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Chrysler Machine & Tool Specifications

Powertrain Operations Vibration Standards

Vibration Standards

1. Purpose ................................................................................................................ 2
2. Intent .................................................................................................................... 2
3. Abstract ................................................................................................................ 2
4. Machine Vibration Data Acquisition ...................................................................... 2
5. Procedure ............................................................................................................. 3
6. Units of Measurement .......................................................................................... 4
7. Signature Readings .............................................................................................. 4
8. Pick-Up Points ...................................................................................................... 4
9. Qualification for Machine Acceptance .................................................................. 5
10. Requirements (Supplier Supplied Material) .......................................................... 5
Appendix A .......................................................................................................... 7
Appendix B .......................................................................................................... 9

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Chrysler Machine & Tool Specifications
Powertrain Operations Vibration Standards

1. Purpose

The purpose of these standards is to insure part quality, machine integrity and
machine maintainability via the means of failure predictability.

2. Intent

When procuring new, rebuilt or repaired equipment, it is Chrysler’s intent to insure


the quality of the purchase by applying vibration analysis and standards to check the
machine operating conditions.

2.1. The supplier is responsible for balancing the equipment in its assembled
state. All tooling, motors, sheaves, belts, etc. must be properly balanced and
aligned when the vibration data is collected. Any rework having to do with an
item not being properly balanced or aligned will be done by the supplier at no
expense to Chrysler.

3. Abstract

3.1. This document formally establishes guide lines for maximum acceptable
levels of vibration and required measurements on all precision and non-
precision machine tools. This includes the following:

1. Precision and non-precision box spindles.


2. All single and multiple spindle drill heads.
3. All single and multiple spindle pot heads.
4. All rough and finish milling, boring and grinding spindles and/or
heads.
5. All fans, pumps, motors, and compressors.
6. All gearboxes and power drive units that transmit motion.
7. All rotating equipment such as idlers.

4. Machine Vibration Data Acquisition

All equipment used to take vibration measurements must be taken with a CSI 2110
analyzer and a velometer or a accelerometer having a rare earth magnetic base
attached to the pick up. In cases where the magnetic base velometer is impractical,
a machined surface must be provided for a permanent accelerometer.

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5. Procedure

5.1. All vibration signatures and measurements must be taken using the following
techniques.

5.1.1. Data may not be collected in the off route mode available on the
analyzer. The complied data must be able to be loaded onto
mastertrend standard software. The purpose of this is so that double
work can be avoided in developing routes. The second reason is that
vibration equipment at the plant may be used in setting up the
equipment after it has been shipped from the supplier to the plant. The
Mastertrend Software can be purchased from CSI There is also a
start- up and technical support package, S - 2, which can be
purchased from CSI. The analysis parameter sets alarm limits or fault
frequencies do not have to be set up to match those in existence at
the plant. However, the supplier may include these in the database.

5.1.2. The method of data collecting shall be as follows:

1. Starting with the functional (output) end of the drive train, be it


tool end of a spindle or impeller end of a pump. Measurements
will be taken all the way back and through the input power
source. All bearing points en-route will have spectral data
taken. This includes idlers, brakes, feed pack bearings,
clutches, rotary couplings, etc.

2. The individual bearing points are to have their signatures taken


in the horizontal, vertical, and where required. Axial planes,
these planes are established by the configuration of the
equipment that is being measured (i.e. the slide unit on a
machining head in the horizontal plane for taking vibration
readings, regardless of its physical location on the equipment.

5.2. Velometers / accelerometers should be placed as close as possible to the


bearing being measured.

5.3. Velometers / accelerometers should be placed in the plane in which freedom


of movement is maximum.

5.4. Consideration should be given during the machine design stage for
accessibility to the points of measurement after guarding is installed without
necessitating removal. If impractical or a safety hazard a permanent mount
should be considered.

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Powertrain Operations Vibration Standards

5.5. When the rotating elements runs at speeds of less than 450 RPM, a low
frequency accelerometer should be used in lieu of a displacement type
transducer.

6. Units of Measurement

6.1. The following units must be used:

1. Peak - to - peak displacement in mils.


2. Peak velocity in inches / second.
3. Peak acceleration in “g's”.
4. High energy bearing readings in HFD.

6.2. Frequency should be measured in HZ or CPM. FMAX (MAXIMUM


FREQUENCY) if not supplied by supplier, the following will apply:

1. 300,000 CPM (5000 HZ) for spindles operating between 400 RPM to
3000 RPM.
2. 450,000 CPM (7500 HZ) for spindles operating above 3000 RPM.
3. 150,000 CPM (2500 HZ) for equipment below 400 RPM.
4. 150,000 - 200,000 for pumps and motors.

7. Signature Readings

Signatures for rotating elements will be taken in velocity and acceleration. In


addition to this, precision box spindles and their related peripherals are to have the
HFD readings taken.

8. Pick-Up Points

8.1. The pick up points of where the vibration signatures are acquired must have
the locations permanently mark with a stamp or an etching.

8.2. OPTION: MACHINED PADS FOR PICK-UP POINTS. Under certain


circumstances, Chrysler may elect to have the vibration pick-up points set off
by a milled pad for ease and accuracy of data collection. These pads are to
have 1.25" square surface. The pads must also have a smooth machined
surface which is raised above the bearing surface between 0.60"m and
0.125".

8.3. Precision box spindles will have the pads located on the horizontal, vertical
and axial locations unless they are overlapped in a cluster. Multiple heads will
have raised surfaces on the input drive shaft and the outermost spindles.
These surfaces will be in the horizontal and vertical plane. Break out the

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Powertrain Operations Vibration Standards

prices for precision spindles from the price for the drill heads. Supplier
responsibility in such instances shall be noted in the R.F.Q. specifications.

