DALOG® Data Analysis

Dr. Franz Muschaweck

Sebastian Muschaweck

Date: 18. January 2010

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 Why is Vibration Monitoring important?

We can hear vibration! 

 Vibration can generate sound!

We can sense vibration! 

 Vibration can generate heat!

We can see vibration! 

 Vibration can move objects!

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 What causes Machine Vibration?

Repeating Forces 

Looseness 

Resonance 

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 Repeating Forces

Repeating Forces in Machines are mostly

 Imbalanced
 Misaligned
 Worn
 Improperly Driven

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 Imbalanced Machine Components

Imbalanced
 Rotor, Coupling, Fan, Shaft, etc.

Static imbalanced

 Moment imbalanced

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 Misaligned Machine Components

Angular Misaligned Shaft

Parallel Misaligned Shaft

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 Worn Machine Components

Worn Rollers

Worn Teeth

Worn Belt

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 Improperly Driven

Misfiring Cylinder

Consistence of the Material

Defect Table

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 Looseness

Excessive Clearness

Loose Screws,
Bolts

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 Resonance – Resonance Frequencies

Most machines have more than

one natural oscillation rate.

The more complex –

the more natural oscillation rates.

Resonance frequencies should always

be avoided as it causes rapid and severe damages.

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 Resonance
Natural Oscillation Rate

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 How is Machine Vibration Described?
The most important numerical descriptors of
machine vibration are

 Amplitude

 Frequency

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 Amplitude and Frequency

Amplitude describes the severity of Vibration

 Amplitude is an indication of the severity of vibration

Frequency describes the oscillation rate of Vibration

 the size and the speed of the vibratory movement

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 What is Amplitude?

The amplitude of vibration is the magnitude of vibration.

Vibration amplitude
of an imbalanced fan!

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 How can a Time Signal be described?

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 Characteristic Values in the Time Domain I

RMS – Root Mean Square - Vibration Energy of the Signal

pure sinus wave RMS = 0.707 * Amplitude

PtP – Peak to Peak - Maximum Peak of the Signal

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 Characteristic Values in the Time Domain II

Cr Crest Value – Degree of peakedness of the Signal

Ku Kurtosis – Degree of peakedness of a

Distribution of the Signal
normal distribution of a signal Ku = 3

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 Acceleration Sinus Signal Curve

RMS = 1.72 [g]

PtP = 4.93 [g]

Cr = 1.48 [-]

Ku = 1.50 [-]

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 Acceleration Signal “normal” Signal Curve

RMS = 0.68 [g]

PtP = 3.60 [g]

Cr = 2.99 [-]

Ku = 2.52 [-]

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 Acceleration Signal with Spikes

RMS = 0.26 [g]

PtP = 2.80 [g]

Cr = 5.45 [-]

Ku = 4.97 [-]

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 Trend of the Characteristic Values
Trend RMS Value

Trend PtP Value

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 Trend of the Characteristic Values

Reason for a change in trend can be:

Process
Bearings
Gears
Coupling

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 Peakedness of a Signal - Broken Teeth

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 Peakedness of a Signal – Damaged Bearings

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 Peakedness, High Vibration of a Signal –
Damaged Mill Plate Rollers

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 What is a Frequency?

The rate at which a machine

component oscillates is called its
oscillation or vibration frequency!

Frequency is an indicator of the

condition of the machine!

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 What is a Frequency?

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 What is a Waveform?

A waveform shows how the vibration level

changes with the time!

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 What is a Spectrum?

A spectrum is a graphical display of the frequencies

at which a machine component is vibrating

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 What is a Spectrum?

Vibration amplitude
of an unbalanced fan!

The waveform is a pure Sinus Wave.

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 What is a Spectrum?

The waveform is a superposed Vibration amplitude of a

Sinus Wave. fan disturbed by a card!

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 What is a Spectrum?

Vibration amplitude of a
The waveform is a pure Sinus Wave.
fan disturbed by a card!

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 What is a Spectrum?

=
Sinus = fn
Sinus = 4 * fn

Add both sinus waves and you get the superposed signal.
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 What is a Spectrum?

Unbalance

Rub
Measured Vibration –
a combination of both
sources of vibration

Add both sinus waves and you get the superposed signal.
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 What is a Spectrum?

