Paper: ASAT-13-TE-13

13th International Conference on

AEROSPACE SCIENCES & AVIATION TECHNOLOGY,
ASAT- 13, May 26 28, 2009, E-Mail: asat@mtc.edu.eg
Military Technical College, Kobry Elkobbah, Cairo, Egypt
Tel : +(202) 24025292 24036138, Fax: +(202) 22621908

A Study on Fault Diagnosis by Vibration Analysis at Different

Loading and Speed Conditions
M. Kotb Ali*, M. F. H. Youssef **, M. A. Hamaad*** and Alaa A. El-Butch
Abstract: Due to the progress made in engineering and science of materials, rotating
machines are becoming faster and lightweight. Theyre also required to run at different
loading and speed conditions. Detection, location and analysis of faults in such machines play
a vital role in the quest for high reliable operations. Vibration analysis has been used as a
predictive maintenance procedure and as a support for machinery maintenance decisions. As a
general rule, machines dont breakdown or fail without some form of warning, which is
indicated by an increased vibration level. By measuring and analyzing the machine's
vibration, it is possible to determine both the nature and severity of the defect, and hence
predict the machines failure. In the present work the effect of working under different speeds
at two loading conditions will be studied. For this reason, intentional faults have been
introduced to a dynamometer testing machine, and the corresponding fast Fourier transform
(FFT) spectrum has been recorded for each case study. Results have shown that the vibration
amplitude affected by changing both load and/or speed, therefore, it is important to fix the
measuring positions as well as speed and load as much as possible to implement a good
maintenance vibration monitoring program.
Keywords: predictive maintenance techniques, vibration analysis, fault diagnosis.

1. Introduction
Improving the machine reliability is the major focus of industry which means to gain the
maximum working life of machinery and also minimize maintenance and operating costs. To
achieve this, it is necessary to establish a maintenance monitoring program to regularly assess
the machine condition. There are different methods that can be employed for machine
condition monitoring to support maintenance decisions [1]. Vibration analysis is a very
powerful condition monitoring technique which is becoming more popular and common
practice in industry. As a general rule, machines dont breakdown or fail without some form
of warning, which is indicated by an increased vibration level [2,3]. The increasing level in
the vibration signature of a machine can provide a variety of information on many
components and structures such as gear meshing frequencies, bearings, structural resonances,
and even electrical faults. Different components and defects are generated at different
frequencies. Using signal processing techniques to analyze the time and frequency spectrums,

M. Sc. graduate student, Mech. Maintenance Eng., Ministry of Military Production,

Factory18, Cairo, Egypt, mkotbali@yahoo.com
**
Dean of Tech. Inst. for Developed Industries, Ministry of Military Production, Cairo, Egypt
***
Assoc. Prof. of Mech. Engg., Faculty of Engg., Helwan, Helwan University, Cairo, Egypt

Prof. of Mech. design, Faculty of Engg., Mataria, Helwan University, Cairo, Egypt
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Paper: ASAT-13-TE-13
it can be possible to determine the defect and natural frequencies of various structural
components. The amplitude of the vibration signature gives an indication of the severity of the
problem, whilst the frequency can indicate the source of the defect [1].Vibration monitoring
and analysis is the primary diagnostic tool for most mechanical systems. When used properly,
vibration data provide the means to maintain optimum operating conditions and efficiency of
critical plant systems. It can be used as part of an overall maintenance program to
significantly improve equipment reliability [4]. The characteristics of a machine vibration can
be used to identify specific problems. There are numerous causes of vibration in machines,
but about 90% of all problems are due to unbalance or misalignment. Some of the other
sources of vibration are mechanical looseness, bad drive belts or chains, bad bearings (antifriction type), hydraulic forces, bent shafts, electromagnetic forces, aerodynamic forces,
resonance, worn, damaged or eccentric gears and rubbing [5].
Another application for vibration analysis is as an acceptance test to verify that a machine
repair was done properly. The analysis can verify whether proper maintenance was carried out
on bearing or gear installation, or whether alignment or balancing was done to the required
tolerances [6]. In general, the vibration will exist in the radial direction, axial direction, or
both. The radial direction is usually broken up into the vertical and horizontal planes to better
describe the characteristics of the vibration. The understanding of this allows the
determination of ideal sensor positions likely to record a maximum of information in the best
conditions [5,7-10].
In the present work, it is intended to apply intentional faults to a mechanical system working
at different speeds and two loading conditions and record the corresponding fast Fourier
transform (FFT) spectrum for each condition. The FFT spectrum will, hence, be analyzed and
compare them with the normal operating conditions in order to study the effect of load and
speed on the measured spectrums.

