01-beginning vibration analysis.pdf
TRANSCRIPT
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Beginning Vibration
Analysiswith
Basic Fundamentals
By: Jack Peters
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Jack D. Peters
Beginning Vibration
2
Introduction
Understanding the basics and fundamentals of vibration analysis arevery important in forming a solid background to analyze problems on
rotating machinery.
Switching between time and frequency is a common tool used for
analysis. Because the frequency spectrum is derived from the data inthe time domain, the relationship between time and frequency is very
important. Units of acceleration, velocity, and displacement are
typical. Additional terms such as peak-peak, peak, and rms. are often
used. Switching units correctly, and keeping terms straight is a must.
As much as possible, this training will follow the criteria as established
by the Vibration Institute.
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Mass & Stiffness
3
Mass & Stiffness
All machines can be broken down
into two specific categories.
Mass & Stiffness
Mass is represented by an object
that wants to move or rotate.
Stiffness is represented by springs
or constraints of that movement.
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Mass & Stiffness
4
Mass & Stiffness
f n = 1 / 2П k/m
Where:
f n = natural frequency (Hz)k = stiffness (lb/in)
m = mass
mass = weight/gravityweight (lb)
gravity (386.1 in/sec2)
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Mass & Stiffness
5
Concept !
f n = 1 / 2П k/m
If k increasesThen f increases
If k decreases
Then f decreases
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Mass & Stiffness
6
Concept !
f n = 1 / 2П k/m
If m increases
Then f decreases
If m decreases
Then f increases
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Spectrum
7
What’s This ?
0.0002
inch
Peak
0
Magnitude
Hz1000 Hz
1
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Spectrum
8
FFT, Frequency Spectrum, Power Spectrum
0.0002
inch
Peak
0
Magnitude
Hz1000 Hz
1
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Spectrum
9
Scaling X & Y
0.0002inch
Peak
0
Magnitude
Hz1000 Hz
1
X
Y
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Spectrum
10
Scaling X & Y
0.0002inch
Peak
0
Magnitude
Hz1000 Hz
1
FREQUENCY
AM
P
L
I
T
U
D
E
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Spectrum
11
Scaling X & Y
0.0002inch
Peak
0
Magnitude
Hz1000 Hz
1
What is it
H
o
w
B
a
d
I
s
I
t
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Time Waveform
12
What’s That ?
0.0004
inch
-0.0004
Real
s7.9960940 s
1
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Time Waveform
13
Time Waveform
0.0004
inch
-0.0004
Real
s7.9960940 s
1
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Time Waveform
14
Scaling X & Y
X
Y
0.0004inch
-0.0004
Real
s7.9960940 s
1
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Time Waveform
15
Scaling X & Y
TIME
A
M
P
L
I
T
U
D
E
0.0004inch
-0.0004
Real
s7.9960940 s
1
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Time Waveform
16
Scaling X & Y
What is it
Ho
w
Ba
d
I
s
I
t
0.0004inch
-0.0004
Real
s7.9960940 s
1
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Time Waveform
17
Scaling X & Y
What is it
Ho
w
Ba
d
I
s
I
t
0.0004inch
-0.0004
Real
s10 s
1
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Time & Frequency
18
Double Trouble
0.0004
inch
-0.0004
Real
s7.9960940 s
1
0.0002
inch
Peak
0
Magnitude
Hz1000 Hz
1
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The X Scale
19
The X Scale
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The X Scale
20
Hertz (Hz)
One Hertz (Hz) is equal to 1 cycle / secondIt is the most common term used in vibration
analysis to describe the frequency of a disturbance.
Never forget the 1 cycle / second relationship !
Traditional vibration analysis quite often expresses
frequency in terms of cycle / minute (cpm). This is
because many pieces of process equipment haverunning speeds related to revolutions / minute (rpm).
60 cpm = 1 cps = 1 Hz
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The X Scale
21
Relationship with Time
The frequency domain is an expression of amplitudeand individual frequencies.
A single frequency can be related to time.
F(Hz) = 1 / T(s)
The inverse of this is also true for a single frequency.
T(s)
= 1 / F(Hz)
Keep in mind that the time domain is an expression
of amplitude and multiple frequencies.