Fast Fourier Transformation FFT

from a time wave to a spectrum!

fn

4 * fn

FFT
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 What is a Spectrum?
Individual Frequencies
Individual Signals

fn
4 * fn
FFT

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 Waveform and Spectrum

Waveform displays the overall effect

Spectrum displays the machine frequencies

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 Imbalanced Coupling - Eccentricity
Shaft speed fs = 1 x rpm

Static imbalance

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 Imbalanced Coupling - Eccentricity
Static imbalance
Shaft speed fs = 1 x rpm

What is the shaft speed of the following Sinus signal?

in Hz

fs = ???[Hz]

and in rpm

ns = ???[rpm]

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 Imbalanced Coupling - Eccentricity
Static Imbalance
Shaft speed fs = 1 x rpm

What is the shaft speed of the following Sinus signal?

in Hz

fs = 12[Hz]

and in rpm

ns = 720[rpm]

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 Gear Boxes

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 Gear Faults – Tooth Problems

 Alignment  Single Pitch Error

 Cracked Tooth  Sum Pitch Error
 Broken Tooth  Radial Run Out
 Pittings, Spallings  Eccentricity
 Wear, Scratches

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 Broken Teeth

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 Pitting, Spalling

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 Calculating the fundamental Gear Frequencies

z1 = number of teeth bevel pinion fs1= input shaft frequency

z2 = number of teeth bevel wheel fs2= bevel wheel shaft frequency

zs = number of teeth sun wheel fzb1= gear mesh frequency bevel gear

zp = number of teeth planet wheel fp = planet frequency

zr = number of teeth ring gear fc = carrier frequency

np = number of planets fzp = gear mesh frequency planet gear

fds = defect frequency sun gear

fdp = defect frequency planet wheel

fdr = defect frequency ring gear

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 Calculating the fundamental Frequencies
Carrier Frequency

Gear Mesh Frequency

fs1
Planetary Stage

Input Shaft Frequency Bevel Wheel Shaft

Frequency
Gear Mesh Frequency
Bevel Gear Stage

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 Calculating the fundamental Frequencies
Input Speed n = 990rpm
Input Shaft Frequency

Gear Mesh Frequency

Bevel Gear Stage

Bevel Wheel Shaft

What is the input speed? fs1 = ???[Hz] Frequency

What is the gear mesh frequency? fzb1 = ???[Hz]

What is the speed of the bevel wheel shaft? fs2 = ???[Hz]

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 Calculating the fundamental Frequencies
Input Speed n = 990rpm
Input Shaft Frequency

Gear Mesh Frequency

Bevel Gear Stage

Bevel Wheel Shaft

What is the input speed? fs1 = 16.50[Hz] Frequency

What is the gear mesh frequency? fzb1 = 214.50[Hz]

What is the speed of the bevel wheel shaft? fs2 = 5.80[Hz]

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 Acceleration Time Signal

Typical normal
time signal curve

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 Frequency Spectrum

Typical normal
frequency curve

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 Waveform of beginning Gear Failure

time signal curve

beginning of gear
failure

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 Spectrum of a beginning Gear Failure

Frequency spectrum
beginning of gear failure

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 Waveform of a broken Tooth

time signal curve

massive gear failure

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 Spectrum of a broken Tooth

frequency spectrum
massive gear failure

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 Bearings

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 Calculating the fundamental Frequencies
Ball Pass Frequency Outer BPFO

Ball Pass Frequency Inner BPFI

Ball Spin Frequency BSF

Fundamental Train Frequency FTF

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 Envelope Analysis
Original Signal Envelope

Outer Ring Frequency + Harmonics

• Band-Pass Filter (10- 20 kHz) > Rectifying > Low-Pass Filter

•Hilbert Transformation Analogue or Digital
• Peak-Hold Method
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 Amplitude Modulation

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 Envelope Signal

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 Roller Bearing with Inner Ring Failure

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 Roller Bearing with Inner Ring Failure (Envelope)

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 Roller Bearing with Outer Ring Failure

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 Roller Bearing with Outer Ring Failure (Envelope)

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 Roller Bearing with Ball Failure

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 Signal Analysis Bearing Failure

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 Signal Analysis Bearing Failure

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 THANK YOU
Maráming Salámat
Terima kasih

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