Professional Documents
Culture Documents
Instrumentation Requirements
Vibration measurements will be made with an FFT analyzer. The type, model, serial number(s) and latest
certified calibration date of all equipment used in the measurement of vibration levels for machine
certification, shall be recorded and made available upon request.
FFT Analyzer
The FFT Analyzer shall be capable of a line resolution bandwidth Df = 150 CPM for the frequency range
specified for machine certification unless this restriction would result in less than 800 lines of resolution, in
which case the requirement defaults to 800 lines of resolution. (Higher resolution may be required to
resolve "Side Bands," or in Band 1 to resolve machine vibration between 0.3X and 0.8X Running Speed.)
The Dynamic Range shall be a minimum of 90 dB.
The FFT analyzer shall be capable of applying a Hanning window.
The FFT analyzer shall be capable of linear non-overlap averaging.
The FFT analyzer shall have anti-aliasing filters.
MEASUREMENT SYSTEM ACCURACY
The measurement system (FFT analyzer, cables, transducer and mounting) used to take vibration
measurements for machine certification and acceptance shall have a measurement system. Amplitude
accuracy over the selected frequency range as follows:
For displacement and velocity measurements l0% or 1 dB.
For acceleration measurements 20% or 1.5 dB.
VIBRATION TRANSDUCERS
An accelerometer shall be used in the collection of data for machine certification and acceptance. The
accelerometer must be selected and attached to the machine in such a way that the minimum frequency
(Fmin) and maximum frequency (Fmax) as specified in Section 9 or specified otherwise by the purchaser,
are within the usable frequency range of the transducer and can be accurately measured (reference
recommendations of pickup manufacturer and/or Section 6.3, ANSI S2.17-1980).
The mass of the accelerometer and its mounting shall have minimal influence on the frequency response of
the system over the selected measurement range. (Typical mass of accelerometer and mounting should not
exceed 10 % of the dynamic mass of the structure upon which the accelerometer is mounted.) Reference
Appendix for Dynamic Mass definition and Procedure to Determine Mass Effect
Integration is acceptable as a means of converting acceleration measurements to velocity or displacement,
or for converting velocity measurements to displacement.
VIBRATION MEASUREMENT AXES DIRECTIONS
Axial direction (A) shall be parallel to the rotational axis of the machine.
Radial directions (R) shall be:
at 90 (perpendicular) relative to the shaft (rotor) centerline.
Vertical shall be in a radial direction:
on a machine surface opposite the machine mounting plate.
For motors or pumps that are end mounted, vertical readings shall be taken in a radial direction relative to
axial readings on a surface opposite the machine to which the motor or pump is attached (reference Figure
2-b).
Horizontal shall be in a radial direction:
at a right angle (90) from the vertical readings:
In the direction of the shaft (rotor) rotation (Reference Figure 2a and 2b).
For electric motors, the Electrical Connection Box (Pot Head) may be used as the horizontal location
relative
to vertical (reference Figure 3).
Other:
Any radial direction other than Horizontal or Vertical
(A) FOOT-MOUNTED
Figure 2 Vibration Measurement Axes Directions
(B) END-MOUNTED
Figure 3 Vibration Measurement Axes Directions
VIBRATION MEASUREMENT LOCATIONS
Required measurement positions and orientations on a machine's surface at which vibration measurements
are to be taken shall be determined by mutual agreement of the purchaser and the machine builder, and
shall meet the following requirements:
Follow the convention specified, unless specified otherwise by the purchaser.
If an obstruction or safety prevents locating a transducer as specified, locate as close as possible to the
standardized position.
Measurement locations used for machine certification and acceptance shall be identified on the machine
layout drawing and/or machine as mutually agreed upon by the purchaser and the machine builder.
Vibration measurement locations shall be on a rigid member of the machine, as close to each bearing as
feasible. Bearing housings, bearing pedestals, machine casings or permanently mounted pickup mounting
blocks are examples of suitable mounting locations.
Vibration measurement location shall NOT be on a flexible cover or shield such as the fan cover on an
electric motor or a sheet-metal belt guard.
