The fundamental Machine Fault Signature Simulator serves as a “variable speed rotor kit” that allows controlled investigations into misalignment and balance issues. It offers flexibility in studying specific problems by enabling the attachment of various “kits” to the machine, which vividly demonstrate the desired phenomena. These kits are designed to showcase specific faults and include resonance, rub, gearbox, belt drive, centrifugal pump, reciprocating mechanism, motor misalignment, among others.

In essence, the Machine Fault Signature Simulator provides a versatile platform for researchers and analysts to explore different fault scenarios and understand their effects on machinery. By utilizing the appropriate kit for a particular fault, users can gain valuable insights into the behavior and vibration signatures associated with common faults found in real-world machines. This allows them to study and analyze various fault conditions in a controlled and repeatable manner, contributing to a deeper understanding of condition monitoring and vibration analysis techniques. Additionally, the simulator’s ability to vary rotor speed enables the examination of faults under different operating conditions, making it a valuable tool in diagnosing and mitigating issues in industrial machinery.

 TIERA offers a comprehensive manual that provides in-depth guidance for conducting laboratory exercises. The manual covers a wide range of experiments, including detailed instructions on topics like shaft alignment, sheave/sprocket alignment, resonance, eccentric rotor, unbalance, defective bearings, phase relationship, reciprocating motion, gearing issues, belt drives, foundation stiffness, centrifugal pumps, motors, and more. Users are encouraged to seek assistance from TIERA engineers for specific applications and further support.

Acquiring the foundational knowledge of shaft alignment on the TMFSS offers a more convenient and conducive environment for information exchange compared to field learning. Mastering the fundamentals of alignment through this simulator lays the groundwork for valuable field experience. Effective alignment tooling is necessary to support and enhance the alignment task during practical applications.

When appropriately set up, the TMFSS has the capability to operate above the first critical speed of the machinery being simulated. This means it can simulate and analyze machine behavior at rotational speeds higher than the critical speed at which resonance occurs. To achieve this, the simulator requires the use of suitable balancing hardware and software. This specialized equipment enables precise balancing of the machine components, ensuring stable and accurate operation even at higher speeds.

Operating above the first critical speed is particularly valuable in understanding the dynamic behavior of turbo-machinery under real-world conditions. It allows analysts to study and diagnose potential issues that might arise during high-speed operations. By using the appropriate balancing tools, the simulator can accurately replicate and assess the vibration signatures and responses of machines operating at various speeds, contributing to a more comprehensive understanding of machine performance and reliability.

Certainly! The TMFSS offers an extensive range of attachments that can simulate various vibration signatures, making it an excellent platform for conducting operating deflection shape (ODS) training. ODS is a technique used to visualize and understand the dynamic behavior of machinery by studying its deformations during operation. 

To do ODS and EMA, users will require the appropriate hardware and software. This includes specialized sensors and data acquisition tools to capture the structural responses of the machine during operation. The acquired data can then be analyzed using relevant software to generate ODS animations and insights into the machine’s behavior. TIERA offers a cost-effective MODALVIEW software that can do ODS and EMA using the data acquired from PhonoVibe DAQ. 

Every dynamic machine experiences vibration to some extent, even if minimal. Baseline data represents the vibratory behavior of a healthy machine under normal conditions, forming a distinctive “signature” for that specific machine. TIERA conducts extensive testing on its simulators using industry-standard sensors, DAQ, and software. We perform in-house balancing and alignment for all systems and provide machine-specific test reports for various fault signatures, serving as reference data for healthy system operation.

When new or unusual vibration peaks occur, they indicate deviations from normal behavior, prompting root cause investigations. By comparing current vibration data with the established baseline, analysts can identify anomalies and potential issues affecting machine performance.

Maintaining baseline data is crucial as it provides insights into regular machine behavior, enabling early problem detection and preventive maintenance. Continuous updates and references to baseline data help monitor machinery health, optimize performance, and prolong its lifespan. 

Since the Machine Fault Signature Simulator only creates the desired vibration signatures, you can apply the DAQ system of your choice. Usually, industry rated brands for acquiring data from IEPE accelerometers, proxy-probes etc. are preferred. For those who do not have such a system, TIERA can provide the necessary TVIB software and PhonoVibe hardware. 

