VIBGUARD XP_Low-frequency vibrations - Online Condition Monitoring | Wireless Condition Monitoring | Advanced Condition Monitoring

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The art of measuring low-frequency vibrations

Rotor blades in wind turbines are growing longer – but also slower. Multimegawatt wind turbines turn even more
slowly. This means that reproducible low-frequency vibration monitoring will gain in importance not only for the
main rotor but also for the slow-operating gearbox components and roller bearings. Reliably measuring low
frequencies, however, can be rather tricky. There are some notable aspects, which also pose new challenges to
sensor and measurement hardware manufacturers. The following presents how PRUFTECHNIK Condition
Monitoring GmbH is testing new products in its own test facilities as well as in wind turbine field trials.

 
1 Introduction

In terms of system size, wind energy is one of the

industries experiencing the most „turbulent“ growth.
In the past, system manufacturers only had very
limited possibilities for testing wind turbines, which Figure 1: Calculation of excitation frequencies
in turn had a somewhat negative effect on system (here, a section of the gearbox analysis)
availability. Condition Monitoring Systems (CMS)
offer possibilities for collecting more information on
operating and functional behavior.This works quite
well in the fast and semi-fast-running drive train
ranges and is the basis for vibration-based condition
monitoring. There are difficulties in the slow-rotation
range, though, and with low-frequency vibrations. It
has happened that vibration measurement results
could not be compared with one another, or that the
wind turbines had highly perceptible vibrations and
visible movements that could not be proven
metrologically. Analyses and research findings showed that
there were limitations to sensor systems, measurement
hardware and the evaluation processes. New measurement
methods, such as „resampling“, have meanwhile become
the state-of-the-art – and not only for the condition
monitoring of variable-speed wind turbines. Experience in
the balancing of rotor blades in wind turbines under

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operating conditions shows that it makes sense to use low-

frequency vibrations as an additional source of information
for continuous condition monitoring. Within the scope of
standardization work for VDI 3834 and ISO 10816-21, low-
frequency vibrations were defined as an additional criterion
for assessing the vibration states of slowly rotating
component groups.

2 What are low-frequency vibrations?

According to VDI 3834 and ISO 10816-21, low-

frequency vibrations are defined as vibrations between
0.1 Hz to 10 Hz. These vibrations are analyzed for
their velocities and acceleration rates, and the least Figure 2: 30-s time
favorable values count. Just which excitation signal of the vibration
frequencies are excited by which component groups velocities at 6 rpm and
can be best determined on the basis of the kinematics 7 rpm and the
and frequency tables in the CMS software. Figure 1 associated frequency
shows a section of the excitation frequency spectra up to 1 Hz
calculations for the first stage on a planetary gearbox. plotted on a
First, of course, the rotational frequency of the main logarithmic amplitude
rotor – with its numerous harmonics – must be scale.
considered. Then, the main rotor with its three rotor
blades generates the rotor blade pass frequency (3p)
with harmonic multiples. Rotational frequency
excitations also originate at the main bearing, along
with other particular excitations that arise from the
roller bearing used (outer race, inner race, rolling
elements and cage). At the gearbox input, most of the
rotational frequencies of the first gear stage (LSS) and
the roller bearing frequencies usually lie in the
frequency range between 0.1 Hz to 10 Hz. In
planetary gear sets, the number of planets and the
associated rollover frequencies must also be taken into
account. The extent to which the excitations from
Figure 3: Different manifestations in a
other gear stages then lie in the frequency range of 0.1
vibration and wind turbine
Hz to 10 Hz depends on the drive train design, the
movement
gearbox design and the rotational speeds in operation.
In addition to these rotational-speed-dependent frequencies,
the frequency range between 0.1 Hz to 10 Hz is more or less
affected by the natural vibrations of the rotor blades, tower,
nacelle and/or drive train. The frequencies and amplitude
levels depend on the wind turbine design, and the
monitoring center providing diagnosis services should have
these data available. Advanced CMS, such as VIBGUARD
XP, are capable of working as an FFT analyzer and
determining these natural frequencies from temporary
measurements, or even monitoring them over the long term
to identify amplitude changes. For example, Figure 2 shows
time signals of the vibration velocity and low-frequency
vibration velocity spectra,measured at 6 rpm and 7 rpm
directly in themhub of a 2 MW wind turbine. The
comparisonof the frequency spectra shows how, at 6 rpm,
resonance can develop between the rotor blade pass
frequency and the tower‘s natural frequency. At 7 rpm, the
3p frequency lies higher and the tower‘s natural frequency

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at 0.33 Hz is not as strongly excited.