Guarding must be designed to allow accessibility to all measurement locations
In the event that vibration monitoring points will be rendered inaccessible after the machine is built or
access to the measurement points would present a safety problem during measurement, the purchaser shall
be contacted to determine if Permanently mounted transducers are to be installed.
Measurement locations shall be numbered consecutively from 1 to N in the direction of power flow per the
following:
Position 1 designates the "out-board" Starting Power Point bearing location of the driver unit of the
machine. Position N designates the bearing location at the "terminating" Power Point bearing location of
the driven machine. (Reference Figure 3A and Figure 4)
When a machine station consists of multiple components, such as two or more spindles, consecutive
numbering of components shall be in the direction of process flow. (Reference Figures 3A and 3B).
Other Component Symbols not listed above should be agreed upon by the machine tool builder and the
purchaser on an as-needed basis.
TRANSDUCER & MACHINE MOUNTING CONDITIONS
VIBRATION TRANSDUCER MOUNTING At the designated measurement positions, suitable surfaces
shall be provided such that the mounted transducer will attach securely.
Hand-held pickups are not acceptable for measurement by this specification.
For a magnetic base mounted transducer the location on a machine's surface at which vibration
measurements are to be taken shall be machined, if necessary, such that the magnet base can be attached
firmly without "rocking."
For a stud mounted transducer the machine's surface at which vibration measurements are to be taken shall
be in accordance with that specified by the transducer manufacturer (torque, grease, etc.) Designated
transducer type to be specified by the purchaser.
If an adhesive is used to attach either the transducer or a magnetic mounting pad, the upper frequency limit
of the transducer shall be reduced by 20% of the manufacturer's stated resonance for "hard" adhesives and
by 50% of the manufacturer's stated resonance for "soft" adhesives. Transducer manufacturer's
specifications should be consulted.
The vibration transducer as mounted must be such that the measurement system Amplitude accuracy over
the selected frequency range equals or exceeds the requirements specified
MACHINE MOUNTING
Where a machine can be tested as an individual unit (e.g. motor, spindle, etc.) the machine must be
mounted as specified
Where an individual machine can be tested only as an assembled unit (e.g. motor/pump, motor/fan, etc.),
the machine mounting conditions shall be as equivalent as possible/feasible to those to be encountered
upon installation at the purchaser's site.
The "Peak" and "Peak-to-Peak" Vibration Amplitude Measurements will be a Calculated Peak not a True
Peak. The Calculated Peak will be derived from the RMS level based on the following equations:
Peak (P) = 1.414 x RMS
Peak-to-Peak (P-to-P) = 2 x (P) = 2 x 1.414 x RMS
If a "True Peak" is required, the units of vibration measurement will be designated by the words "True
Peak".
FREQUENCY BANDS
The frequency range of measurement shall be divided into sub-groups called bands. The Fmin and Fmax
for each band will be defined in units of frequency or orders of running speed of the machine.(Ref. Figure
5)
Mandatory Bands Band 1 shall be (0.3 - 0.8) X Running Order Band 2 shall be (0.8 - 1.2) X Running
Order Band 3 shall be (1.2 - 3.5) X Running Order
Other Bands
Bands 4 through N shall be defined by the specific machine tool application.
The maximum amplitude of any line of resolution contained within a band shall not exceed the Line
Amplitude Acceptance Limit
for the Band.
BAND-LIMITED OVERALL AMPLITUDE ACCEPTANCE LIMITS
For vibration level limits specified in terms of "BAND-LIMITED OVERALL AMPLITUDE
ACCEPTANCE LIMITS" the Total vibration level "A" in a band, as defined by the following equation,
shall not exceed the Overall Amplitude Acceptance Limit specified for the Band
the half key used for balancing, is not provided with the rotating machine, a tag, as shown below, will be
attached to the machine indicating the dimension of the key used to perform the balance test.
The purchaser shall have the option to verify vibration data of equipment during machine "run-off' at the
vendor's test site prior to shipment
The machine layout drawing shall be submitted as a part of the Machine Vibration Certification. Vibration
measurement locations on the machine's surface at which vibration measurements are taken shall be
designated on the drawing. At the option of the purchaser, Shaft speeds (RPM), gear type and number of
gear teeth, gear mesh frequencies (CPM), bearing manufacturer's name, bearing type number and class,
shall be identified on the machine layout drawing. Where gearboxes are involved, an insert such as
illustrated in Figure 4-e shall be included on the machine layout drawing.
