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Dec 14, 2012

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vibration analysis

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vibration analysis

Attribution Non-Commercial (BY-NC)

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Beginning Vibration

Introduction

Understanding the basics and fundamentals of vibration analysis are very 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 in the 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.

Jack D. Peters

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.

Jack D. Peters

fn = 1/2 k/m

Where: fn = natural frequency (Hz) k = stiffness (lb/in) m = mass mass = weight/gravity weight (lb) gravity (386.1 in/sec2)

Jack D. Peters 4

Concept !

fn = 1/2 k/m

If k increases Then f increases If k decreases Then f decreases

Jack D. Peters

Concept !

fn = 1/2 k/m

If m increases Then f decreases If m decreases Then f increases

Jack D. Peters

Spectrum

Whats This ?

1 0.0002 inch Peak

Magnitude

0 0 Hz 100 Hz

Jack D. Peters

Spectrum

1 0.0002 inch Peak

Magnitude

0 0 Hz 100 Hz

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Spectrum

Scaling X & Y

1 0.0002 inch Peak

Magnitude

0 0 Hz 100 Hz

X

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Spectrum

Scaling X & Y

A M P L I T U D E

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Magnitude

0 0 Hz

FREQUENCY

10

100 Hz

Spectrum

Scaling X & Y

1

H o w B a d I s I t

Magnitude

0 0 Hz

What is it

11

100 Hz

Jack D. Peters

Time Waveform

Whats That ?

1 0.0004 inch

Real

-0.0004 0 s 7.996094 s

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12

Time Waveform

Time Waveform

1 0.0004 inch

Real

-0.0004 0 s 7.996094 s

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13

Time Waveform

Scaling X & Y

1 0.0004 inch

Real

-0.0004 0 s 7.996094 s

X

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Time Waveform

Scaling X & Y

A M P L I T U D E

Jack D. Peters

1 0.0004 inch

Real

-0.0004 0 s

TIME

7.996094 s

15

Time Waveform

Scaling X & Y

H o w B a d I s I t

-0.0004 0 s 1 0.0004 inch

Real

What is it

7.996094 s

Jack D. Peters

16

Time Waveform

Scaling X & Y

1

H o w B a d I s I t

0.0004 inch

Real

-0.0004 0 s

What is it

17

1 s

Jack D. Peters

Double Trouble

1 0.0002 inch Peak Magnitude 0 0 Hz 1 0.0004 inch Real -0.0004 0 s 7.996094 s 100 Hz

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18

The X Scale

The X Scale

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19

The X Scale

Hertz (Hz)

One Hertz (Hz) is equal to 1 cycle / second It 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 have running speeds related to revolutions / minute (rpm). 60 cpm = 1 cps = 1 Hz

Jack D. Peters 20

The X Scale

The frequency domain is an expression of amplitude and 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.

Jack D. Peters 21

The X Scale

Concept !

If: Then:

Jack D. Peters

22

The X Scale

Concept !

FT = 1 If: F increases

Then: F decreases

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The X Scale

Single Frequency

X:55 Hz Pwr Spec 1 1 V rms Magnitude 0 0 Hz X:27.00806 ms dX:18.18848 ms Time 1 1 V Real -1 0 s 62.46948 ms Y:3.579427 mV dY:2.449082 mV 100 Hz Y:706.8129 mV

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24

The X Scale

Multiple Frequencies

X:55 Hz Pwr Spec 1 1 0 Hz X:78 Hz Pwr Spec 1 1 0 Hz X:21 Hz Pwr Spec 1 1 0 Hz X:42 Hz Pwr Spec 1 1 0 Hz 100 Hz Y:706.9266 mV 100 Hz Y:706.7825 mV 100 Hz Y:706.9236 mV 100 Hz Y:706.8129 mV

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25

The X Scale

Multiple Time

Time 55 1 1 V 0 s Time 78 1 1 V 0 s Time 21 1 1 V 0 s Time 42 1 1 V 0 s 62.46948 ms 62.46948 ms 62.46948 ms 62.46948 ms

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26

The X Scale

55 + 78 + 21 + 42 = Trouble !

TIME 1 4 V Real -4 0 s 62.46948 ms

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27

The X Scale

Frequency Spectrum

TIME 1 4 V Real -4 0 s X:21 Hz X:42 Hz X:55 Hz X:78 Hz FREQUENCY 1 1 V rms 0 Hz 100 Hz Y:706.7825 mV Y:706.9266 mV Y:706.8129 mV Y:706.9236 mV 62.46948 ms

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28

The X Scale

Amplitude

Inp ut

Tim e

Tim eW

Fr

cy uen eq

um ectr Sp

ave for m

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29

The X Scale

Lines of Resolution

The FFT always has a defined number of lines of resolution. 100, 200, 400, 800, 1600, and 3200 lines are common choices.

1 0.0002 inch Peak

Magnitude

This spectrum has 800 lines, or the X scale is broken down into 800 points.

