuring and controlling the rotating test object, which is crucial to ensure reliable test results. The specification should also consider the potential for testing additional products in the future. In cases where a variable for verification is derived from data collected by multiple sensors, the accuracy of the entire measurement chain must be calculated. This ensures a holistic understanding of potential errors. Furthermore, tolerances must be established with traceable measurement accuracy and ensure alignment with the requirement specification.
Why is it more cost-effective to use an automated test system to test rotating machinery?
An automated test system performs tests faster than a human and with greater repeatability. While the test system is testing, the operator can be used for something else, such as manufacturing products.
Do we lose control over testing if we automate instead of having an operator run manual tests?
A well-designed test system for rotating machines ensures that appropriate tests are conducted for each product. In the event of test modifications prompted by updated requirements, altering just one configuration file is sufficient to execute the test with the revised steps or parameters. Once the test procedure undergoes an update, all tests, irrespective of the operator, seamlessly transition to the latest version, ensuring meticulous control. Relying on manual test procedures necessitates updating and retraining all operators, which leads to higher costs and vulnerability to human error.

Contact Us About Test Systems

Unleash the full potential of your development cycle with Novator Solutions. Our innovative test systems for rotating machines streamline your process, boosting efficiency and saving you valuable time. Join us and collaborate with our team of skilled engineers who are with you at every step, crafting a custom-made solution to maximise your testing capabilities.