ACCEPTANCE
Authorization for machine/equipment acceptance based on the vibration limits of this specification requires
signature by the purchaser's authorized representative. A copy of the acceptance must be sent to the plant's
purchasing department before final acceptance is authorized.
CRITICAL SPEED
Completely assembled motors shall have a percentage separation between the rotor shaft first actual critical
speed and the rated motor speed as specified:
Vibration data and signatures must be submitted with the motor to the Maintenance Engineering
Department or other authorized representative before acceptance of the motor will be authorized.
Motors not meeting the certification shall be rejected.
Figure 1 DEFAULT Line Amplitude Acceptance Limits for Non-Machine Tools and Non-Precision
Machine Tools
Figure 2 DEFAULT Band-Limited Overall Amplitude Acceptance Limits for Non-Machine Tools and NonPrecision Machine Tools
JACKSHAFTS
Below critical speed of Jackshaft Short coupling tolerances apply to each coupling of the jackshaft.
Above critical speed of Jackshaft Short coupling tolerances apply relative to the centerlines of the two
machines.
*References: The Optalign Training Book, 1990, Ludeca Inc., Miami, FL.
The Tolerances specified are the maximum allowable deviations from Zero-Zero Specifications or
ALIGNMENT TARGET SPECIFICATIONS (i.e. an intention targeted offset and/or angularity).
Acknowledging that machines often move after start-up due to THERMAL GROWTH, dynamic load
shifts, etc., the alignment parameters shall be measured and adjusted for operating conditions.
COUPLED SHAFTS ALIGNMENT VERIFICATION
Laser alignment will be performed on the machine tool builders floor on all shaft coupled machines.
When verifying the alignment of coupled shafts the machine tool builder must document and provide the
following data for each set of coupled shafts:
a. Alignment tolerances used.
b. SOFTFOOT
c. Vertical ANGULARITY (Pitch) at the COUPLING POINT
d. Vertical OFFSET at the coupling point.
e. Horizontal angularity (Yaw) at the coupling point.
f. Horizontal offset at the coupling point.
This information shall be provided to the purchaser at the time of functional check out.
Verification of alignment and re-alignment will be conducted at the purchasers facility during installation
of the equipment.
MACHINE BASES
MACHINE BASE CONSTRUCTION
A solid and rigid machine base is required to achieve and maintain shaft alignment.
Where bases are constructed using concrete or grouts final shaft alignment shall not be conducted until
ample curing time has taken place. (A minimum of Thirty days is recommended)
Where the machine foundation installation specification does not require a concrete or grout base or the
installation schedule does not permit the proper cure time for the concrete/grout
Where corrosion is or may be a problem the base must be fabricated of corrosive resistant materials. Where
the machine base is constructed from commercially available steel or castings:
Use H, M, I, square, tube, and bar shapes with a minimum 0.5 inch (1.27 cm) thickness.
For machine bases consisting of a single steel plate, plate thickness must equal or exceed the thickness of
the machine foot, but be no less than 1.0 inch (2.54 cm). The plate surface that the driver and driven
machines will bolted to must be machine ground and of sufficient size to accommodate the machine
components, push/pull blocks and/or jack screws. Jackscrews must not rest on any rounded edges.
Use of channel or angle stock is not recommended. Where use is necessary, the channel or angle stock must
be reinforced using square bar or plate meeting the preceding thickness requirements.
After all welding and machining is completed, stress relieve the entire base.
FOOT CENTER LINES
The stiffness of the machine base shall be sufficient that no foot centerline shall deform or deflect more that
.001 (.0254 mm) over the operating range from alignment conditions to full load conditions.
JOINING SHAPES TOGETHER
When joining shapes together they shall conform to the appropriate applicable A.S.M.E. and/or C.W.B.
standard(s) for welding.
REQUIREMENTS FOR MACHINE PADS OR FLATS
After all welding and machining has been completed and the base has been stress relieved, the surface of
all pads or flats for each machine to be installed on the base must be co-planar, within .001 inch (0.0254
mm).