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The X Scale
22
Concept !
If: F = 1/T and T = 1/F
Then: FT = 1
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The X Scale
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Concept !
FT = 1
If: F increases
Then: T decreases
If: T increasesThen: F decreases
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The X Scale
24
Single Frequency
1
V
rms
0
Magnitude
Hz1000 Hz
Pwr Spec 1
1
V
-1
Real
ms62.469480 s
Time 1
X:55 Hz Y:706.8129 mV
dX:18.18848 ms dY:2.449082 mV
X:27.00806 ms Y:3.579427 mV
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The X Scale
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Multiple Frequencies
1
Hz1000 Hz
Pwr Spec 1
1 Hz1000 Hz
Pwr Spec 1
1
Hz1000 Hz
Pwr Spec 1
1
Hz1000 Hz
Pwr Spec 1
X:55 Hz Y:706.8129 mV
X:78 Hz Y:706.9236 mV
X:21 Hz Y:706.7825 mV
X:42 Hz Y:706.9266 mV
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The X Scale
26
Multiple Time
1
V
ms62.469480 s
Time 78 1
1
V
ms62.469480 s
Time 21 1
1
V
ms62.469480 s
Time 42 1
1
V
ms62.469480 s
Time 55 1
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The X Scale
27
Real Life Time
4
V
-4
Real
ms62.469480 s
TIME 1
55 + 78 + 21 + 42 = Trouble !
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The X Scale
28
Frequency Spectrum
4
V
-4
Real
ms62.469480 s
TIME 1
1
V
rms
Hz1000 Hz
FREQUENCY 1
X:78 Hz Y:706.9236 mV
X:55 Hz Y:706.8129 mV
X:42 Hz Y:706.9266 mV
X:21 Hz Y:706.7825 mV
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The X Scale
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The Most Copied Slide in the History of Vibration Analysis !
A m p
l i t u d e
I n p u t T i m e F r e q u e
n c y
T i m e W a v e f o r m S p
e c t r u m
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The X Scale
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Lines of Resolution
0.0002inch
Peak
0
Magnitude
Hz1000 Hz
1
The FFT alwayshas a defined
number of lines
of resolution.
100, 200, 400,
800, 1600, and
3200 lines are
commonchoices.
This spectrum
has 800 lines, or
the X scale is
broken down into
800 points.
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The X Scale
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Filter Windows
• Window filters are applied to the timewaveform data to simulate data that
starts and stops at zero.
• They will cause errors in the time
waveform and frequency spectrum.
• We still like window filters !
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The X Scale
32
Window Comparisons
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The X Scale
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Filter Windows
• Hanning (Frequency)• Flat Top (Amplitude)
• Uniform (No Window)
• Force Exponential
• Force/Expo Set-up
(Frequency Response)
Hanning 16% Amplitude Error
Flat Top 1% Amplitude Error
Window functions courtesy of Agilent “The Fundamentals of Signal Analysis”
Application Note #AN 243
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The X Scale
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Filter Windows
• Use the Hanning Window for normalvibration monitoring (Frequency)
• Use the Flat Top Window for calibration
and accuracy (Amplitude)
• Use the Uniform Window for bump
testing and resonance checks (NoWindow)
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The X Scale
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Minimum Derived Hz
The minimum derived frequency is determined by:Frequency Span / Number of Analyzer Lines (data points)
The frequency span is calculated as the ending
frequency minus the starting frequency.
The number of analyzer lines depends on the analyzer
and how the operator has set it up.
Example: 0 - 400 Hz using 800 lines
Answer = (400 - 0) / 800 = 0.5 Hz / Line
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The X Scale
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Bandwidth
The Bandwidth can be defined by:
(Frequency Span / Analyzer Lines) Window Function
Uniform Window Function = 1.0
Hanning Window Function = 1.5
Flat Top Window Function = 3.5
Example: 0 - 400 Hz using 800 Lines & Hanning Window
Answer = (400 / 800) 1.5 = 0.75 Hz / Line
Note: More discussion
later on window functions for the analyzer !