3 Low-frequency vibrations and movements around a

rotating main rotor
 
Wind turbines are demanding and complex vibration
and motion systems. Of
foremost interest are the mutually interactive motion
characteristics of the „rotor and rotor blade“ drive
machinery and how they are affected by gravity.
If gravity accelerometers are installed on the main
rotor of a wind turbine, the rotor movements – e.g. in
the centrifugal force direction – can be pinpointed as a
function of direction. Figure 4 presents an example of
a wind turbine start-up procedure. Shown are the
Figure 4: The generator speed and DC
generator rotational speed and a gravity acceleration acceleration of a rotor blade in the
in the centrifugal force direction, near rotor blade 3. circumferential direction while trundling and
When the accelerometer mounted on the rotor is at the during subsequent acceleration
bottom, then 1 g (9.81m/s²) is measured; when it is at
the top, then -1g (-9.81 m/s²) is measured. If
additional acceleration rates and tilting movements
occur with respect to gravity, vectoral influences take
effect. Using these measurements, it can be
graphically tracked just how the rotor with its rotor
blades accelerates, rotates or runs out. In the context
of condition monitoring, such sensors can be used to
detect whether it is always the same rotor blade, for
example, that comes to a halt at the bottom due to an Figure 5: Influencing the DC acceleration in the
unbalanced mass. In addition to determining the wind direction with specific pitches
rotational speeds and the acceleration, accelerometers such
as these make it possible to evaluate additional position-
dependent movements, angles of rotation of the individual
rotor blades and the effective unbalanced mass. In fact, it is
also possible to make in situ quality and acceptance checks
of the rotor blade sets right in the wind turbine. If the
gravity accelerometers are installed in the direction of the
wind, the same sensors offer the possibility of measuring
and tracking low-frequency movements and vibrations in
the wind direction. Here, of course, the direction and
positional dependencies in relation to gravity must be taken
into account. Figure 5 illustrates how specific changes in the
pitch angle influence the DC acceleration. This gives rise to
possibilities for process control and for regulating the wind
turbine.

In conjunction with condition monitoring, what is of

interest is how the elastic rotor blades deform as a
function of the wind speed and how consistently the
three rotor blades move relative to one another. Using
data collected over a period of one and a half day on

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VIBGUARD XP_Low-frequency vibrations - Online Condition Monitoring | Wireless Condition Monitoring | Advanced Condition Monitoring

one rotor blade, Figure 6 depicts these types of

accelerations in the centrifugal force direction and in
the wind direction, and also shows a plot of the wind
speed. As wind speeds become stronger, the 
acceleration changes based on the wind direction; this
can be used for condition monitoring of the rotor
blades. The question now arises as to how such
varying gravitational acceleration rates can be
explained. Answers are provided by operational
deflection shape (ODS) analyses, where identically
constructed sensors are installed in the pod, hub, rotor
blades and drive train,as well as in the tower, and
synchronized measurements are made at the same
time and in the same phase. With regard to condition
Figure 6: Acceleration rates for rotor blade 3 in
monitoring, such innovative measurement possibilities
the
whet the appetite to obtain more information on the
vibrational behavior at the upper and lower deflection
points of the rotor blades. Thus, for instance, wear and
tear in the pitch bearing mounts, electrical or
hydraulic pitch errors, or individual rotor blade
damage can all lead to runtime differences between
the 3 rotor blades. These can be monitored using
cameras or laser technology. Or, directionally-
dependent additional vibrations and additional
movements can occur. Gravity accelerometers make
taking these measurements a lot easier.
  centrifugal force direction (above) and in the
wind

4 Low-frequency vibration analyses in the stationary

tower/pod system

In drive train condition monitoring, it has become

practice to monitor the radial and axial pod vibrations
in the frequency range of 0.1 Hz to 10 Hz on a
continual basis.
If peaks become apparent in the statistical distribution,
the causes should now be analyzed and eliminated if
possible. How is this done?

