“Vibration analysis based machine unbalance

fault detection and correction.”

Siva Shankar Rudraraju

January-May 2005

INDIAN SCHOOL OF MINES

DHANBAD, INDIA
 INDEX

I. Introduction 3

II. Vibration Signal Analysis: In a nutshell 4

III. Machine Faults 5

IV. Unbalance: The Problem 6

V. Balancing 8

VI. Experimental Setup 10

VII. Unbalance Detection 12

VIII. Balancing / Removal of unbalance 14

IX. Conclusions & Suggestions 18

X. References 19

3
 Introduction

Why do machines vibrate…….?

Every machine component has an inherent capacity to store energy. This
energy is stored in certain quantum states which are called modes.

When the machine component is excited by an external force, the machine
takes up the energy and starts vibrating with various frequencies and
corresponding amplitudes. The resultant vibrational state is a superposition of
all the individual modes of vibration.

Understanding vibration response.

Understanding of a vibrational state can achieved through the analysis of the
response signal in time domain and frequency domain.

Time Domain: Variation of energy with respect to time ( Amplitude vs Time)

Frequency domain: Distribution of energy across various frequencies of
vibration. (Amplitude vs Frequency)

Response Signal

Time Domain Frequency Domain

Energy variation Energy Distribution

Fourier Transform

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Vibration Signal Analysis: In a nutshell

Modern vibration signal analysis is based on frequency domain analysis using

sophisticated spectrum analyzers, which are required to perform the Fourier
transform of the response signals.
The various forms of Fourier transform are
 Fourier series: Transforms an infinite periodic time signal into an infinite
discrete frequency spectrum.
 Fourier Integral Transform: Transforms an infinite continuous time signal
into an infinite continuous frequency spectrum.
 Discrete Fourier Transform (DFT): Transforms a discrete periodic time
signal into a discrete periodic frequency spectrum.
 Fast Fourier Transform(FFT): A computer algorithm for calculating the DFT
Today, FFT analyzers are the preferred choice for obtaining the frequency domain
spectrum.

Analysis Methodology

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Machine Faults
A fault is an irregularity in the functioning of the equipment which results in
component damage, energy losses and reduced efficiency of the machine.
The common types of machine faults are:
 Unbalance
 Shaft misalignment or bent shaft
 Damaged or loose bearings
 Damaged gears
 Faulty of misaligned belt drive.
 Mechanical looseness
 Increased turbulence
 Electrical induced vibration

Fault detection using vibrational analysis involves analysing the vibrational signature
for signs of fault. Any predominant fault occurring results in increased vibration level
which has energy concentrated at certain frequency levels.
The relation of the predominant vibration frequencies with the forcing frequency
(input force frequency) gives us an idea about the source of the fault. The increased
amplitude of the predominant frequencies indicates the severity of the fault.
Standard relations between common faults and corresponding fault signatures are
available. For example, fault due to an unbalance mass results in an increased
vibrational energy around the forcing frequency (1X RPM), i.e. the predominant
frequency is the frequency of rotation of the shaft.

Fig.1.Vibration Signature of an unbalanced shaft rotating at 50Hz

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Unbalance: The Problem

Rotating Machines
Rotating machines are becoming increasingly precise and operating at higher speeds
due to the progress and demand of modern technology. These machines should offer
stable functioning and higher operating efficiencies even under the most severe
conditions. The primary factors that degrade the performance of machines operating
at a high speed are vibration and accompanying problems such as fatigue and noise.
Balancing of rotors is the most fundamental and effective process to prevent
vibration of machines, and thus is one of the most indispensable processes in
manufacturing and maintenance of rotating machines.

Unbalance
Unbalance is a result of uneven distribution of a rotor’s mass and causes vibration to
be transmitted to the bearings and other parts of the machine during operation.
Imperfect mass distribution can be due to material faults, design errors,
manufacturing and assembly errors, and especially faults occurring during operation
of the machine. By reducing these vibrations, better performance and more cost-
effective operation can be achieved and deterioration of the machine and ultimately
fatigue failure can be avoided.
This requires the rotor to be balanced by adding and/or removing mass at certain
positions in a controlled manner.

Unbalance may occur due to the following reasons.

 The shape of the rotor is unsymmetrical.
 Unsymmetrical mass distribution exists due to machining or casting error.
 A deformation exists due to a distortion.
 An eccentricity exists due to a gap of fitting.
 An eccentricity exists in the inner ring of a bearing.

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Theory: Vibration due to unbalance
Assume that a weight with a mass of m is added to a balanced rotor having a thin-
disk shape at a distance of r from its center. When this rotor is rotated at a speed of
N, the generated centrifugal force is expressed as

P=m.r.ω2

Where ω represents the angular speed of rotation (ω=2πN/60). The centrifugal force
P changes its direction as the rotor rotates which repeatedly acts on the bearing and
so causes vibration of the whole machine.

Types of Unbalance.
 Unbalance in single plane: If the unbalance mass is a concentrated mass
present along a single plane, then the unbalance force is present only in that
plane.