2. Experimental Work
2.1 Test Rig Description
Tests have been carried out on a loading testing system consisting of a dynamometer coupled
to an electric motor as shown in Fig. 1(a & b). The dynamometer is mounted on a base
equipped with quick-release fasteners and alignment pins. Positioning the alignment pins into
holes in the adjacent base unit ensures shaft alignment of the two machines.

Fixing
Studs

Motor under test

Alignment pins

Dynamometer

Quick-release Coupling
fasteners

(a)

(b)
Fig. 1. Test rig components
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Paper: ASAT-13-TE-13
The dynamometer has the following specifications:

250 w continuous operation

3000 rpm nominal speed
220 V nominal supply

2.2 Vibration Measuring Device

An accelerometer has been used to measure the acceleration, velocity and displacement as
vibration amplitude. Since the majority of general rotating machinery operates in the range of
101000 Hz, velocity is commonly used for vibration measurement and analysis [10]. The
dynamometer operates in this range; so its vibration amplitude has been measured as a unit of
velocity in mm/s, root mean square value (rms). The sensor is connected to Brel & Kjaer
VIBROTEST 60 analyzer and data collector Fig.2. The sensor operates in accordance with the
piezoelectric compression principle. Its frequency range is from 4 Hz to 10 kHz and its
resonance frequency is 35 kHz.

2.3 Application of Some Intentional Faults

The system vibration has been measured at three different positions on the dynamometer,
namely horizontal, vertical and axial positions as shown in Fig. 3.
The sequence of measurements is as following
a- First, the system vibration has been measured at normal operation without loading at
different speeds 1800, 2400 and 3000 rpm (30, 40 and 50 Hz)
b- Measurements have been taken after loading the dynamometer with 0.5 Nm torque
load for the three speeds 30, 40 and 50 Hz.
c- Repeating (a) after applying intentional faults, namely (unbalance, looseness and
misalignment)
d- Repeating (b) after applying looseness fault.

Fig. 2. Brel & Kjaer VIBROTEST 60 vibration device and sensor

Horizontal

Vertical

Fig. 3. Horizontal, vertical and axial positions for vibration measurement

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Axial

Paper: ASAT-13-TE-13

3. Results and Discussions

The FFT spectrums have been recorded for both perfect working conditions, (no intentional
faults), and faulty conditions at different speeds without loading and for loosening fault at
different speeds and two loading conditions, (No load & 0.5 Nm torque load), as following:

3.1 Effect of speed at no load condition and no faults

A sample of the FFT spectrum for the dynamometer at 30 Hz frequency, (horizontal position),
for normal working conditions, no intentional faults & no load is shown in Fig. 4.
The results are tabulated for speeds 1800, 2400 and 3000 rpm for 1 (1* rpm) and its
harmonics 2, 3, and sometimes up to 5, for horizontal, vertical and axial positions, Table
1. We can see that in the vertical position, the vibration amplitude increases for 1 with the
increase of the shaft running speed as illustrated in Fig. 5. There is a high peak at 2 harmonic
of the 40 Hz running speed in the vertical position but its just tolerable according to the
German Standard VDI 2056 as given in Fig. 6.