Sure. The Machine Fault Signature Simulator is ideal for this application because faults can be introduced on a controlled and repeatable basis. ISO 18432-2 recommends but does not require additional training on machine knowledge. It recommends machinery and component training (or equivalent on the job training) of at least half the duration of the

required training. Some customers have training programs that presently use the TMFSS as evidence of skill level. Experiments up to Category 4 related topics can be demonstrated on TMFSS. 

Yes. Please keep in mind that the TMFSS is a real machine and exhibits the same behavior, but in a much safer environment. One can learn single plane and two plane balancing by purchasing balancing toolkits. One can also purchase the balancing module of TVIB software with the required accessories as a cost-effective alternative. 

Unlocking the true potential of Predictive Maintenance Programs begins with the right equipment, but it doesn’t end there. Many suppliers oversimplify vibration analysis, leaving analysts with only superficial knowledge. At TIERA, we believe in empowering analysts with a deep understanding of machinery kinematics, making them the most successful in the field. That’s why our Machine Fault Signature Simulator serves as a proven and excellent platform for comprehensive training.

When it comes to Research Projects, success hinges on the right “test bed.” TIERA’s basic TMFSS offers an economical and efficient solution, tailor-made for your specific scenarios. Our experienced engineers are passionate about your work, providing the necessary support and modifications to ensure your focus remains on the critical issues.

For Training Programs that stand out, look no further than TIERA’s unique turnkey vibration training program. The Machine Fault Signature Simulator serves as the hands-on laboratory device, setting the benchmark for quick and cost-effective vibration training. With TIERA’s expertise, your analysts will be well-prepared to tackle real-world challenges with confidence and skill.

The manuals are written to be self-explanatory, reducing the necessity of formal training. We also are providing free subscription to our CAT I/II courses bundled with the powerful TOLearnVibe teaching software that is more than sufficient for majority of clients.

 However, since our customers come from a wide variety of backgrounds, TIERA provides an optional onsite-training seminar specifically on the use of the TMFSS to assure a hands-on comfort level.

The Machine Fault Signature Simulator is carefully designed for producing reputable signatures, hence, run-to- failure studies are not recommended. However, we do offer specialized modules like the accelerated bearing life testing module, which allows you to predict the usable life of rolling element bearings through run-to-failure studies. To ensure your simulator’s longevity, we offer affordable spares for easy component replacement if needed.

While the TMFSS is robust, we advise against running it under fault simulation for extended periods beyond the guidelines in the user manual. Doing so may alter baseline data, affecting repeatability. If you’re considering run-to-failure studies that may cause damage, we encourage you to consult with our experts first. We’re here to assist you in making the most of your training and experimentation without compromising the reliability of your simulator.

 Since the kits are numerous and continuously increasing, and some are not openly marketed, it is recommended that the customer discuss the needs with appropriate TIERA personnel to determine what is available. The most common kits are as follows:

• Eccentric/cocked rotor
• Eccentric sheave
• Centrally bent shaft
• Set of different style couplings
• Resonance study kit
• Set of faulted bearings with severity levels
• Mechanical bearing loader (dead weight/screw type)
• Set of sleeve bearings
• Multi-belt drive, straight tooth gearbox, and magnetic brake
• Set of defective pinions to fit gearbox
• Worn gearbox
• Multiple spring/stroke reciprocating mechanism
• Mechanical rub
• Damped bearing housing
• Centrifugal pump system
• Unbalanced motor armature
• Misaligned motor armature (adjustable)
• Bent motor armature
• Motor with inner and outer race defects

TIERA’s vibration training stands out with its innovative approach, ensuring a solid understanding of machinery behavior and core concepts. While maintaining a logical and systematic curriculum like other courses, TIERA places greater emphasis on hands-on experience using the Machine Fault Signature Simulator. This intimate contact with real mechanisms, data collection, and analysis enhances understanding, confidence, and creativity.

Unlike just presenting case histories, TIERA focuses on coaching students to develop a systematic approach, relying on their experience, skills, and critical thinking to troubleshoot vibration-related problems effectively. The program encourages independent thinking and challenges established diagnostic rules and norms.