9. Qualification for Machine Acceptance

9.1. Vibration data required for machine acceptance will be taken before the run-
off on the supplier's facility by Chrysler. The responsibility for such a case will
be noted in the R.F.Q. specifications. The supplier is responsible for
adherence to the vibration limits spelled out in section 11 appendix A and B
which are provided in this document. Any deviation of this requirement must
be noted in writing by the supplier and the Chrysler representative.

9.2. The signatures of all vibration points will be taken once the overall allowable
limits have been met. These signatures will then be (*) "enveloped" for use in
on site qualification.

9.3. Upon shipment and installation of the quality run-off at the Chrysler facility
vibration data will be taken on the equipment. The supplier is responsible for
adherence to the vibration limits spelled out in section 11 appendix A and B
which are provided in this document. Any vibration signatures that deviate at
or above twenty five (25) percent are to be corrected by the supplier at no
expense to Chrysler.

9.4. The equipment is not acceptable until the overall levels of vibration along with
the signature envelope criterion are adhered to. Under no circumstances is
the supplier, in any way, relieved of responsibility to meet vibration tolerances
and limits for the entire machines purchased.

9.5. The machine builder is responsible for the precision alignment of all
couplings not disconnected for shipping / delivery purposes.

9.6. All data must be submitted to receiving Chrysler plant Manufacturing


Manager, for review and approval. Any deviation of this requirement must be
noted in writing by the supplier and the Chrysler representative.

10. Requirements (Supplier Supplied Material)

10.1. Locating points for vibration transducers placement will be supplied to


Chrysler (upon request) in a set of operation sheets which have a drawing of
that whole machine along with the location points.

10.2. The supplier will provide the Chrysler facility, upon request, with gear mesh
frequencies in cycles per minute (CPM) and shaft speeds in revolutions per
minute (RPM) on all equipment requiring vibration analysis. This includes

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gear boxes, multi- spindle heads, geared or belt driven box spindles.

10.3. Guarding must be designed so that measurement points are accessible.

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Powertrain Operations Vibration Standards

Appendix A

Definitions:

Acceleration - Acceleration is a measure of the change in velocity over an


interval of time, or the rate of change of velocity. It is
expressed in g's (where 1 "g" = 386 inches/ sec / sec) or
the force of gravity on a body.

Peak Acceleration - The maximum overall rate of change with respect to time
(measured in g's).

Displacement- The total distance traveled by the part, peak to peak, from
the rest position. It is expressed in mils (where 1 mil =
0.001 inch).

Velocity - Velocity is the measure of displacement over an interval of


time, or the rate of change of displacement. It is expressed
in inches / sec.

Peak Velocity - The maximum overall rate of change in velocity with


respect to time (measured in inches / sec).

HFD Energy - The measurement of transient impacts which in turn cause


high frequency energy.

Vibration - The complex periodic motion of a rotating or reciprocating


system in response to one or more forcing functions.

Forcing Function - A periodic force that causes a system to vibrate and then
maintain that vibration.

Period - The amount of time, normally in minutes, required to


complete one cycle of motion of the vibrating machine or
component.

Phase - The position of the vibrating component at a given instant


with reference to another vibrating part. Phase readings are
expressed in degrees from 0 to 360.

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Frequency - Frequency is the number of cycles of motion that occur


within a unit of time.

Amplitude - The distance centerline to peak of the vibration


displacement.

Signature - A graph of vibration amplitude versus time and / or


frequency.

Precision Spindles - Spindles containing class 7- 9 ball bearings or equivalent


roller bearings.

Resonance - The condition where the forcing function frequency


coincides with a system resonant frequency.

Resonant Frequency - The frequency at which a system will amplify the energy
input from the forcing function causing a rise in vibration
amplitude.

Bump Test - The method of testing for natural occurring frequencies via
the means of impacting (shock excitation). The vibration
signature then being recorded.

Harmonics - Multiples of a particular time interval (usually running


speed) which can be seen as clearly spaced peaks on the
vibration signature.

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Appendix B

Tables of Maximum Allowable Vibration Limits

Machine Tool Type: Peak Velocity Peak Acceleration

Grinders with
Precision Spindles

Using sleeve bearings - 0.02 0.5

Using rolling-element bearings - 0.04 0.4

Boring Machines with


Precision Spindles

Ultra precision - 0.04 0.4

Motorized spindle - 0.04 0.4

Standard precision - 0.05 0.5

Reaming Operations
Precision Spindles

Single box spindles - 0.04 0.4

Multi-spindle head - 0.09 1.0

Gun reaming - 0.05 0.04

Finish Milling
Precision Spindles

All types - 0.3 1.0

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Machine Tool Type: Peak Velocity Peak Acceleration

Turning Machines Using


Precision Spindles

Turret lathes - 0.3 1.0

Standard lathes - 0.4 1.25

Drilling with Non-


Precision Spindles

Single spindle (finish) - 0.2 0.75

Single spindle (rough) - 0.3 0.9

Single spindle (gear) - 0.3 1.0

Multiple spindle (finish) - 0.3 1.25

Multiple spindle (rough) - 0.4 1.5

Milling with Non-


Precision Spindles

Single spindle belt-driven (rough) - 0.35 1.4

Single spindle gear-driven (rough) - 0.4 1.5

Other Related Mechanical


Components

Hydraulic pumps - 0.25 1.0

Non precision gearboxes - 0.4 1.6

Electric motors - 0.25 1.5

Precision electric motors - 0.18 1.0

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Powertrain Operations Vibration Standards

Revision: Sec/Para Changed Change Made: Date


1 NA Initial re-release 1/2007
2 Entire Doc Changed all references of DaimlerChrysler to Chrysler 7/2007

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