1 of 30 Hz shaft speed, 0.27 mm/s

2 harmonic, 0.09 mm/s

Fig. 4. Horizontal FFT spectrum in normal operating condition

at 30 Hz frequency & no load.
Table 1. Vibration amplitude in mm/s in normal operation
Load
Speed
Sensor
Position
30 Hz
40 Hz
50 Hz

No Load
Horizontal
1
0.27

2
0.09

0.21
0.28

Vertical
3

Axial

1
0.38

2
0.93

3
0.20

1
0.52

2
0.80

0.24

0.69

2.40

0.08

0.61

0.58

0.25

1.26

1.74

0.48

0.51

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Paper: ASAT-13-TE-13

Fig. 5. Speed effect on vibration amplitude at 1 in

the vertical position (No Load)

Fig. 6. German Standard VDI 2056

3.2. Effect of Speed at 0.5Nm Torque Load Condition and No Faults

A sample of the FFT spectrum for the dynamometer at 50 Hz frequency (axial position) in
normal working conditions, no intentional faults & 0.5 Nm torque load is shown in Fig. 7.
The results are tabulated for the test speeds for 1 (1* rpm) and its harmonics at horizontal,
vertical and axial positions in table 2. Here we can see that for the axial position, the vibration
amplitude increases for 1 with the increase of the shaft running speed as illustrated in Fig. 8.
But the high peak at 2 harmonic of the 40 Hz running speed in the vertical position increased
after applying the load, and enters the not permissible range according to the German
standard.
Comparing Table 1 and Table 2 we can see the effect of load appears in the vertical position
for 2 especially with the 30 and 40 Hz running speed, the vibration amplitude has been
nearly doubled and other harmonics, 3 and 5 has been appeared.

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Paper: ASAT-13-TE-13

1 of 50 Hz, 0.94 mm/s

2, 0.67 mm/s

3, 0.17 mm/s

Fig. 7. The axial FFT spectrum in normal operation

at 50 Hz and 0.5 Nm load
Table 2. Vibration Amplitude in Normal Operation with Loading
Load
Speed
Sensor
Position
30 Hz
40 Hz
50 Hz

0.5 Nm Torque Load

1

Horizontal
2
3
4

0.17

0.10

0.56

0.40

1.96

0.18

0.21

0.50

5.32

0.31

0.38

0.14

1.20

0.83

Vertical
3
4

0.30

0.26

0.43

0.47

0.59

1.53

0.94

0.67

Axial
3

5
0.08

0.17

Fig. 8. Speed effect on vibration amplitude

for 1, (0.5 Nm Torque Load)

3.3 Effect of Faults at Different Loading and Speed Conditions

3.3.1. Effect of Unbalance at Different Speed Conditions and No Load
The unbalance is introduced to the system by adding external mass on the shaft at the
coupling as shown in Fig. 9. After applying unbalance the results has been tabulated for the
test speeds for 1 and its harmonics for horizontal, vertical and axial positions, Table 3.
Figure 10 shows the FFT spectrum for the dynamometer at 50 Hz frequency in the vertical
position while applying unbalance fault.
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From these results we notice that the effect of the unbalance fault appears as high vibration
amplitude at 1 in the horizontal, vertical and axial positions and the value of this amplitude
increases with the increase of the speed and enters the not permissible range according to the
standard especially in the vertical position as shown in Fig. 11.

Fig. 9. Unbalance caused by additional mass on the machine coupling

Table 3. Vibration Amplitude with Unbalance Fault

Load
Speed
Sensor
Position
30 Hz
40 Hz
50 Hz

No Load
1

Horizontal
2
3

5.42

0.20

4.56
3.89

0.53

0.31

Vertical
2
3

Axial
2 3

6.11

1.07

0.44

2.68

0.47

15.39

1.11

1.02

8.08

0.45

15.67

4.81

1.61

4.88

1.08

1 of 50 Hz, 15.67 mm/s

2 of 50 Hz, 4.81 mm/s

Fig. 10. FFT spectrum for vertical unbalance at 50 Hz & no load.

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3.3.2. Effect of Misalignment at Different Speed Conditions and No Load

Intentional misalignment fault is introduced to the system by unlocking the quick-release
fasteners and alignment pins in the bases and putting a distance keeper between them as
shown in Fig. 12.
Results are tabulated in Table 4 from which we can see that the effect of misalignment
appears as small elevation in the vibration amplitude for 1 in the vertical position with 30
and 40 Hz speed, in comparison with the normal operations values in table 1. This is due to
the flexible coupling which absorbs a part of the vibration caused by misalignment effect. On
the other hand we notice high amplitude at 2 in the vertical position with 30 and 40 Hz speed
the value of this amplitude grows with the increase of the speed and enters the not permissible
range according to the standard, also some harmonics, namely, 3 and 4 has been appeared.