MACHINE BASE SUPPORT
The feet of the driver and driven machines must not overhang the machine base.
JACKBOLTS
Jackbolts shall be located at the front and rear feet of the movable machine for horizontal alignment
positioning. (This requirement also applies to vertically mounted units and vertically mounted flanged
units). Jackbolts shall be parallel to the flat/pad surface and align on the center line formed by the hold
down bolts in the cross machine direction. Ample room shall be left for removal and insertion of shims
used in the vertical alignment of the coupled machines.
HOLD-DOWN BOLTS
The use of hold down bolts is the preferred method of fastening components to the base. Hold-down bolts
shall meet the following specifications:
a. Hold-down bolts for both the driver and the driven machine(s) (in pairs or in trains) shall be positioned
(spotted) after the machines shafts have been aligned.
b. Hold-down bolts shall be centered in the hole of the machine foot.
c. Hold-down bolts shall be the preferred method of fastening machines to the base.
d. Hold-down bolts shall not be undercut (Chicagoed) to achieve HORIZONTAL adjustment.
PIPING
Piping must be fitted, supported, and sufficiently flexible such that softfoot due to movement caused by
tightening pipe flanges doesnt exceed .002 (.051 mm). Piping must not restrict the minimum 180 degree
rotation requirement of the laser alignment system.
SHIMS
Shims shall meet the following specifications:
a. Commercially die-cut.
b. Made of corrosion and crush resistant stainless steel, which is dimensionally stable when subjected to
high compression over long periods of time.
c. Consistent over the whole shim area, without seams or folds from bending.
d. Clean, free from burrs, bumps, nicks and dents of any kind.
e. Size numbers or trademarks etched into the shim, not printed or stamped.
f. The smallest commercial shim that will fit around the hold down bolts without binding shall be used.
g. The overall shim pack shall not exceed a total of three (3) shims.
h. Shims must rest on bare metal, not paint or other coatings.
MACHINE VERTICAL MOBILITY
All machines shall be installed with a minimum of .125 inch (3.0 mm) dimensionally stable shims under
each surface mounting point for vertical mobility.
COUPLING PLAY/BACKLASH
OEMs must use only the couplings specified unless otherwise agreed upon by the purchaser. During the
alignment process coupling play or backlash must be eliminated to accomplish a precision shaft alignment.
AXIAL SHAFT PLAY
Axial shaft play or end play must be no greater than .125 inch (3.175 mm). Accommodation of end
movement must be done without inducing abnormal loads in the connecting equipment.
MACHINE BASE
MACHINE BASE CONSTRUCTION
A solid and rigid machine base is required to achieve and maintain spindle alignment.
Proper Civil engineering and Soil base Sampling should take place prior to pouring the machine base
foundation.
Where bases/foundations are constructed using concrete or grouts, final spindle alignment shall not be
conducted until ample curing time has taken place. (A minimum of Thirty days is recommended)
The machine base shall meet Level, Flat, and Coplanar requirements in a stress free condition.
The base shall have qualified leveling points. the qualified leveling points allow the machines flatness and
LEVEL to be checked quickly and easily.
a. The qualified leveling points shall be ACCESSIBLE and outside the projected area occupied by the
machine components. (Motors, Pumps, Spindle, Slide, Guards, etc.)
b. The qualified leveling points shall be located above each machine mounting point.
After all welding and machining is completed, stress relieve the entire base.
MACHINE BASE TOLERANCES:
a. Those portions of the machine base surface that support the slide assembly and the qualified leveling
points shall be flat within .0002 in per foot (0.0167 mm/meter).
b. The accumulative error in Flatness Surface Integrity over the entire machine base surface shall not
exceed the value agreed upon by purchaser and builder.
c. Qualified leveling points shall be coplanar within .0005 inch (0.0127 mm).
d. The qualified leveling points shall be parallel to the slide assembly mounting surface with .0005 inch
(0.0127 mm).
MACHINE BASE FLOOR MOUNTING
a. The machine base floor mounting technique shall be approved by the purchaser.
b. Machine base mounting points shall be accessible, adjustable and induce no unnecessary strains on the
machine base.