0 0 Hz 100 Hz

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30

The X Scale

Filter Windows

Window filters are applied to the time waveform 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 !

Jack D. Peters

31

The X Scale

Window Comparisons

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32

The X Scale

Filter Windows

Hanning (Frequency) Flat Top (Amplitude) Uniform (No Window) Force Exponential (Frequency Response)

Force/Expo Set-up

Window functions courtesy of Agilent The Fundamentals of Signal Analysis Application Note #AN 243

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33

The X Scale

Filter Windows

Use the Hanning Window for normal vibration monitoring (Frequency) Use the Flat Top Window for calibration and accuracy (Amplitude) Use the Uniform Window for bump testing and resonance checks (No Window)

Jack D. Peters 34

The X Scale

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

Jack D. Peters 35

The X Scale

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

Jack D. Peters 36 Note: More discussion later on window functions for the analyzer !

The X Scale

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

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

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

Data sampling time is the amount of time required to take one 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

Average - On Overlap Percent - 50% TR#1 TR#2 TR#3

FFT#1 FFT#2 FFT#3

0% Overlap

TR#1 How long will it take for 10 averages at 75% overlap using a 800 line analyzer and a 200 Hz frequency span? TR#2 TR#3

FFT#1

50% Overlap

FFT#2 FFT#3

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41

The X Scale

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

Jack D. Peters 42

The Y Scale

The Y Scale

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43

The Y Scale

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

The Peak - Peak value is expressed from the peak to peak amplitude. The spectrum value uses the suffix Pk-Pk to denote this.

X:55 Hz Pwr Spec 1 2 V Pk-Pk Magnitude 0 0 Hz X:22.43042 ms dX:9.094238 ms Time 1 1 V Real -1 0 s 62.46948 ms Y:-993.8563 mV dY:1.994871 V 100 Hz Y:1.999169 V

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45

The Y Scale

Pk (Peak)

The time wave has not changed. The Peak value is expressed from zero to the peak amplitude. The spectrum value uses the suffix Peak to denote this.

X:55 Hz Pwr Spec 1 1 V Peak Magnitude 0 0 Hz X:27.00806 ms dX:4.516602 ms Time 1 1 V Real -1 0 s 62.46948 ms Y:3.579427 mV dY:997.4356 mV 100 Hz Y:999.5843 mV

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46

The Y Scale

The time wave has not changed. The RMS value is expressed from zero to 70.7% of the peak amplitude. The spectrum value uses the suffix RMS to denote this.

Jack D. Peters

Y:706.8129 mV

62.46948 ms

47

The Y Scale

Suffix Comparison

X:27.00806 ms dX:2.288818 ms Time 1 Y:3.579427 mV dY:709.1976 m 2 V rms Magnitude 0 0 s X:27.00806 ms dX:4.516602 ms Time 1 62.46948 ms Y:3.579427 mV dY:997.4356 m 2 V Peak Magnitude 0 0 s X:22.43042 ms dX:9.094238 ms Time 1 62.46948 ms Y:-993.8563 mV dY:1.994871 V 2 V Pk-Pk Magnitude 0 0 s 62.46948 ms 0 Hz 100 Hz 0 Hz X:55 Hz Pwr Spec 1 100 Hz Y:1.999169 V 0 Hz X:55 Hz Pwr Spec 1 100 Hz Y:999.5843 mV X:55 Hz Pwr Spec 1 Y:706.8129 mV

RMS

1 V Real -1

Peak

1 V Real -1

Peak - Peak

1 V Real -1

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48

The Y Scale

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

Jack D. Peters 49

The Y Scale

Standard Suffixes

Now that we have learned all about the three standard 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 = gs Peak or rms..

Note: 1 mil = 0.001 inches

Jack D. Peters 50

The Y Scale

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 1 V / in/s 50 mV / psi 33 mV / %

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51

The Y Scale

Sometimes we forget to use EUs, or just dont understand how to 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 gs ? Answer = 10 mV / 100 mV = 0.1 g

Jack D. Peters

52

The Y Scale

Jack D. Peters 53

The Y Scale

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 EUs ?

Jack D. Peters

54

The Y Scale

386.1 What ?

1g = 32.2 feet/second2 32.2 feet 2 second

X

12 inches foot

2

386.1 inches/second g

Jack D. Peters

55

The Y Scale

386.1 Acceleration (gs) x 386.1

Jack D. Peters 56

2(Pi)f

2(Pi)f

The Y Scale

9807 Acceleration (gs) x 9807

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2(Pi)f

2(Pi)f

The Y Scale

Peak - Peak

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x .707

The Y Scale

0.5g x 386.1 inches second2 g

1.23 inches/second

Jack D. Peters 59

The Y Scale

Acceleration - Velocity

Example: Find the equivalent peak velocity for a 25 Hz vibration 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

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60

The Y Scale

Velocity - Displacement

Example: Find the equivalent pk-pk displacement for a 25 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

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61

The Y Scale

Acceleration - Displacement

Example: Find the equivalent Pk-Pk displacement for a 52 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

Jack D. Peters

62

Sensors

Sensors

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63

Sensors

Accelerometers

Integrated Circuit

Electronics inside Industrial

Charge Mode

Charge Amplifier Test & Measurement

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64

Sensors

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

Jack D. Peters 65

Sensors

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 all applications

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Sensors

Relative movement between post & mass creates shear in ceramic producing charge. Mass Ceramic/Quartz Post

Jack D. Peters 67

Sensors

Accelerometer Parameters

Performance Suited for Application

Sensitivity (mV/g) Frequency Response of target (f span) Dynamic Range of target (g level)

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68

Sensors

500

Hz.