Fig. 11. Speed effect on vibration amplitude for 1, vertical position

in the presence of unbalance fault & no load

Fig. 12. Misalignment intentional fault

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Paper: ASAT-13-TE-13

3.3.3. Effect of looseness at different speeds & no load

By loosing the fixing bolts of the dynamometer as shown in Fig. 13, looseness fault is
introduced to the system and measurements are recorded and tabulated in Table 5.
From Table 5 we can see that the effect of looseness fault appears as small elevation in the
vibration amplitude at 1 in the vertical position for 40 and 50 Hz speed, also at 1 in the
axial position with 50 Hz speed and some harmonics, namely, 3 and 5 has been appeared if
compared with the values in Table 1.
3.3.4. Effect of Looseness at Different Speeds and 0.5 Nm Torque Load
Figure 14 shows the FFT spectrum for the looseness fault at 40 Hz frequency in the vertical
position while applying 0.5 Nm torque load. The measurements has been recorded and
tabulated in Table 6.

Fig. 13. Looseness intentional fault.

Table 4. Vibration Amplitude with Misalignment Fault

Load
Speed
Sensor
Position
30 Hz
40 Hz
50 Hz

No Load

Horizontal
2
3

0.32

0.42

0.44

0.86

0.42

0.85

0.28

Vertical
2
3

Axial
2
3

0.62

5.80

0.24

0.21

0.78

8.96

0.54

2.20

1.14

3.31

0.83

1.07

4
0.41

0.19

Table 5. Vibration Amplitude with Looseness Fault & No Load

Load
Speed
Sensor
Position
30 Hz
40 Hz
50 Hz

No Load
1

Horizontal
2
3
4

0.41

0.06

0.23

0.15

0.40

0.26

0.20

0.16

0.37

Vertical
3
4

1.72

0.41

0.52

0.86

3.03

0.45

1.20

1.63

1.05

0.63

0.63

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Axial
3
4

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Paper: ASAT-13-TE-13

Table 6. Vibration Amplitude with Looseness Fault with 0.5 Nm Load

Load
Speed
Sensor
Position
30 Hz
40 Hz
50 Hz

0.5 Nm Load
1

Horizontal
2
3
4

0.45

0.25

0.39

0.81

1.51

0.31

0.31

0.60

3.18

0.26

0.11

1.39

1.10

0.54
0.68

Vertical
3 4

0.23

0.56

0.36

0.47

1.36

0.65

0.62

Axial
3 4

5
0.41

0.25

2 of 40 Hz, 3.18 mm/s

Fig. 14. FFT for Vertical Looseness At 40 Hz Frequency & 0.5 Nm Torque Load..
Comparing tables 6 to 5 we can see that the effect of applying load on the system with
looseness fault appears as small increase in the vibration amplitude for 2 in the vertical
position with 40 and 50 Hz speed, also at 1 and 3 in the axial position at 50 Hz speed and
some harmonics, namely, 3 and 4 has been appeared if compared with the values in table 1.

4. Conclusions
From the results and discusion the following concluding points may be drawn:
1. For the vertical position, the vibration amplitude increases for 1 with the increase of
the shaft running speed
2. The effect of increasing the machine load appears in the vertical position for 2 and
other harmonics, 3 and 5 are appeared.
3. The effect of the unbalance fault appears as high vibration amplitude at 1 in the
horizontal, vertical and axial positions. and the value of this amplitude increases with
the increase of the speed and enters the not permissible range according to the
standard especially in the vertical position
4. The effect of misalignment appears as elevation in the vibration amplitude for 1 in
the vertical position
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Paper: ASAT-13-TE-13
5. The effect of looseness fault appears as small elevation in the vibration amplitude at
1 in the vertical position.
6. The effect of applying load on the system with looseness fault appears as small
increase in the vibration amplitude for 2 in the vertical position
The results also confirm that, for proper preventive maintenance, measurements should be
taken at the same positions and preferably for the same operating conditions.

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