MACHINE WAYS
MACHINE WAYS BOLTED TO MACHINE BASE
Where the individual machine ways are bolted directly to the machine base, shims and/or grinding may be
used to achieve vertical angular alignment and a vertical position alignment as dictated by the process and
part tolerance. Alignment methodology and tolerances to be determined and agreed upon by the purchaser
and the machine builder.
MACHINE WAYS ASSEMBLY
The machine way assembly load bearing areas shall be mounted on individual FULL BEARING FITTING
SPACER BLOCKS. The SPACER BLOCKS shall be used to adjust the way assembly VERTICAL angular
alignment (PITCH) and vertical position alignment. The blocks shall have slotted holes for easy removal,
have a nominal thickness of .250 inch (6.350 mm) and mounting surfaces (top and bottom) shall be parallel
with .0005 inch. (0.0127 mm).
Individual spacer blocks at each bolt may be used where a full bearing fitting spacer block is not practical.
JACKBOLTS shall be used to move the way assembly vertically and be located adjacent to each
shim/hold down bolt support point.
PUSH/PULL BLOCKS shall be used to adjust the way assemblys HORIZONTAL angular alignment
(YAW) and horizontal position alignment. The push/pull blocks shall be accessible.
The machine way assembly shall not be doweled to the machine base.
MACHINE SPINDLE ADJUSTMENT DESIGN
The design of an align-able machine spindle assembly shall incorporate the following:
SINGLE AXIS BOX SPINDLES AND BOX SPINDLE CLUSTERS
Push/pull blocks shall be used for tracking and position alignment in the horizontal plane.
Full bearing fitting spacer blocks located under the front, rear, and all other support points of the spindle
shall be used for tracking and position alignment in the vertical plane. The blocks shall have slotted holes
for easy removal, have a nominal thickness of .250 inch (6.350 mm) and mounting surfaces (top and
bottom) shall be parallel within .0005 inch (0.0127 mm).
Flange mounted box spindles are not recommend.
MULTIPLE SPINDLES
Provide push/pull blocks for tracking and position alignment in the horizontal and vertical plane.
A reference spindle shall be designated by the purchaser.
All other spindle axes shall be parallel to the reference spindle axis within .0005 inch per foot (0.0417
mm/meter).
FLANGE MOUNTED SPINDLES
Push/pull blocks shall be used for position alignment in a plane parallel to the flange mounting.
Jackbolts shall be used for tracking error alignment.
BUSHING PLATES
Machine spindle and tooling shall be designed whenever possible to eliminate the need for Bushing Plates.
Where Bushing Plates are necessary:
Bushing liners shall not extend past or above the surface of the bushing plate. Bushing liner ID centerline
shall be perpendicular to the bushing plate mounting surface within .0010 inch per foot (0.0833 mm. per
meter).
Bushing plate liner position tolerances shall not exceed 5% of total part tolerance.
All bushing plate locating and mounting surfaces shall be ground to a known datum, square and parallel to .
0010 inch per foot.(0.0833 mm. per meter).
LASER ALIGNMENT SUPPORT SYSTEMS
NOTE: Nominal English/Metric dimensioning is used for Laser/Target Holding Adapter I.D. and Bushings
I.D.., therefore English to Metric I.D. conversions will not be exact, however the tolerance integrity must
be maintained.
LASER/TARGET HOLDING ADAPTERS shall be:
a. Practical to install and use while machine is in a production environment.
b. Shall mount to represent the spindles axis of rotation.
c. Provided by machine tool builder.
d. Standard inside diameter of each Laser holding adapter shall be ground to .7500 inch +.0010/-.0000 inch
I.D. (20 mm +.0250/-.0000 mm I.D.). If spacing or center distance constraints do not allow for a .7500 inch
(20 mm) inside diameter, then the inside diameter may be reduced to the next appropriate nominal size
+.0010/-.0000 inch (+.0250/-.0000 mm). Laser holding adapters shall be of a length that is as long as is
practical and conditions allow, and runout of the inside diameter to the mounting journal shall not exceed .