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69

Sensors

Realistic Mounting

Stud Bees Wax Adhesive Magnet Hand Held

In the real world, mounting might not be as good as the manufacturer had in the lab ! What happened to the high frequency ?

100

1,000 Frequency, Hz

10,000

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70

Sensors

Mounting Location

Vertical

Axial Horizontal

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71

Sensors

Mounting Location

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72

Sensors

Accelerometer Alarms

Machine Condition Velocity Limit rms peak < 0.08 < 0.12 0.12 - 0.28 > 0.28 < 0.16 < 0.24 0.24 - 0.7 > 0.7

Acceptance of new or repaired equipment Unrestricted operation (normal) Surveillance Unsuitable for Operation

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.

Jack D. Peters 73

Sensors

Proximity Probes

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74

Sensors

Driver 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 also varies. 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.

Target

Jack D. Peters

The variation of dc voltage is the dynamic signal indicating the vibration or displacement.

75

Sensors

Output Values

Typical

100 mv/mil 200 mv/mil

Calibration Examples

Copper Aluminum Brass Tungsten Carbide Stainless Steel Steel 4140, 4340 380 mV/mil 370 mV/mil 330 mV/mil 290 mV/mil 250 mV/mil 200 mV/mil

Depends on probe, cable (length), and driver. Target material varies output.

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76

Sensors

Non-contact Measure shaft dynamic motion Measure shaft static position (gap) Flat frequency response dc 1KHz Simple calibration Suitable for harsh environments

Jack D. Peters 77

Sensors

Probe can move (vibrate) Doesnt 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 from surrounding metal

Jack D. Peters 78

Sensors

Typical Mounting

vertical probe horizontal probe H V time

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Sensors

Looking at Orbits

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80

Sensors

Mils

ils

Mils

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81

Sensors

Unbalance

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82

Sensors

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83

Sensors

Misalignment

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84

Sensors

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85

Sensors

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86

Sensors

Machine Condition Allowable R/C < 3,600 RPM < 10,000 RPM 0.3 0.3 - 0.5 0.5 0.7 0.2 0.2 - 0.4 0.4 0.6

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.

Jack D. Peters 87

Sensors

Coupling - AC, DC

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.

Analyzer Input Capacitor Blocks DC

Prevents frequencies that are greater than span from wrapping around in the spectrum.

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 Hz 175 Hz - 128 Hz = 47 Hz. 128 Hz - 47 Hz = 81 Hz

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88

Sensors

To the right is a typical problem with frequency response at the low end of the frequency spectrum. This low end roll off was a result of AC coupling on CH #2 of the analyzer. Values below 2.8 Hz are in error, and values less than 0.5 Hz should not be used.

Jack D. Peters

Input 1 0.01 V rms Magnitude 0.002 0 Hz Output 2 0.01 V rms Magnitude 0 0 Hz X:500 mHz X:2.8125 Hz Freq Resp 2:1 2 Magnitude 0 0 Hz X:5.34375 Hz Coherence 2:1 1.1 Magnitude 0.9 0 Hz 25 Hz Y:1.000001 25 Hz Y:720.0918 m Y:984.7542 m 25 Hz 25 Hz

89

Data Collection

Data Collection

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90

Data Collection

Multi-channel digital audio tape recorders.

Jack D. Peters 91

Data Collection

Large PC driven solutions with multiple channels and windows based software.

Smaller portable units with 2 4 channel inputs and firmware operating systems.

Jack D. Peters 92

Data Collection

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93

Data Collection

Route Based Frequency Spectrum Time Waveform Orbits Balancing Alignment

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94

Beginning Vibration

Bibliography

Eisenmann, Robert Sr. & Eisenmann, Robert Jr., Machinery Malfunction Diagnosis and Correction, ISBN 0-13-240946-1 Eshleman, Ronald L., Basic Machinery Vibrations, ISBN 09669500-0-3 LaRocque, Thomas, Vibration Analysis Design, Selection, Mounting, and Installation, Application Note, Connection Technology Center Agilent Technologies, The Fundamentals of Signal Analysis, Application note 243 Agilent Technologies, Effective Machinery Measurements using Dynamic Signal Analyzers, Application note 243-1

Jack D. Peters

95

Beginning Vibration

Thank You !

You can find technical papers on this and other subjects at

www.ctconline.com

in the Technical Resources section

Jack D. Peters

96

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