Onsite Testing & Analysis of Materials

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Accreditation makes the difference.

The Rexnord Innovation Center is differentiated from competitors because our A2LA accredited engineers and technicians will travel to customer locations and take real-time data on a piece of machinery while in its actual working conditions. This method of field engineering allows for far more accurate results than simple simulations or sample tests. Here are a few of our global customer field-testing success stories:

Strain Gauging of Rock Crushing Equipment

A mining equipment manufacturer asked if the Rexnord Innovation Center could determine the maximum and minimum material strains experienced by one of their rock crushers during different operating conditions. The Rexnord Innovation Center engineers traveled to the client’s mine site, instrumented the equipment and recorded the strain measurements. Once the data was analyzed, Rexnord was able to provide a detailed report summarizing the exact amount of strain experienced by the crusher at various locations in the machine, giving the customer a much deeper understanding of the loads and stresses experienced by the equipment.

Failure Analysis

A law firm contacted the Rexnord Innovation Center to render an expert opinion in a case involving several hundred feet (in excess of 30 m) of conveyor chain. Rexnord engineering professionals traveled to the claimant’s facility to inspect and analyze the chain to determine the root cause for failure. After initial inspection, the chain was shipped back to the Rexnord Innovation Center for further analysis. Upon conclusion of the analysis, Rexnord engineers testified in court to substantiate the claims.

Field Measurement & Vibration Testing of Electronic Equipment

An aggregate processing machinery manufacturer wanted to know whether an electrical cabinet would be able to withstand the vibrational loads sustained in the field. Rexnord Innovation Center engineers traveled to the customer’s site and collected vibration data on the machine. Then they were able to replicate in the lab what was experienced during operation. Next, Rexnord accurately predicted component failures, allowing for redesign before deployment of the equipment into the field.

The Rexnord Innovation Center has five electro-dynamic shakers, each capable of generating up to 6,000 pounds force (27 kN). Random, shock and drop, and wind milling tests are typical. Professionals can also perform “at altitude” tests in the environmental chamber while the shaker is running, which means customers save money because the equipment stays in its same location.

Thermal Evaluations of Equipment

An industrial equipment manufacturer required that a piece of their equipment pass a foreign specification for temperature rise during operation. The Rexnord Innovation Center was contracted to conduct a preliminary thermal test to ensure that the equipment could pass the specification before spending time and money shipping the product overseas. In addition to thermal temperature data, Rexnord was able to provide real-time thermal images of the product via a thermal imaging camera system.

Equipment Shaft Alignments

An industrial equipment company contracted the Rexnord Innovation Center to align two shafts of a hoist trolley within a specified tolerance of angular and parallel alignment. Rexnord engineers used a precision laser alignment system to ensure that the customer requirements were met. This solution ensured proper operation of the connected equipment, saving the customer unplanned downtime.

Field Testing: Load Investigative Capability

Worldwide onsite evaluation and data acquisition is an RTS specialty. Portable high speed data acquisition, including 24 SoMat channels using standard strain gage application or specialty transducers is used to measure loads, stresses, speeds, pressures, noise and vibration. Telemetry and field computer systems are mounted directly to moving or rotating machinery to dynamically measure transducer output.

Testing can be designed to correlate laboratory and field measurements. Vibration data are taken using accelerometers or modal hammer and a field computer, and subsequently converted to useable data. The use of VRC field data simulation software permits simulating field conditions in the laboratory on servo-hydraulic or electro-mechanical test stations.

Mechanical Testing

Determination of strength, ductility and toughness for both metallic and plastic materials is done to ASTM, SAE or ISO standards. Test modes include tension, compression, flexural, torsional, impact, 3 or 4-point bending on standard samples or specialized materials. Equipment Capabilities include: 25 lb to 300,000 lb tension/compression testers, Drop Weight, and extensive sample preparation facility.

Analytical Mechanics (incl. FEA)

Stress analysis can involve both “hand” calculations, for simple structures and modes of load application or Finite Element Analysis, for more complex situations. The use of FEA can often minimize the physical testing required for successful products.

RTS uses 3-Dimensional SolidWorks to create CAD drawings and then COSMOS-FEA to analyze structures, and to solve complex linear or non-linear stress, loading, thermal or deformation problems. Prior projects included design of rock crushers, electric generation turbine blades, flexible shaft couplings, and pressure vessels.

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