001 inch (0.0254 mm).
e. Standard inside diameter of each Target holding adapter shall be ground to .7500 inch +.0002/-.0000 inch
I.D. (20 mm +.0051/-0000 mm I.D.) If spacing or center distance constraints do not allow for a .7500 inch
(20 mm) inside diameter, then the inside diameter shall be reduced to the next appropriate nominal size
+.0002/-.0000 inch (+.0051/-.0000 mm).
f. Laser and Target post sizes should be common within one machine.
Adapters are required for each line-up application to secure the laser or target.
Each adapter shall be black oxide coated and have the following information clearly stamped and filled
with yellow paint on the body of the adapter.
The indexing direction of the pallet shall be clearly marked to eliminate incorrect loading by the operator.
The ability to index the master through each station with the transfer shall be considered during the initial
design.
The master will be used to periodically master the pallet checking gauge and shall incorporate all design
features for this inspection requirement.
All design concepts shall be approved by the purchaser prior to equipment build.
GUARDS & UTILITY CONNECTIONS
Guards shall have access covers and or be designed for easy removal ensuring that all alignments points,
shims and adjustment bolts are accessible.
All hard lines will be routed such that all alignment points, shims and adjustment bolts are accessible.
GLOSSARY
1) ACCESSIBLE: The ability to reach and adjust the aligning feature. Consideration should be given to
confined space restrictions, removing guards, bushing plates, hydraulic lines, lubrication lines, electric
lines etc.
2) ALIGNMENT TARGET SPECIFICATIONS: Desired intentional offset and angularity at coupling
center to compensate for thermal growth and/or dynamic loads. Most properly specified as an OFFSET,
and an angle in two perpendicular planes, horizontal and vertical.
3) ANGULAR ERROR: A misalignment condition characterized by the angular error between the desired
centerline and the actual centerline. This misalignment condition may exist in planes both horizontal and
vertical to the axis of rotation.
4) ANGULARITY: The angle between the rotational centerlines of two shafts. Angularity is a
slopeexpressed in terms of a rise (millimeters or thousandths of an inch) over a run (meter or inches).
5) A.S.M.E.:
American Society of Mechanical engineers
345 East 47th Street
New York, NY 1017
212-705-7722
6) AXIAL PLAY, AXIAL FLOAT, END FLOAT: Shaft axial movement along its centerline caused by axial
forces, thermal expansion or contraction, and permitted by journal bearings, sleeve bearings and/or
looseness.
7) BASE PLATE: The surface , often made of steel plate or cast iron, to which the feet of a machine are
attached.
8) CO-LINEAR: Co-linear means two lines that are positioned as if they were one line. Co-linear as used
in alignment means two or more centerlines of rotation with no offset or angularity between them. Two or
more lines are co-linear when there is no offset or angularity between them (i.e. they follow the same path).
9) COPLANAR: The condition of two or more surfaces having all elements in one plane. (per ANSI
Y14.5)
10) COUPLING POINT: The phrase COUPLING POINT in the definition of SHAFT ALIGNMENT is
an acknowledgment that vibration due to misalignment originates at a the point of power transmission, the
coupling. The shafts are being aligned and the coupling center is just the measuring point.
11) C.W.B.: Canadian Welding Bureau:
7250 West Credit Avenue
Mississauga, Ontario
L5N5N1
416-542-1312
12) FULL BEARING FITTING SPACER BLOCK: A single spacer block used for aligning the machine
tool in the vertical plane.
13) FLATNESS: The condition of a surface having all elements in one plane. (Per ANSI Y 14.5.)
Note: As used in this specifications, a flat is a small surface flush with or cut into a BASE PLATE,
machined flat, and co-planar with the other flats in the base plate. The flats support the Shims and/or feet of
the machine to be installed. A pad is a small block of metal that serves to elevate the feet of the machine
above the surface of the base plate. Pads are commonly used compensate for differences in machine center
line heights, and for increased corrosion resistance by raising the machine feet out of any possible standing
fluids. Pads and flats have holes drilled and tapped in their centers to accept hold down bolts.
14) HORIZONTAL: Parallel to the mounting surface.