 Unbalance in multiple planes: If the unbalance mass is distributed, then the

unbalance forces are acting on multiple planes. The resultant force can be
obtained by vector summation of the individual forces. These resultant forces
can be substituted in place of the individual forces, to simplify the balancing
operation.

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Balancing
“Balancing means a process of restoring a rotor which has unbalance to a balanced
state by adjusting the mass distribution of the rotor”

Unbalance is caused by the displacement of the mass centerline from the rotor's axis
by an eccentricity in the distribution of the rotor mass. In simpler terms, due to
centrifugal force, the "heavy" point of a rotor exceeds the centrifugal force exerted
by the light side of the rotor and pulls the entire rotor in the direction of the heavy
point. Balancing is the correction of this phenomenon by the removal or addition of
mass to the component to compensate for centerline error.

Why Balancing is required?

An unbalanced rotor causes the following problems.
 The whole machine vibrates.
 The performance of a rotating machine deteriorates.
 Abrasion of bearings may shorten the life of the machine.
 Machine may fail in the worst case.
 Noise produced due to excessive vibration.

Types of Balancing

 Static Balancing
 Dynamic Balancing

Static balancing involves installing the component into a balancing machine and
measuring the "heavy" point in relation to the centerline, while the part is rotating. If
the required balance correction is at a single axial point on the rotor the balance is
said to be "Single-Plane". Single plane balancing is adequate for rotors which are
short in length, such as pulleys and fans.

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Dynamic balancing is required for components or assemblies of significant length.
Rotors with some axial length can have two "heavy" points at opposing ends of the
component, acting independently on the mass center line. In order to balance the
component, both planes must be corrected for center line error. Dynamic balancing
is required for components such as shafts and multi-rotor assemblies.

Balance correction is typically done per customer supplied specifications. Test

Devices can perform balance correction on materials ranging from plastics to
aerospace superalloys, by the following methods:
• Abrasive Material Removal - Grinding equipment is used to remove mass at the
appropriate location.
• Drilling or Milling Material Removal - Drills are used to plunge to specified depths
at the appropriate location.
• Mass Addition - Mass is added by the addition of epoxy, welding metal strips, or
by adding mechanical hardware (set screws, washers, etc.) if provisions are
included in the design.

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 Experimental Setup

The experimental setup for unbalance fault detection and diagnosis can be broadly
classified into two categories:
 Fault generator.
 Vibration analysers.

Fault generator is the SpectraQuest Machine Fault Simulator (MFS) unit. MFS
comprises of a shaft rotor assembly driven by an AC motor. MFS comprises facilities
to introduce various machine faults like rotor unbalance, misalignment, faulty
bearings, damaged gear box and faulty belt drive.

Fig.2.MACHINE FAULT SIMULATOR (MFS)

Bearing

Rotor Unbalance

Gear Box

Belt Drive

Fig.3. Various possible fault locations in MFS unit.

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Vibration Analysers: The following hardware was used for vibration signal
acquisition & processing. The signal acquired was further processed in signal analysis
software.

Hardware:
1. Portable vibration meter
2. Larson Davis 2900B spectrum analyser
3. Oros 25 FFT analyser

Larson Davis 2900B Analyser

Software: Oros 25 FFT analyser

1. Oros analysis software
2. Larson Davis RTA utility

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Real time analysis Utility
 Unbalance Detection

A machine without faults has a vibration signature which has low energy distribution
across a wide frequency range. The exact frequency distribution of energy depends
on the dynamics and working condition of the specific equipment.

Fig.4. Vibration signature obtained on the bearings of the MFS unit

running at 20 Hz without any faults.

From above figure it can be seen that non-faulty equipment has a low energy
distribution across a wide frequency range.

On introducing an unbalance fault by adding a small additional weight, the vibration

signature changes significantly. The energy (amplitude) at the forcing frequency (1X
shaft RPM) shows substantial increase. A comparative representation of the vibration
signature obtained with and without unbalance at different RPM is presented below.

Balanced Rotor

Unbalanced Rotor

Fig.5. Comparison of vibration signatures of balanced and unbalanced

rotor of MFS unit running at 20 Hz.

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 Balanced Rotor

Unbalanced Rotor

Fig.6. Comparison of vibration signatures of balanced and unbalanced

rotor of MFS unit running at 40 Hz.

Balanced Rotor

Unbalanced Rotor

Fig.7. Comparison of vibration signatures of balanced and unbalanced

rotor of MFS unit running at 50 Hz.

Thus from above study we can observe that during unbalance fault the vibration
spectra has higher energy (vibration amplitude) concentration at the predominant
frequency (1XRPM). Also the increase in vibration amplitude (from balanced to
unbalanced rotor) increases with the increase in rotor RPM.

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 Balancing / Removal of Unbalance

Single plane balancing

When the unbalance mass is a concentrated mass in a single plane then the
corrective measure taken to restore the balance of the rotor constitute single plane
balancing.

In Single Plane balancing, the unbalanced centrifugal force is neutralized by an

equivalent opposite force generated by a correction weight.

To simulate an unbalance in the rotor, we add a small unbalance weight (=7gm),

at a distance (10cm) from the rotation axis. Now we attempt to rectify this
unbalance by using vibration analysis, described below.