 
Figure 7: Achieved rotor blade balance grades

Based on frequency and/or order analyses, diagnostic

specialists first evaluate which component
predominates when and how. Then, they try to
identify natural frequency excitations by measuring
runout amplitude spectra or using operational
deflection shape analyses. If rotational frequency

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VIBGUARD XP_Low-frequency vibrations - Online Condition Monitoring | Wireless Condition Monitoring | Advanced Condition Monitoring

excitations dominate in the radial measurement

direction, single-plane operational balancing will
often correct the problem. If the tower‘s natural
frequency is very prominent, however, finely-tuned
balancing will be necessary to take as much energy
out of the tower as possible so that the natural
vibration in question is no longer excited. The
necessary balance grade is achieved when the green
range stipulated by VDI 3834 is reached
during the balancing process.
Just how precise are such quantitative vibration
velocity analyses?The devil is in the details,
particularly as the integration of very low-frequency
vibration signals is no easy task. In the following
section, the results of „the art of measuring low-frequency
vibrations“ will be presented.

 
5 Sensors, measuremen technology and test options
Using hybrid accelerometers

Specifically for the wind energy sector,

PRUFTECHNIK has developed a hybrid
accelerometer that can measure from 0 Hz (type VIB
6.216). The characteristic lines of the new Triax
accelerometer and a picture of the sensor are shown in
Figure 8. The sensor has no damping along the X and
Y axes and its sensitivity is 500 mV/g. Users of
accelerometers should note that only special
accelerometers have such ideal characteristic lines. In
the past, the most commonly used piezoelectric
accelerometers could only measure from 2 Hz. This Figure 8: Characteristic lines of the hybrid
dropped to 0.5 Hz and, today, devices that can triaxial accelerometer VIB 6.216 (top:
measure from 0.1 Hz are already available at characteristic line for the X and Y axes, bottom:
haracteristic line for the Z axis)
affordable prices. Users should first have sensor
manufacturers provide them with the characteristic
lines of the sensors in order to see the magnitude of the
damping. For instance, at first glance, deviations of 3 dB or
9 dB might not seem like much numerically, but when
viewed in relation to pod vibrations of 100 mm/s, they
would lead to erroneous measurements of 70.8 mm/s (3 dB)
or even 35.5 mm/s (9 dB). This results in the rotor blade
and pod vibration readings being too low on the measuring
device by orders of magnitude. Roller bearing condition
analyses are, however, different. Here, piezoelectric
accelerometers are unparalleled; they make it possible to

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measure acceleration shocks of up to 100 g and can even

handle the high-frequency resonance frequencies of rolling
elements.
With the new hybrid Triax acceleration sensors,
PRUFTECHNIK has combined the proven TANDEM-
PIEZO technology with MEMS technology. This equipment
uses a single sensor to perform not only machine diagnoses
along the x, y and z axes, but also additional roller bearing
diagnostics (along the z axis) and the previously described
directionally-dependent acceleration rate diagnoses (along
the x and y axes).

The measurement chain determines the quality of the results

Sensors alone are not enough to precisely measure low

frequencies. DIN ISO 2159 and other standards specify that
the entire measurement chain should operate with an
inaccuracy of no more than 2 dB in specific frequency
ranges. A measurement chain consists of the vibration
sensor, the measurement system and the analysis software.
It starts with the AD conversion and continues through to
measurement processing and integration before finally
providing vibration velocities. Hardware and software
manufacturers require suitable testing equipment in order to
adapt the entire measurement chain, right up to the
software, to specific applications and to control it
throughout.