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The X Scale
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Resolution
The frequency resolution is defined in the following
manner:
2 (Frequency Span / Analyzer Lines) Window Function
or
Resolution = 2 (Bandwidth)
Example: 0 - 400 Hz using 800 Lines & Hanning Window
Answer = 2 (400 / 800) 1.5 = 1.5 Hz / Line
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The X Scale
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Using Resolution
The student wishes to measure two frequency
disturbances that are very close together.
Frequency #1 = 29.5 Hz.
Frequency #2 = 30 Hz.
The instructor suggests a hanning window and 800 lines.
What frequency span is required to accurately measure these two frequency disturbances ?
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The X Scale
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Using Resolution
Resolution = 30 - 29.5 = 0.5 Hz / Line
Resolution = 2 (Bandwidth)
BW = (Frequency Span / Analyzer Lines) Window Function
Resolution = 2 (Frequency Span / 800) 1.5
0.5 = 2 (Frequency Span / 800) 1.5
0.5 = 3 (Frequency Span) / 800
400 = 3 (Frequency Span)
133 Hz = Frequency Span
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The X Scale
40
Data Sampling Time
Data sampling time is the amount of time required to takeone record or sample of data. It is dependent on the
frequency span and the number of analyzer lines being used.
TSample = Nlines / Fspan
Using 400 lines with a 800 Hz frequency span will require:
400 / 800 = 0.5 seconds
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The X Scale
41
Average & Overlap
• Average - On• Overlap Percent - 50%
TR#1 TR#2 TR#3
FFT#1 FFT#2 FFT#3
TR#1
TR#2
TR#3
FFT#1
FFT#2
FFT#3
0% Overlap
50% Overlap
How long will it take for 10
averages at 75% overlap
using a 800 line analyzer anda 200 Hz frequency span?
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The X Scale
42
75% Overlap ?
• 10 Averages• 75% Overlap
• 800 Lines• 200 Hz
Average #1 = 800 / 200
Average #1 = 4 seconds
Average #2 - #10 = (4 x 0.25)
Average #2 - #10 = 1 second
each
Total time = 4 + (1 x 9)
Total time = 13 seconds
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The Y Scale
43
The Y Scale
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The Y Scale
44
Amplitude
The “Y” scale provides the amplitude value for each
signal or frequency.
Default units for the “Y” scale are volts RMS.
Volts is an Engineering Unit (EU).
RMS is one of three suffixes meant to confuse you !
The other two are:
(Peak ) and (Peak - Peak)
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The Y Scale
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Pk-Pk (Peak - Peak)
1
V
-1
Real
ms62.469480 s
Time 1
2
V
Pk-Pk
0
Magnitude
Hz1000 Hz
Pwr Spec 1
dX:9.094238 ms dY:1.994871 V
X:22.43042 ms Y:-993.8563 mV
X:55 Hz Y:1.999169 V
The Peak - Peak value
is expressed from the
peak to peak amplitude.
The spectrum value
uses the suffix “Pk-Pk”
to denote this.
Th Y S l
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The Y Scale
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Pk (Peak)
1
V
-1
Real
ms62.469480 s
Time 1
1
V
Peak
0
Magnitude
Hz1000 Hz
Pwr Spec 1
dX:4.516602 ms dY:997.4356 mV
X:27.00806 ms Y:3.579427 mV
X:55 Hz Y:999.5843 mVThe time wave has notchanged. The Peak
value is expressed
from zero to the peak
amplitude.
The spectrum value
uses the suffix “Peak”
to denote this.
The Y Scale
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The Y Scale
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RMS (Root Mean Square)
1
V
rms
0
Magnitude
Hz1000 Hz
Pwr Spec 1
1
V
-1
Real
ms62.469480 s
Time 1
X:55 Hz Y:706.8129 mV
dX:2.288818 ms dY:709.1976 mV
X:27.00806 ms Y:3.579427 mV
The time wave has
not changed. The
RMS value is
expressed from zeroto 70.7% of the peak
amplitude.
The spectrum value
uses the suffix
“RMS” to denote this.