Understanding data acquisition and signal processing is paramount, empowering students to collect and manipulate information effectively to identify machinery defects. Additionally, TIERA’s training evaluates aspects of machine design for possible improvements or precautions, fostering an attitude of alertness and prudence in equipment selection.

With TIERA’s training, students are equipped not just with knowledge but also with practical skills and a mindset that sets them apart in the field of vibration analysis and condition monitoring.

Sure, TIERA can set up a comprehensive training program and establish a Center of Excellence in vibration-based condition monitoring research and modal analysis at your facility. Our aim is to empower your team with the knowledge and expertise to excel in the field of industrial vibration analysis and research.

For instrumentation, we will provide state-of-the-art accelerometers, sensors, Data Acquisition Systems (DAQ), and software, ensuring accurate and reliable data collection. Our training program will cover a wide range of topics, including vibration analysis techniques, signal processing, fault diagnosis, and more.

The Center of Excellence will serve as a hub for industrial vibration certification, offering industry-standard training and certifications to ensure your team is recognized for their skills and knowledge. Additionally, we will collaborate with colleges and universities to foster research in the field of vibration analysis, encouraging innovation and advancement in this domain. This can be a source of your revenue generation. 

With TIERA’s expertise and support, your facility will become a hub of excellence in vibration-based condition monitoring research and modal analysis, positioning your organization at the forefront of this critical industry.

Indeed, TIERA offers a dedicated online forum, the TMFSS Community (https://community.tieraonline.in/), designed to enhance the user experience, particularly after-sales support. This forum serves as a valuable resource for customers, allowing them to access a wealth of information. Users can browse through discussions, doubts, answers, clarifications, suggestions, and error reports posted by others within the community. The forum also contains the posts related to CAT I/II training and TOLearnVibe software. 

The forum fosters a collaborative environment, where users can engage with each other and share their thoughts, experiences, and insights related to the Machinery Fault Signature Simulator. Our team of experts actively participates in the forum and promptly responds to queries and clarifications within 48 hours.

This online platform serves as a knowledge hub, empowering customers to find solutions, seek guidance, and stay updated on the latest developments and best practices related to the TMFSS. By leveraging the collective knowledge and expertise within the community, users can maximize the benefits of the simulator and explore new ways to optimize their machinery fault analysis and diagnostic capabilities. TIERA will always strive to improve our simulators and training materials based on user responses.

Not required normally. But if you are planning to connect the analog output tach signal from the control panel to the IEPE DAQ, an intermediate IEPE simulator is required to avoid damage of the sensor. Connecting the tach output directly to IEPE DAQ will damage the sensor and void warranty. If DAQ has option to switch off the IEPE current source and operate in voltage mode, then the conditioner is not required. 

For, phonovibe series of DAQ’s from TIERA signal conditioner is a must have. There is no option to switch off the IEPE current source.

• The warranty is confined only to the first purchase of TMFSS and is non-transferable. This warranty card shall be presented to our staff at the time of service and the warranty shall be void if the warranty card is altered / tampered with or lost.

• The Warranty period (both Standard Warranty Period and Extended Warranty Period) starts from the date of purchase of the appliance.

• The warranty covers only manufacturing defect in material and workmanship that may arise despite normal operation and usage of the appliance, as prescribed in the operating manual.

• Repairs, installations & removal of the appliance shall be carried out only by an Authorized Service Personnel or under their supervision, failing which this warranty will be void.

• In the event of change of address, the new address shall be intimated to the Authorised Service Center via email to sales@tieraonline.in.

• Repairs & replacements of parts would be purely at the discretion of the Authorised Service Personnel only. The company’s obligation under this warranty shall be limited to repair and providing replacement of defective parts only. It is hereby clarified that after the Standard Warranty Period, visiting charges will be applicable for all visits and the same will be borne by the customer. In the Extended Warranty period, in case the appliance needs to be transported to the Authorised Service Centre for repair, the transportation charges from and to the place of installation shall be borne by the customer.

• The customer shall provide a reasonable, sufficient and safe working space to access the appliances for service. The customer is liable to move away all blocking objects or move the appliance to an appropriate location with electricity / gas / water supply and drainage for testing of the appliance.