15) JACKBOLTS, JACKSCREWS , PUSH/PULL BLOCKS: Positioning bolts on the machine base which
are located at, each foot of the machine and are used to adjust the position of the machines. Bolts mounted
on the machine base or foundation, optimally at the machine foot locations, which provides exact control in
positioning the machine.
16) LASER/TARGET ADAPTER: A laser/target adapter is an adapter which allows the laser/target to be
mounted into the spindle or master part.
17) LEVEL: Parallel to a reference plane or a reference line established by a laser.
18) MACHINE: The total entity made up of individual machine components such as motors, pumps,
spindles, fixtures, etc. Also reference MACHINE COMPONENT.
19) MACHINE BASE: The structure that supports the machine or machine components under
consideration.
20) MACHINE COMPONENT: An individual unit such as a motor, pump, spindle, fixture, etc. often
referred to as a machine in its own context.
21) MACHINE DEPENDENT: A condition which is dependent on the machining operation and the design
requirement of the part being machined.
22) OFFSET: The distance (in thousands of an inch or in millimeters) between two reference centerlines
such as a spindle center line and a part characteristic centerline or the rotational centerlines of two parallel
shafts.
35) TOLERANCE VALUES: Maximum allowable deviation from the desired values, whether such values
are zero or non-zero.
36) TRACKING/TRACKING ERROR: An angular MISALIGNMENT condition between spindle
centerline and the machine way centerline. This condition may be present in both parallel and
perpendicular to the way centerline
37) VERTICAL: Perpendicular to the horizontal plane.
38) YAW MISALIGNMENT: An angular misalignment in the horizontal plane.
39) N.I.S.T.
National Institute of Standards and Technology
Building 304, Room 139
Gaithersburg, MD 20899
301-975-3503
We plan to procure a gear box which will be attached to a motor of 500 Kw. The
manufacturer of the gear box is specifying 4.8 mm/s RMS as the vibration limit though we
would like to set the limit to 1.8 mm/s max. Is there any guideline available?
I would go for accepted at 2.8mm/s RMS as brand new or after a reasonable run in period at least some
70% full load or more to be a fair level in real life. How many have seen 1.8mm/s IRL unless you paid a
fortune for it and its a wonder of precision, in that case you may be correct. In my world all machines are
large and on weak foundation as there are no stiff foundations I(my)RL. Olov
Overcoming constraints in order to allow an inspection can help to extend gearbox life and avoid
catastrophic failure. This might save time, money, injury to personnel and damage to adjacent equipment.
This article describes the equipment and techniques necessary to perform an on-site gearbox inspection.
Getting Prepared
Before beginning an inspection, prepare an inspection form for documenting your observations. It should
be designed for your specific application. Next, assemble the necessary equipment (see sidebar on page
14).
Detecting Overheating
The following are signs of overheating:
Water in sight glass or sludge on filter element (may indicate oil cooler failure)
Metal chips on magnetic plugs, chip detectors or filters (may denote gear or bearing failure caused
by overheating)
Visual walkaround
Borescope inspection
Measure temperature
o Thermometers
o Resistance temperature detector (RTD)
probes
o Thermography
o Written
o Sketches
o Photography
o Contact patterns
For pressure-fed systems with an oil cooler, measure temperature at the gearbox oil inlet and outlet,
as well as the cooler water inlet and outlet.
Survey the gearbox housing temperature by touching it with the palm of your hand and using
temperature-sensitive paint, crayons and labels or a digital thermometer probe.
Check the gearbox housing temperature using an infrared thermometer or infrared imaging camera.
Analyze gearbox oil for signs of oxidation or thermal degradation using on-site and laboratory tests.
Analyze gearbox oil using particle counters, spectrometric analysis and ferrography to detect wear
debris.
Inspect internal gearbox components through inspection ports for signs of overheating,
misalignment, inadequate backlash, inadequate bearing endplay or oil oxidation.
If the gears or bearings are damaged but still functional, management may decide to continue operation and
monitor damage progression. In this case, the gear system should be continuously monitored. You should
also make certain there are no risks to human life.
For critical applications, examine the gears with magnetic particle inspection to ensure there arent any
cracks that prevent safe, continued operation. If there are no cracks, you should periodically perform a
visual inspection and measure temperature, sound and vibration.
