Beruflich Dokumente
Kultur Dokumente
Dennis H. Shreve
Success in predictive maintenance depends on several A typical time waveform signal in analog form
key elements in the data acquisition and conversion from an accelerometer could take an appearance
process: (1) the trend of the overall vibration level, like that shown in Figure 2.
(2) the amplitudes and frequencies of the individual
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Analog Anti- Windows Display &
Input A/D
Aliasing and Input FFT Averaging
Signal Converter Storage
Filter Buffer
a) The time period that can be viewed. This is These are the raw ingredients for digital signal and
equal to the sample period times the number of analysis. Within the limitations discussed and further
samples. The highest frequency that can be processing, it becomes quite possible to perform
chosen for sampling is an attribute of the extremely accurate diagnoses of equipment condition.
instrument and is expressed in Hertz or CPM
(where 1 Hz = 60 CPM). Sample rates of up 3. FFT
to 150 KHz are not uncommon in modern
instruments. The most common form of further signal
processing is known as the FFT, or Fast Fourier
b) The highest frequency that can be seen. This Transform. This is a method of taking a real-
is always less than half the sample frequency. world, time-varying signal and splitting it into
components, each with an amplitude, a phase, and
The number of samples chosen is typically a a frequency. By associating the frequencies with
number like 1024 (this is 210, a good reference for machine characteristics, and looking at the
later computation of FFTs). The resulting time amplitudes, it is possible to pinpoint troubles very
waveform requires a discerning eye to evaluate, accurately. With analog instruments, the same
but is very popular as an analysis tool in industrial information is provided with a swept filter. This is
processes. It is important to note that brief referred to as constant Q (or constant %
transients are often visible in this data, where they bandwidth) filtering, where a low/high pass filter
could be covered up by further signal processing. combination of say 2.5 % bandwidth is swept in
real time through a signal to produce a plot of
In processing a digital signal for analysis, there are amplitude vs. frequency. This gives good
a number of limitations to take into account: frequency resolution at lower frequencies (e.g. 2.5
% of 600 CPM is 15 CPM resolution), and at high
• Low pass filters - to eliminate any high frequencies resolution is lower (2.5 % of 120,000
frequencies. CPM is 3000 CPM). For this reason, the
frequency axis is usually a log scale, as shown in
• High pass filters - to eliminate DC and low Figure 3.
frequency noise.
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in./sec. waveform (Figure 5); and if we look end on to
eliminate the time axis, we get a picture of the
0.4
frequencies and amplitudes (Figure 6). This is our
FFT.
0.3
amplitude
0.2
0.1
0.0
10 100 1K 10K 100K
frequency
time
frequency
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Key parameters are as follows:
6. ALIASING
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T(obs) = observation time (sec.).
See Figure 11 for an example on sampling.
folding
sampling frequency Fs
or T(sample)
. . . N samples . . .
frequencies of
interest
Fmax 2.56*Fmax
2*Fmax
Figure 10. Aliasing Fold-over Phenomena T(obs)
Two signals are said to alias if the difference of their
frequencies falls within the frequency range of Figure 11. Sampling and Observation Time
interest. This difference frequency is always
generated in the process of sampling. If we assume we want an Fmax of 120,000 CPM
and 400 lines of resolution, we can now determine
To ensure that we do not have any high frequency how long our sampled time waveform must be.
components in our signal (higher than the chosen
Fmax value), we use an anti-aliasing filter to • To avoid aliasing, a low pass filter of 120,000
suppress the raw signal above Fmax. This CPM is selected
combination of techniques saves processing time • To avoid aliasing, we sample at 307,200 CPM
and ensures that the information in the frequency (=2.56 x 120,000).
range we have chosen is accurate. • There are 1024 samples to yield 400 lines of
resolution
7. DATA CAPTURE TIME
The section of time waveform observed will be
As the parameters Fmax and lines of resolution are 1024 samples at a sample time of 2 msec., for a
selected, the total sample time for capturing valid total of 0.2 sec. Thus, we need an instrument with
FFT data is determined. at least 5 KHz sampling rate (1024 samples in 0.2
secs = 5120 samples/sec).