The Y Scale
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The Y Scale
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Suffix Comparison
2
V
rms
0
Magnitude
Hz1000 Hz
Pwr Spec 1
2V
Peak
0
Magnitude
Hz1000 Hz
Pwr Spec 1
2V
Pk-Pk
0
Magnitude
Hz1000 Hz
Pwr Spec 1
1
V
-1
Real
ms62.469480 s
Time 1
1
V
-1
Real
ms62.469480 s
Time 1
1
V
-1
Real
ms62.469480 s
Time 1
X:55 Hz Y:706.8129 mV
X:55 Hz Y:999.5843 mV
X:55 Hz Y:1.999169 V
dX:2.288818 ms dY:709.1976 m
X:27.00806 ms Y:3.579427 mV
dX:4.516602 ms dY:997.4356 m
X:27.00806 ms Y:3.579427 mV
dX:9.094238 ms dY:1.994871 V
X:22.43042 ms Y:-993.8563 mV
RMS
Peak
Peak - Peak
The Y Scale
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The Y Scale
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Changing Suffixes
Many times it is necessary to change between suffixes.
Pk-Pk / 2 = Peak
Peak x 0.707 = RMS
RMS x 1.414 = Peak
Peak x 2 = Pk-Pk
The Y Scale
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The Y Scale
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Standard Suffixes
Now that we have learned all about the threestandard suffixes that might possibly confuse the
“Y” scale values, what is the standard ?
Vibration Institute:
Displacement = mils Peak - Peak
Velocity = in/s Peak or rms..
Acceleration = g’s Peak or rms..
Note: 1 mil = 0.001 inches
The Y Scale
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The Y Scale
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Engineering Units (EU)
Engineering units are used to give meaning to the
amplitude of the measurement.
Instead of the default “volts”, it is possible to incorporate
a unit proportional to volts that will have greater
meaning to the user.
Examples: 100 mV / g 20 mV / Pa
1 V / in/s 200 mV / mil
50 mV / psi 10 mV / fpm
33 mV / % 10 mV / V
The Y Scale
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EU’s the Hard Way
Sometimes we forget to use EU’s, or just don’t understand howto set up the analyzer.
There is no immediate need to panic if ????
You know what the EU is for the sensor you are using.Example: An accelerometer outputs 100 mV / g and there is a
10 mV peak in the frequency spectrum.
What is the amplitude in g’s ?
Answer = 10 mV / 100 mV = 0.1 g
The Y Scale
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The Big Three EU’s
Acceleration
Velocity
Displacement
The Y Scale
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Converting the Big 3
In many cases we are confronted with Acceleration,Velocity, or Displacement, but are not happy with it.
Maybe we have taken the measurement in
acceleration, but the model calls for displacement.Maybe we have taken the data in displacement, but
the manufacturer quoted the equipment
specifications in velocity.
How do we change between these EU’s ?
The Y Scale
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386.1 What ?
1g = 32.2 feet/second2
32.2 feet 12 inches
second2 X foot
386.1 inches/second2
g
The Y Scale
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Go With The Flow I
Acceleration (g’s)
Velocity (inch/s)
Displacement (inch)
x 386.1
÷ 2(Pi)f
÷ 2(Pi)f x 2(Pi)f
x 2(Pi)f
÷ 386.1
The Y Scale
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Metric Go With The Flow I
Acceleration (g’s)
Velocity (mm/s)
Displacement (mm)
x 9807
÷ 2(Pi)f
÷ 2(Pi)f x 2(Pi)f
x 2(Pi)f
÷ 9807
The Y Scale
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Go With The Flow II
Peak - Peak
Peak
RMS
÷ 2
x .707x 1.414
x 2
The Y Scale
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Doing the Math Units
0.5g x 386.1 inches
second2
g
2π x 25 cyclessecond
0.5g x 386.1 inches x 1 second
g second2
2π x 25 cycles
0.5 x 386.1 inches
2π x 25 cycles second
cycle
1.23 inches/second
There is a 0.5 g
vibration at 25 Hz.
What is the velocity ?
The Y Scale
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Acceleration - Velocity
Example: Find the equivalent peak velocity for a 25 Hzvibration at 7 mg RMS ?
= (g x 386.1) / (2 Pi x F)
= (0.007 x 386.1) / (6.28 x 25)
= 0.017 inches / second RMS
Answer = 0.017 x 1.414 = 0.024 inches / second Pk
The Y Scale
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Velocity - Displacement
Example: Find the equivalent pk-pk displacement for a25 Hz vibration at 0.024 in/s Pk ?