Necessary quality controls

The quality of low-frequency vibration measurements can be

examined internally and externally, and can even be
confirmed by the PTB (Physikalisch-Technische
Bundesanstalt, Germany‘s national metrology institute). In
addition to „conventional“ measurement and test facilities,
PRUFTECHNIK has of its own 3-axis motion simulator
(Fig. 9), which makes it possible to rotate, position, wobble,
tip, pivot and pitch items at freely-selectable rotational
speeds, frequencies and signal waveforms. We will now
report on verification measurements taken with
VIBGUARD XP in the motion simulator, where positioning
procedures, rotational movements and pitch movements can
be simulated – much like in a wind turbine. In order to
obtain an idea of which signal deviations can be expected in
the low-frequency range, other accelerometers were also
tested at the same time.

Figure 10, on the left, shows simple positioning

procedures in the form of gravity acceleration, and on

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the right, it shows them as RMS and 0-p vibration

velocity in the frequency range of 0.1 Hz to 10 Hz.
The respective sensor positions are read from the
directionally-dependent acceleration operations, and
the stresses that occur when the motion simulator is
accelerated or slowed are determined using the
vibration velocity. By comparing the amplitudes, it is
even possible to detect the influences of residual
Figure 10: Positioning procedures in the motion
imbalance.
simulator (left: acceleration rates in the
Vibration velocity analyses in the motion simulator are
gravitational vector; right: RMS and 0P vibration
handled similarly to those in a wind turbine.
velocities at 0.1 Hz – 10 Hz)

Figure 11 shows the vibration velocity time signals at

6 rpm and 9 rpm and the frequency spectra computed
in VIBGUARD XP in a logarithmic diagram.

Figure 11: Time signals and frequency spectra at

6 rpm and 9 rpm in the 3D motion simulator

Figure 12 shows a comparison of continually recorded

RMS and 0-p vibrationvelocities in the frequency
range of 0.1 Hz to 10 Hz while the system was
inmotion at different rotational speeds in the motion
simulator. The diagrams reveal that the signal levels
of the right sensor deviate significantly, giving us
reason to doubt the linearity here.
 

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6 Outlook
Figure 12: RMS and 0P vibration velocity values
The experience and examples described here at 0.1 Hz – 10 Hz for three different
demonstrate that manufacturers of measuring and accelerometers (simultaneously measured at
testing equipment have the potential and the different rotational speeds)
possibilities to make new technologies available to the
wind energy sector in the form of innovative and
hybrid solutions. Even the slow-operating „rotor with
rotor blades“ drive machinery can now be measured
and monitored using the new hybrid triaxial
accelerometers described above. Manufacturers and
operators of wind turbines have the option of
extending the conventional condition monitoring of
the drive train to the main rotor and rotor blades. In
future, it should even be possible to use acceleration
signals in single-pitch systems for low-vibration pitch
actuation.
 
7 Literature
[1] www.telediagnose.com , Issue 5 and Issue 12
[2] Becker E., Lösl: “Unwucht birgt Gefahren für
Komponenten- Das Auswuchten von Rotorblättern
kann Schwingungen mindern” (Imbalance poses
hazards to components; rotor blade balancing can
reduce vibrations); Z. Erneuerbare Energien (Renewable
energies publication), 08-2009
[3] VDI 3834 Sheet 1 “Messung und Beurteilung der
mechanischen Schwingungen von Windenergieanlagen und
deren Komponenten – Windenergieanlagen mit Getrieben“
(Measuring and assessing the mechanical vibrations of wind
turbines and their components; wind turbines with
gearboxes)
[4] ISO DIS 10816-21:2013 (E): “Mechanical
vibration evaluation of machine vibration by measurements
on non-rotating
parts; Part 21: Horizontal axis wind turbines with gearbox”
[5] Germanischer Lloyd Industrial Services GmbH, Wind
energy business sector, 2013: “Richtlinie für die
Zertifizierung von Condition Monitoring Systemen für
Windenergieanlagen” (Guidelines for the certification of
condition monitoring

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systems for wind turbines) Windenergieanlagen“

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