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When we think of Condition Monitoring, we usually think of vibration analysis. The technology
and techniques have been developing for over 30 years. Majority of manufacturing or processing
plants use vibration analysis. Vibration analysis of rotating machines such as motors, pumps,
fans, and gears is widely accepted as a viable technique to identify changing conditions. Reduced
costs of test equipment and data management (primarily computers), availability of training, and
development of computer-based expert systems are all contributing to this acceptance.
Vibration can be defined as the to and fro motion of a body around its mean position caused by
the influence of variable force vector. In its simplest from vibration can be explained by a
pendulum set system figure 1.
Machine vibration is simply the back-and-forth movement of machines or machine components
3. Some Common Machine Problems that Amplify Mechanical Vibration ( But Don't
Cause It ):
1. Resonance
2. Looseness
The two indicative numerical values, which describe the vibration motion, are amplitude and
frequency.
VIBRATION AMPLITUDE
The vibration amplitude describes the severity of vibration motion and can be expressed in three
different units, Figure 2
(a) Displacement
(b) Velocity and
(c) Acceleration.
It is the distance covered by the vibrating body between its two extreme positions i.e. upper limit
and lower limit. It is measured as peak-to-peak displacement and expressed normally in microns
(1x10-6 meter) or mils (1/1000 inch).
It is indicative of how fast the body moves. The rate at which vibrating body is moving between
its peak values is not constant but gradually become zero and its peak position, changes its
direction and increase towards its mean position. Velocity is indicative of these changes and is
measured as peak velocity or RMS velocity (RMS = Root Mean Square). It is expressed in
mm/s or inch/sec. (either peak or RMS).
Acceleration is the rate of change of velocity. As the velocity of a vibrating body changes, it
experiences acceleration, which can be used as a measurement characteristic. With increase in
velocity of vibrating body, acceleration reduces & vice versa. Hence acceleration is maximum
where the velocity is zero (i.e. max. displacement). Acceleration is normally measured in gs
peak units where g is the acceleration produced by the force of gravity at the surface of the
earth and is equal to 980.665 cm/sec/sec.
FREQUENCY:
A wave, as represented in fig.3 when it comes to its original position is said to have
completed 1 revolution. The time interval of that revolution is known as period of that wave
and the reciprocal of period of wave is called the frequency of the wave and is measured in
cycles per minute (CPM) or Hertz.
The rate at which a machine component vibrates vibrates is represented by the frequency.
Where 1 Hertz = 1 Cycle/sec.
= 60 Cycle/minute.
The use of vibration analysis should not be restricted to predictive maintenance. The diagnostic
capability of this analysis technique has an abundance of useful applications. Some of its other
areas of use are as follows:
Acceptance Testing
Vibration analysis is a proven means of verifying the actual performance versus design
parameters of new mechanical, process and manufacturing equipment.
Quality Control
Vibration checks on a production line are an effective method of ensuring product
quality.
I. Vibration Measurements
The first step is selecting parameter for monitoring vibration severity level,
The next important step is to carry out actual vibration measurement in terms of that
parameter.
For collection of vibration severity data, selection of correct transducer or pickup plays very
crucial role. The transducers, which are used for this data collection, have been described below.
1. Velocity Transducer:
1. Accelerometer Transducer:
These are the most widely used transducers for data collection, because of their rugged design
and relatively high output signal Figure 4
This type of transducer works on the property of piezoelectric materials to generate an electric
charge when an external force is applied on them. These material produce electric charge which
is proportional to the force applied. Since the applied force is a function of acceleration, the
output charge can be directly calibrated in terms of acceleration amplitude. Introduction of
integrating circuit helps us to translate this to velocity reading. . Figure 5
The pickups discussed above were of contact type i.e. in order to measure vibration amplitude;
actual contact of this transducer with the vibrating part was necessary. Non-contact pickups
utilize principle of eddy currents to view the vibrating part and record the signal proportional to
displacement of vibrating part. Hence actual contact of the transducer with vibrating body does
not take place.
These types of pickups are generally used in machinery where the casing is rigid as compared
with the rotor and the vibrations of rotor might not reflect on the casing. Hence in such cases
displacement or velocity cannot be measured and use of non-contact type transducer becomes a
necessity. These transducers are fitted on rigid housing/bearing casings and view the rotor
surface. . Figure 6
VIBRATION MONITORING
After selecting proper instrumentation and personnel for condition monitoring setup, vibration
monitoring must be religiously carried out.
In a manual data collection system, a person takes readings on various equipments using suitable
vibration meter and records this data in his field book. He then comes to his monitoring cell and
rewrites this data to carded files.
3. Data Acquisition
The instrument is then taken to field and vibration data/spectrums are captured using suitable
pickups. This data gets stored onto the data collector. It should be noted that the route of data
collection offloaded to the data collector must be strictly followed.
CONCLUSION
VIBRATION SEVERITY
The vibration severity measurement is a very efficient monitoring method for detecting common
machine faults as imbalance, structural weakness, loose parts etc. Few input data are needed and
it is easy to apply. The evaluation is based on international industrial standard ISO-10816 as
shown in figure9. The measurement returns the RMS value of vibration velocity in mm/s or
inch/s industrial.
VIBRATION ANALYSIS
The vibration data is usually collected with a portable device for periodic monitoring, or a
continuous monitoring system may be installed for costly or critical systems.
One display is commonly used in vibration analysis which is the wave form. A waveform is a
graphical representation of how vibration motion changes with time. Figure10 shows an
example.
Analysis of the vibration data requires a detailed understanding of machinery operations and of
vibration analysis techniques.
Vibration analysis can measure many aspects of the vibration wave
Look at where the vibration is strongest (usually converted into RPM).
Vibration analysis relies on interpretation of the vibration spectrum.
The interpreter can then determine the vibration origin.
10 YANBU INDUSTRIAL COLLEGE
Educating Technologies
INFORMATION SHEET
MODULE 2: VIBRATION MONITORING AND ANALYSIS
Figure 12
Spectrum Interpretation
Examples of these figures 13 are designed to provide typical examples of the vibration spectrums
that will result from different problems a machine might experience. They are probability based
and field testing should always be performed regardless of how "sure" you are of the diagnosis.
Remember:
Figure 13 (Cont)