For a 400-line FFT, due to the calculations
involved, we need to take 1024 points on the As another example, a 400 line FFT with an Fmax
waveform. This number (N = 2.56*(#lines)) is of 6000 CPM would require an observed time
derived from the following calculations: waveform calculated as follows:
Bandwidth (BW) = Fmax/(#lines) T(obs) = N*T(sample) = N*(1/(2.56*Fmax))
T(obs) = 1/BW = (#lines)/Fmax = 1024*(1/(2.56*100 Hz.))
T(obs) = N*T(sample) = N*(1/(2.56* Fmax)) = 1024*(1/256)
N = 2.56*(#lines) = 4 seconds.
where While lower values of Fmax offer much improved
resolution for the frequencies displayed, it does not
(#lines) = total number of lines of FFT resolution come for free. Collection time for data is
significantly longer. (The same holds true when
Fmax = highest analyzed frequency (Hz.) low frequency corners are selected for the
measurement.)
N = number of samples collected
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To illustrate the relationship between the length of This technique takes the most recent spectrum
the time waveform we need to observe and the collected and weighs it more heavily than the past
resolution achieved, consider how you would need data. It is useful in observing conditions that are
to examine a signal made up of two waveforms changing slowly with respect to sampling time -- i.e.,
with very close frequencies. If the waveforms a steady-state process.
started off in phase, it would take a long time
before they separated enough to show their synchronous
different frequencies. For example, this can be
heard as "beats" when two machines run at nearly This method utilizes a synchronizing signal from the
the same speed. The bottom line is: In order to machine being analyzed. The synchronizing signal is
achieve high resolution in the frequency domain, usually derived from a photocell, electromagnetic
long sample times are required. pickup, or some other form of tachometer input.
exponential
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There are many available windowing functions.
Rectangular (actually no window), Flat-Top,
Hamming, Kaiser-Bessel, and Hanning are among
DIGITIZED SIGNAL
the list available. Perhaps the most commonly
used window is Hanning (raised cosine). It is good
for analyzing sine waves, as it provides a good
compromise on both frequency and amplitude
resolution. Its effect is shown in Figure 13.
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The filter shape has sloping sides and does not have a Hanning window. This can be used to separate
flat top. Thus, some errors are introduced. The close frequency components.
shapeof the top of the filter can give up to 16% error kaiser-bessel
in amplitude (often called the Picket Fence Error) and
due to the slope, a frequency in one bin will be seen This window is even better than the Hamming
in several other bins. This is leakage. See Figure 15. technique for separating close frequencies because
the filter has even less leakage into side bins. The
bin initial main envelope however covers several bins
so resolution is less than with Hamming.
blackman-harris
overlap averaging
Figure 15. Hanning Leakage Effect
When more than 1 average is used to calculate the
Hanning is a good compromise window as the FFT, it is possible to use overlapping samples, as
main frequency is well defined and is usually at a shown in Figure 16.
maximum in only 1 bin, and amplitudes are
comparatively accurate. sampling time
flat top
This is actually no window at all. The advantage of This works well since the first part and last part of
using this comes in run-up or coast-down where if the sample have their amplitudes reduced in
the windows are triggered by a signal in phase normal averaging, while the overlapping sample
with rotation, where very good order tracking can takes full readings at these positions. The
be achieved. This window is also used for reduction in accuracy is very small, and for FFTs
transients. with a low Fmax and a lot of averages, collection
times can be reduced considerably. For example,
hamming an FFT with 400 lines, an Fmax of 6000 CPM, and
8 averages without overlapping takes 32 seconds
The Hamming window provides better frequency to gather the samples. With 50% overlap
resolution at the expense of amplitude. Less of the averaging, sampling requires only 18 seconds.
signal leaks into adjacent bins than with the
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folded fft
Each number is matched with an imaginary In the first case, as the adjacent bins are exactly
number . In our calculations, we need a number in equal, the frequency of the vibration is in the
every position, and there are n2 multiplications, but center of its bin -- exactly at 3000 CPM.
we eventually throw away half of the answers. To
optimize the time spent, we can replace all the In the second case, as the leakage into the 3100 bin
imaginary numbers on input with real data and is larger, the exact frequency is not 3000 but is
have an array half as long. This means somewhere between 3000 and 3050 (where the bin
approximately half the calculation time, as shown ends). By calculation, it is possible to pin down
by the equation the frequency of a component very accurately,
giving 10 times or better resolution than the raw
512 ln (512) FFT.