Procedure of Single Plane Balancing

Step 1: Measurement of the overall vibration using portable vibration meter.
The overall vibration level showed a substantial increase from the normal working
vibration level. This is an indication of the presence of a fault.

Step 2: Analysis of frequency spectra using the Larson Davis 2900B analyser
and Oros 25 FFT analyser.
The vibration spectra showed predominant frequency at the shaft rotation frequency
(30 Hz).

Fig.8. Vibration Spectra of MFS unit with unbalance 15

 Observation
Shaft rotation frequency=30Hz
Highest frequency Peak in vibration spectra at 30.0781Hz

Vibration level in vibration spectra at 30.0781Hz, Vunbalance = 1.35 mm/s

Next high frequency peaks at 60Hz,90Hz,120Hz (1XRPM,2XRPM,3XRPM)….

Step 3: Adding Trial Weight

Add a trial weight W (=5.1gm), at any position on the rotor at a distance R from the
rotation axis. Then obtain the vibration spectra again.

Fig.9. Vibration Spectra of MFS unit with trial weight, W.

Observation
Highest frequency Peak in vibration spectra at 30.0781Hz

Vibration level in vibration spectra at 30.0781Hz, V0 = 2.26 mm/s

Next high frequency peaks at 60Hz,90Hz,120Hz (1XRPM,2XRPM,3XRPM)….

Step 4: Add the Trial Weight at 1800

Remove the trail weight and add it at 1800 on the other side of the rotor, at the
same distance R form the rotation axis. Again obtain the vibration spectra.
.
Observation
Highest frequency Peak in vibration spectra at 30.0781Hz

Vibration level in vibration spectra at 30.0781Hz, V180 = 0.785 mm/s

Next high frequency peaks at 60Hz,90Hz,120Hz (1XRPM,2XRPM,3XRPM)….

Step 5: Calculate the correction weight and position.

The correction weight and position is determined by geometrically representing the
forces.

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The following procedure is followed to determine the unbalance.
1. Draw a circle of radius Vunbalance, with centre O.

2. With centre A, draw an arc AX of radius V0.

3. With centre B, draw an arc BY of radius V180.

4. Let the point of intersection be P, Join OP.
5. OP is the geometric representation of the unbalance force produced only due
to the trial weight, W.
ΟΑ × W
6. Correction weight, Wcorrection=
ΟΡ
7. Location of unbalance is at an angle ∠ΑΟΡ (or - ∠ΒΟΡ ) from the initial

location of the trial weight, W. Add the balance weight at an angle +/- ∠ΒΟΡ
from the initial location of W.
8. Determine one of the positions (T) from +/- ∠ΒΟΡ , which has minimum level
of vibration at shaft rotation frequency (30.0781Hz). The location of the
actual unbalance is diagonally opposite to this minimum vibration position (T).
The correction weight should be added at position T.

OA- Initial Unbalance

AX- V0 (trial weight 00)
O BY- V180 (trial weight 1800)
OP- Unbalance due to W
Y
X
P

B
Fig.10. Geometric representation of the unbalance forces

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Calculation
W=5.1 gm
OA=1.35
From diagram, OP=1.00
1.35 × W
Correction weight, Wcorrection= = 6.885 gm.
1.00
∠ΒΟΡ = 400

Minimum vibration level is obtained at -400 from the position (00) of the trial weight.

So this is the location of the correction mass. And diagonally opposite is the original
single plane unbalance in the rotor.

Result
The calculated correction mass (6.885gm) is close to the initially introduced
unbalance (7gm).

The results obtained from the Larson Davis 2900B analyser were cross checked with
the more advanced Oros 25 multi channel analyser and Oros software. Both results
showed good agreement.

After balancing the overall vibration level substantially decreased.

Fig.11. Vibration signature of balanced rotor MFS unit

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Conclusions

 Vibration signature analysis backed by good signal analysers (Like Larson Davis
2900B, Oros 25) results in excellent machine fault detection and correction.
 Various balancing experiments conducted with different unbalance
configurations using vibration analysis resulted in excellent balancing. This lead
to drastic reduction in the overall vibration levels.

Suggestions

 Unbalance fault detection in presence of other machine faults can be

performed, as in actual working conditions multi-fault condition exists.
 The present balancing method should be extended to include multi plane
balancing and flexible rotor balancing.

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References

1. Steve Goldman, “Vibration Spectrum Analysis – A Practical Approach”, Second

Edition, Industrial Press Inc.
2. Keith Mobley, “Vibration Fundamentals”, Newnes.
3. Thompson, W.T., “Theory of Vibration with Applications”, Prentice Hall, New
Jersey, 1972.
4. Madhujit Mukhopadhyay, “Vibrations, Dynamics and Structural Systems”, Oxford

& IBH Publishing Company Pvt. Ltd., New Delhi, 2000.

5. Alan V.Oppenheim & Ronald W.Schafer, “Discrete-Time Signal Processing”,

Pearson Education Signal Processing Series, 2002.
6. Larson Davis 2900B User Manual and Training Guide
7. Oros 25 User Manual
8. Other technical resources on the Internet.

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