= Velocity / (2 Pi x F)
= 0.024 / (6.28 x 25)
= 0.000153 inches Pk
Answer = 0.000153 x 2 = 0.000306 inches Pk-Pk
The Y Scale
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Acceleration - Displacement
Example: Find the equivalent Pk-Pk displacement for a52 Hz vibration at 15 mg RMS ?
= (g x 386.1) / (2 Pi x F)2
= (0.015 x 386.1) / (6.28 x 52)2
= 0.000054 inches RMS
Answer = (0.000054 x 1.414) 2 = 0.000154 inches Pk-Pk
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Sensors
Sensors
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Accelerometers
• Integrated CircuitElectronics inside
Industrial
• Charge ModeCharge Amplifier
Test & Measurement
Sensors
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Accelerometer Advantages
• Measures casing vibration• Measures absolute motion
• Can integrate to Velocity output
• Easy to mount
• Large range of frequency response
• Available in many configurations
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Accelerometer Disadvantages
• Does not measure shaft vibration• Sensitive to mounting techniques and
surface conditions
• Difficult to perform calibration check• Double integration to displacement often
causes low frequency noise
• One accelerometer does not fit allapplications
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Mass & Charge
Mass
Ceramic/QuartzPost
Relative movement
between post &
mass creates shear
in ceramic
producing charge.
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Accelerometer Parameters
Performance Suited for ApplicationSensitivity (mV/g)Frequency Response of target (f span)
Dynamic Range of target (g level)
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Mounting the Accelerometer
500 2000 6,500 10,000 15,000 15,000
Hz.
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Realistic Mounting
Stud
Bees Wax
Adhesive
Magnet
Hand Held
100 1,000 10,000Frequency, Hz
In the real world,mounting might
not be as good as
the manufacturer
had in the lab !
What happened
to the high
frequency ?
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Mounting Location
Axial
Horizontal
Vertical
Load Zone
Radial
Vertical
Horizontal
Axial
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Mounting Location
Load Zone
Radial
Vertical
Horizontal
Axial
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Accelerometer Alarms
Machine Condition
rms peak
Acceptance of new or repaired equipment < 0.08 < 0.16
Unrestricted operation (normal) < 0.12 < 0.24
Surveillance 0.12 - 0.28 0.24 - 0.7
Unsuitable for Operation > 0.28 > 0.7
Velocity Limit
Note #1: The rms velocity (in/sec) is the band power or
band energy calculated in the frequency spectrum.
Note #2: The peak velocity (in/sec) is the largest positive
or negative peak measured in the time waveform.
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Proximity Probes
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Proximity Probe Theory
Driver
Target
Cable
Probe
The tip of the probe broadcasts a radio frequency signal
into the surrounding area as a magnetic field.If a conductive target intercepts the magnetic field, eddy
currents are generated on the surface of the target, and
power is drained from the radio frequency signal.
As the power varies with target movement in the radio
frequency field, the output voltage of the driver alsovaries.
A small dc voltage indicates that the target is close to the
probe tip.
A large dc voltage indicates that the target is far away
from the probe tip.
The variation of dc voltage is the dynamic signal
indicating the vibration or displacement.
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Output Values
• Typical – 100 mv/mil – 200 mv/mil
• Depends onprobe, cable(length), anddriver.
• Target materialvaries output.
Calibration Examples
• Copper 380 mV/mil
• Aluminum 370 mV/mil
• Brass 330 mV/mil• Tungsten Carbide 290 mV/mil
• Stainless Steel 250 mV/mil
• Steel 4140, 4340 200 mV/mil
Based on typical output sensitivity
of 200 mV/mil.