• In case repair cannot be completed onsite, the company reserves the right to carry the appliance to its Authorised Service Center and return the same after repair.

• In case of appliances installed beyond municipal limits of the jurisdiction of company’s Authorised Service Center, all expenses incurred in transportation of the appliance or parts thereof from and to the company’s Authorised Service Center, as well as expenses incurred on deputing of service personnel / technician towards conveyance and other incidental expenses, will be borne by the customer.

• In case of repairs the appliance and/or the replaced spare part will be warranted only for the remaining of the original warranty period and the replaced components will become property of the company.

• The company shall be under no obligation or deemed to be in default for any delay or failure in performance resulting from causes beyond its reasonable control (e.g. strikes, floods, earthquakes, pandemic etc.) including but not limited to delay in servicing due to non-availability of spare parts and / or accessories.

• In case of a repair, the company owns the right to repair or replace the spare part, which are tested thoroughly to ensure the appliance is operational.

• Authorised Personnel appointed and trained by the company will provide installation, demonstration and repair services to the customer.

Warranty is not applicable in any of the following cases:

• If the warranty card is not duly filled and does not bear the stamp, date and signature of an Authorised Service Personnel.

• The warranty does not cover any consequential or resulting liability, damage or loss to property or life arising directly or indirectly as a result of appliance failure, breakdown, or accident or usage of the Appliance not in accordance with the operating manual.

• If the Appliance has been subjected to improper use such as operated on a trolley other than the one, if any provided by the Company, misused, not cared for, abnormal use, exposure to dampness, excessive heat, excessive humidity and other extreme environmental conditions, corrosion, damage beyond repair, rusting, unauthorised modifications, unauthorised repairs, neglect, accident, alteration, acts of God, spillage of liquid or food particles, faulty electric wiring/ cabling, abnormal voltage/ power supply beyond appliance specifications, damage/ breakage/ non-functioning of appliance due to rodents, rats, termites,cockroaches and ants etc.

• The warranty does not cover consumables, normal wear & tear parts, plastic, glass and/or rubber parts, nonoperational parts and related accessories.

• The warranty does not include preventive checks, routine maintenance, cleaning, de-scaling and overhaul.

• If the serial number of the Appliance is removed, altered, made illegible/ tampered with.

• 9. If repair work is carried out by persons other than Authorised Service Personnel.

• 10. Damage to the appliance or any part(s) due to transportation or shifting or arising out of improper storage of the appliance at the Customer’s premises.

• 11. These warranty conditions apply to appliances purchased in India. If appliances are shipped abroad, the warranty shall become void.

Warranty Terms

Warranty: We warrant that in all material respects the drive will conform with our written specifications and that the drive will be free of defects in materials and workmanship for a period of five (5) years from the date of purchase of the drive (“warranty period”).

Remedy: We will remedy any defects or defective drives by repair, or at our option, by supply of a replacement drive or drive parts, provided such defects or defective drive has been reported to us promptly upon discovery, within the warranty period. A “defect” or “defective drive” means a failure of the drive caused solely by non-compliance with specifications or faulty materials or workmanship, which appears in the drive under proper use, care and maintenance. You must contact the sales office or authorised distributor from whom you purchased the drive (the “seller”) to report a defect. You must request in advance, via the seller, our approval and authorisation of any return of a defective drive, which you must send at your cost, including the cost of insurance, to the address we provide to you. If, in our reasonable determination, defects in returned drives are not found to arise solely from failure to comply with specifications, faulty materials or workmanship, or where the defects are found to arise from improper use, care and maintenance, we will return the drive to you at your cost. The repaired drive or a replacement drive will be made available for you to collect from the seller. Any replaced drives will become our property. Any drive which has been repaired or replaced by us under this warranty will be subject to these warranty terms for the unexpired portion of the warranty period.

Exclusions: We will not be liable for any defects caused by: wilful damage; negligence; abnormal use of the drive or use of the drive for a purpose other than as specified by us; fair wear and tear; materials or workmanship made, provided or specified by you; non-compliance with our storage, installation, operation or environmental requirements for the drive; lack of proper maintenance of the drive; any modification or repair to the drive not previously authorised by us in writing; the use of non-authorised software or spare or replacement parts for the drive. Our costs incurred in investigating and rectifying such defects will be paid by you upon demand. This warranty only applies to the drive if it is readily available; it does not cover the costs of disassembly and reassembly of the drive in the equipment into which it is mounted. This warranty only covers parts and the labour necessary to repair the drive, if required.