Collect samples of the lubricant for analysis, examine the oil filter for wear debris and contaminants, and
inspect magnetic plugs for wear debris.
The best place to take an oil sample from a gearbox is as close to the gearset as possible. Using a minimess
sample port with tube extension will allow you to mount the sample port in the drain and manipulate the
tube so that it terminates exactly where you want it.
The rule of thumb for installing sample port tube extensions is to keep the end of the tube at least 2 inches
away from any static or dynamic surface.
You will need to flush the entire combination of tube extension, minimess sample port, sample port adapter
and sample tube before you take your sample for analysis. Flush at least 10 times the volume of all the
components prior to taking the sample for analysis. This typically works out to 3 or 4 ounces of fluid for a
sample port with a tube extension of 12 inches.
To prevent further damage to the gears and bearings from wear debris, replace the filter element and then
drain, flush and refill the reservoir with new lubricant. Continue to monitor lubricant properties during
operation and repeat the maintenance if necessary.
If cracks are found or the damage is severe enough to warrant removal of the gearbox, measure shaft
coupling endplay and alignment before removing the gearbox. Note the condition and loosening torque of
fasteners including coupling and mounting bolts. To check for possible twist in the gear housing, install a
dial indicator at each corner of the gearbox and then measure movement of the mounting feet as bolts are
loosened. If theres no twist, each indicator will record the same vertical movement. If there is twist,
calculate the twist from relative movements.
If no obvious damage is detected, document the condition of gears and bearings with photographs, sketches
and written descriptions. Also, record gear tooth contact patterns for future reference (see Recording Gear
Tooth Contact Patterns section).
3.5-inch magnifier
Torque wrench
contact tapes
Inspection forms
Ear plugs
Micrometers
Sweatband
Borescope
Toolbelt
Sound meter
Tweezers
Vibration probe
Spatula
Digital thermometer
Telescoping magnet
misalignment of the gear mesh. The result is that the gears are misaligned and the load distribution is not
uniform.
Recording Macropitting
A permanent record of macropitting can be obtained by painting teeth with marking compound and lifting
the macropitting pattern with transparent tape. The procedure is:
1. Clean the tooth by rubbing with a clean, lint-free cloth soaked in fast-drying solvent.
2. Paint teeth with a thin coat of marking compound. The compound PT-650 Tooth Marking Grease
available from Products/Techniques Inc. works best.
3. Place a length of transparent tape over the entire tooth. Allow the tape to fold over the edges and
topland to define boundaries of the tooth. Scotch No. 845 Book Tape is preferred.
4. Rub the back of the tape with a clean cloth to ensure intimate contact with the tooth surface.
5. Starting at one end, carefully peel the tape from the tooth.
6. Place one end of the tape (with adhesive side down) on white paper and carefully spread the tape
across the paper. Macropitted areas will appear white.
7. Annotate the record to fully describe tooth location and orientation.
Recording Micropitting
A permanent record of micropitting can be obtained by rubbing fine graphite into micropitted areas and
lifting the graphite pattern with transparent tape. The procedure is as follows:
1. Clean the tooth by rubbing with a clean, lint-free cloth soaked in fast-drying solvent.
2. Place a clean lint-free cloth on a flat surface and rub a drafting pencil on a file or sandpaper to coat
the cloth with graphite.
3. Rub the entire tooth surface with the cloth so graphite covers micropitted areas, topland and edges
of the tooth.
4. Rub the entire tooth surface with a clean lint-free cloth to remove loose graphite.
5. Place a length of transparent tape over the entire tooth. Allow the tape to fold over the edges and
topland to define the boundaries of the tooth. Scotch No. 845 Book Tape works best.
6. Rub the back of the tape with a clean cloth to ensure intimate contact with the tooth surface.
7. Starting at one end, carefully peel the tape from the tooth.
8. Place one end of the tape (with adhesive side down) on white paper and carefully spread the tape
across the paper. Micropitted areas will appear as dark gray, machining marks as lighter gray and
polished areas will look white.
9. Annotate the record to fully describe tooth location and orientation.
Machinery Lubrication (2/2012)