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Proximity Probes - Advantages
• Non-contact• Measure shaft dynamic motion
• Measure shaft static position (gap)
• Flat frequency response dc – 1KHz
• Simple calibration
• Suitable for harsh environments
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Proximity Probes - Disadvantages
• Probe can move (vibrate)• Doesn’t work on all metals
• Plated shafts may give false measurement
• Measures nicks & tool marks in shaft• Must be replaced as a unit (probe, cable &
driver)
• Must have relief at sensing tip fromsurrounding metal
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Typical Mounting
vertical probe horizontal probeH
V
time
Facing Driver to Driven(independent of rotation)
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Looking at Orbits
Vertical for
AmplitudeHorizontal for
Time Base
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The Orbit Display
i l s
M i l
s
Mils
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Unbalance
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Unbalance with Orbit
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Misalignment
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Misalignment with Orbit
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And the problem is ?
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Proximity Probe Alarms
Machine Condition
< 3,600 RPM < 10,000 RPM
Normal 0.3 0.2
Surveillance 0.3 - 0.5 0.2 - 0.4
Planned Shutdown 0.5 0.4
Unsuitable for Operation 0.7 0.6
Al lowable R/C
Note #1: R is the relative displacement of the shaft
measured by either probe in mils peak-peak.
Note #2: C is the diametrical clearance (difference between shaft OD and journal ID) measured in mils.
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Analyzer Input - Front End
• Coupling - AC, DC
• Antialias Filter - On, Off
AC coupling will block the DC voltage.
It creates an amplitude error below 1
Hz. DC coupling has no error below 1
Hz, but the analyzer must range on the
total signal amplitude.
Prevents frequencies that are greater
than span from wrapping around inthe spectrum.
Analyzer Input Capacitor
Blocks DC
AC Coupling Capacitor in DSA
If the antialias filter is turned off, at what
frequency will 175 Hz. appear using a 0 -
100 Hz span, and 800 lines ?
1024/800 = 1.28
100 x 1.28 = 128 Hz175 Hz - 128 Hz = 47 Hz.
128 Hz - 47 Hz = 81 Hz
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Low End Frequency Response
0.01
V
rms
0.002
Magnitude
Hz250 Hz
Input 1
0.01
V
rms
0
Magnitude
Hz250 Hz
Output 2
2
0
Magnitude
Hz250 Hz
Freq Resp 2:1
1.1
0.9
Magnitude
Hz250 Hz
Coherence 2:1
X:2.8125 Hz Y:984.7542 m
X:500 mHz Y:720.0918 m
X:5.34375 Hz Y:1.000001
To the right is a typical
problem with frequencyresponse at the low end of
the frequency spectrum.
This low end roll off was aresult of AC coupling on
CH #2 of the analyzer.
Values below 2.8 Hz are inerror, and values less than
0.5 Hz should not be used.
Data Collection
D t C ll ti
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Data Collection
Data Collection
T R d “I P li ”
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Tape Recorders “Insurance Policy”
Multi-channel
digital audio tape
recorders.
For the
Measurement that can’t get away !
Data Collection
Dynamic Signal Analyzers “Test & Measurement”
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Dynamic Signal Analyzers Test & Measurement
Large PC driven solutions
with multiple channels and
windows based software.
Smaller portable units
with 2 – 4 channel
inputs and firmware
operating systems.
Data Collection
Data Collectors “Rotating Equipment”
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Data Collectors Rotating Equipment
Data Collection
Data Collectors “Rotating Equipment”
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Data Collectors Rotating Equipment
• Route Based• Frequency
Spectrum
• Time Waveform
• Orbits
• Balancing
• Alignment
• Data Analysis• History
• Trending
• Download to PC
• Alarms
• “ Smart” algorithms
Beginning Vibration
Bibliography
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Bibliography
• Eisenmann, Robert Sr. & Eisenmann, Robert Jr., Machinery
Malfunction Diagnosis and Correction, ISBN 0-13-240946-1
• Eshleman, Ronald L., Basic Machinery Vibrations, ISBN 0-
9669500-0-3
• LaRocque, Thomas, Vibration Analysis Design, Selection,
Mounting, and Installation, Application Note, ConnectionTechnology Center
• Agilent Technologies, The Fundamentals of Signal Analysis,
Application note 243
• Agilent Technologies, Effective Machinery Measurements usingDynamic Signal Analyzers, Application note 243-1
Beginning Vibration
Thank You !
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Thank You !
You can find technical papers on
this and other subjects at
www.ctconline.comin the “Technical Resources” section