Disclaimer: To the fullest extent permitted by law this warranty is our sole warranty and your exclusive remedy for breach thereof and no representations, warranties or conditions of any kind, express or implied, will apply as to satisfactory quality, merchantability, fitness for any particular purpose or any other matter with respect to the drive. This free 5-year manufacturer’s warranty is not transferable or assignable to any other person or company.

TMFSS has VFD normally set with fault detection on. This will detect any short/open circuit as well as phase unbalance. Also, an acrylic safety cover with limit switch is provided as a mechanical safety device. Moreover, the emergency stop switch and IEC inlet port with fuse prevents sudden surge in current. All the attachments are machined to perfection and proper high-quality fasteners and tools are provided along with. Safety instructions are well documented and handed over to the customer.

Certainly, all spares and parts can have AMC/CMC whose terms have to be mutually agreed. AMC costs up to 30% more on regular maintenance depending on the type of AMC selected. Terms and conditions of AMC formulated by both customer and service provider.

The customer gets preventive maintenance and quick response from the service provider under AMC/CMC. The period for AMC/CMC usually from 1 to 3 years. It may differ as agreed by the customer and the service provider. It ensures the success of the customer company.

In AMC everything is planned before, so there is no loss of profits or income for the customer. The AMC/CMC contract is signed between the customer and the service provider once the warranty period expires. 

Extended warranty up to 2 years (excluding initial 1year warranty) can be provided at charge of 30% of the total product cost. This must be availed during the purchase of the product or 1 month before warranty expires.  The extended warranty is 30% of the product cost per year if taken after the expiry of initial warranty period. During the extended warranty period all the spares and parts are completely replaced or repaired by TIERA. Customer will have to ship the damaged parts to TIERA’s facility, and the shipping charges would be borne by TIERA. Please note that the damages arising due to the violation of safety/operation guidelines will void all types of warranty. There won’t be any onsite installation. In such a case the TA/DA as actuals has to be provided by the customer, but the service charges will be free. 

It depends on what type of analysis and number/type of faults that should be simultaneously monitored. Basic DAQ, Phonovibe D has two channels and can be used for monitoring two accelerometer channels or may be one tach plus one accelerometer. Say for example one needs to do absolute and relative phase measurements for two accelerometers simultaneously, then atleast 3 channel must be present. So, in all normal tests it is recommended to go with Phonovibe  Quad (4 channels) unless there is strict budget limitation. If one wants to monitor MDE and NDE sides in all three axis, for example for ODS/Modal analysis, one require atleast 7 channels including Tacho. So, in such cases 8 channel DAQ, Phonovibe Octa is recommended. 

In the same manner the number of accelerometers, proximity sensors etc has to be selected based on the tests and analysis option chosen.

Due to the size and logistics issues, we don’t offer demo unit shipping either for exhibition or for customer testing. But, we have a demo kit available at our office, which can be demonstrated to the customer online. Moreover, we have a detailed video manual and other manuals that makes the operations crystal clear. Customers can also look into the white papers, case studies and journal paper published based on TMFSS. 

We can offer trial versions (7 days) of TOLearnVIbe software as well as demo video of the ISO CAT I/II course platform.  This makes it easy for the customer to evaluate the same. 

The same process can be followed for TVIB software. 

In case of PhonoVibe hardware, our distributor can demonstrate the same onsite if the customer location is nearby. Otherwise, we can provide a live online demo.

Sure, many students are doing their projects (BTECH/MTECH/PhD) using the simulator and there are published journal and conference papers regarding the same. Syllabus of some universities like the Maharashtra university has a paper and lab on condition monitoring which makes TMFSS a must have. Students can also use TMFSS coupled with ISO CAT I/II courses and TOLearnVibe to achive industry level experience and certification which incresess the scope of getting job. 

Sure, Some of the links are given below 

Electrical, physical and mechanical requirements