1024 ln (1024)
In the third case, there are two large components at
for this example, but we do need to add a little close frequencies. The only way to separate these
time to sort out the answers at the very end. There is to use an FFT with higher resolution (e.g.
is still a very worthwhile saving in time. Zoom), or to move the transducer to a position
where one or other disappears.
12 IMPROVING FREQUENCY
RESOLUTION 13. OVERALLS, BANDS, and POWER
CALCULATIONS
With the Hanning window, we know that
whenever we have an amplitude showing up in a As a general rule, if you want to have a good
bin, we will have leakage into the bins adjacent to measurement of an overall level, use the raw
it and possibly in bins farther apart as well. Figure analog signal, or calculate it directly from the
18 shows three possibilities. digitized signal. This is because power
calculations (or overalls) from FFTs are subject to
several errors.
case 2
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Overall = ∑ amplitude2
100 200 300 √ 1.5
zero bin
The 1.5 factor is used to correct for the Hanning
Figure 19. Zero Bin Suppression window characteristics and for leakage of signal
into adjacent bins. It is possible to get an alarm
The zero bin is discarded because the FFT circuitry without any of the individual lines in a band
is generally not DC coupled. The first bin may be exceeding the limit. Note also that if the band is
discarded for example due to low end noise caused only 1 bin wide, there will be no leakage into
by integration. If there should be a significant adjacent bins. Hence, an absolute alarm level
component at these frequencies, its amplitude will should be used rather than a calculated power. (A
be lost. guideline to avoid this situation is to always set
alarm limits to cover at least 4 bins of
Some manufacturers of instrumentation use information.)
overalls calculated from the FFT because this is
fast. Fast it may be; however, accuracy suffers. If 14. REAL TIME
insufficient settling time is allowed before signals
are sampled, errors can be introduced into the FFT The term real time is often applied to instruments
as well. on which the screen display changes quickly.
While this is a requirement for real time analysis, it
Secondly, an overall calculated from an FFT will is not the whole story. Real time capability can be
ignore everything above Fmax. Generally analog described as the highest rate at which data can be
overalls do not -- hence, there will be a difference. captured and displayed without leaving any gaps in
the analysis. In other words, for FFTs this means
The net result is that if you want to make sense of the instrument must be capable of taking a full
overalls that are generated from digital sample, and calculating and displaying that sample
information, you need to know exactly what you while the next sample is being captured. An
are doing. With analog overalls, results are exact, example could be as follows:
and not subject to setup or interpretation.
For a 400-line FFT and an Fmax of 12,000 CPM,
Nevertheless, there are excellent reasons to the sample rate is 512 Hz and each sampled
calculate overalls from FFTs. One of these is band window takes 2 seconds. If the screen updated
alarming where the energy in a frequency range is every 2 seconds the unit could be said to have a
real time rate of 200 Hz or 12,000 CPM -- the
used as an indicator of trouble (Figure 20). highest frequency which can be displayed.
overall
unbalance Modern instruments today often refer to “live-time”
displays. Graphical displays are presented in this
format to observe measurements in progress.
misalignment/looseness Generally, we can apply the following formula:
bearings Real Time Rate = (#lines FFT)*(update rate)
high frequency
example:
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16. REFERENCES
15. CONCLUSIONS
1. Bradley, Dan, “Introduction to FFT Terms and
The advent of affordable, reliable FFT data collectors Parameters”, IRD Mechanalysis, Inc, Technical
and analyzers have introduced a number of new terms Report #139, May 1989.
to the practicing vibration technician.
2. Catlin, John Jr., “The Significance of Averaging
An understanding of these basic concepts in signal for Swept Filter and FFT Analysis of Machinery
processing and data manipulation will enable one to Vibration”, Vibration Institute Proceedings,
select instrumentation and to understand its use. Tenth Meeting, June 1986.
In order to acquire accurate data, the vibration 3. Frarey, John L., “Concepts and Use of Real Time
technician must carefully select the proper Analyzers”, Vibrations, Vol. 2, No. 3,
parameters: measurement units, Fmax, lines of December 1986.
resolution, averaging, bands/alarms, history size, etc.
4. Harris and Crede, Shock and Vibration
The current trend in setting acceptable vibration Handbook, Mc-Graw-Hill, New York, NY, 1976.
limits is to use industry-proven severity charts
specific to machine type and operating conditions. 5. Gade and Hurlufsen, “Windows to FFT
Analysis”, Sound and Vibration, Vol. 22, No. 3,
March 1988.
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