Professional Documents
Culture Documents
1
Unbalance Vibration Monitoring
m Unbalance is the condition when the geometric centerline of a rotation axis doesn’t
coincide with the mass centerline.
Funbalance = m d ω2
1X
Radial
MP MP
A pure unbalance will generate a signal at the rotation speed and predominantly in
the radial direction.
3
Static Unbalance Vibration Monitoring
U
The static unbalance is seen when the machine is not in
operation, the rotor will turn so the unbalance mass is
at the lowest position.
4
Pure Couple Unbalance Vibration Monitoring
U = -U
-m
Pure couple unbalance is caused by two identical
S unbalance masses located at 180° in the transverse area of
the shaft.
Pure couple unbalance may be statically balanced.
m When rotating pure couple unbalance produces a
vibration signal at 1X, radial predominant and in
opposite phase signals in both ends of the shaft.
U b
5
Dynamic Unbalance Vibration Monitoring
6
Documentation of balancing Vibration Monitoring
.. after balancing
before ..
7
Overhung Rotors Vibration Monitoring
1X
Radial
Axial
8
Unbalance location Vibration Monitoring
9
Misalignment Vibration Monitoring
1X 2X
MP MP
Axial
10
Angular Misalignment Vibration Monitoring
1X 2X 3X
Axial
11
Parallel Misalignment Vibration Monitoring
1X 2X 3X
Radial
12
Misalignment Diagnosis Tips Vibration Monitoring
13
Alignment Tolerance Table Vibration Monitoring
The suggested alignment tolerances shown above are general values based upon experience and should not be exceeded.
They are to be used only if existing in-house standards or the manufacturer of the machine or coupling prescribe no other values.
14
Shaft Bending Vibration Monitoring
1X 2X
Axial
15
Rotating Looseness Vibration Monitoring
Rotating looseness is caused by an excessive clearance between the rotor and the bearing
Radial
Journal bearing:
Rotation frequency
1X Harmonics and
sub Harmonics.
Radial
16
Structural Looseness Vibration Monitoring
Structural looseness occurs when the machine is not correctly supported by, or well
fastened to its base.
MP
• Poor mounting
• Poor or cracked base
MP
MP MP • Poor base support
• Warped base
Condition Monitoring
17
Resonance Vibration Monitoring
Resonance is a condition caused when a forcing frequency coincides (or is close) to the
natural frequency of the machine’s structure. The result will be a high vibration.
1st form of natural 2nd form of natural flexure 3rd form of natural flexure
flexure
v v v
tx tx
t tx t t
18
Resonance Vibration Monitoring
1 2
Resonance
Step-up
rev/min
Grad
Phase jump
MP MP
by 180°
rev/min
1. 1.
O. O.
19
Resonance Diagnosing Tests Vibration Monitoring
20
Resonance Diagnosing Tests Vibration Monitoring
Bump Test:
s 1 2
Excitation - force pulse Response - component vibration
F/a 3
D t t
ouble beat
5 ms 1
2 Decaying function
Shock component, natural vibration, vertical Frequency response, vertical Frequency response, horizontal
2
Natural frequency, nd mod.
vertical
1st mod.
Natural frequency,
horizontal
t
21
Journal Bearings Vibration Monitoring
Journal bearings provides a very low friction surface to support and guide a rotor through a cylinder
that surrounds the shaft and is filled with a lubricant preventing metal to metal contact.
0,3-0,5X 1X
Oil whirl
Radial
• Oil-film stability problems.
• May cause 0.3-0.5X component in the spectrum.
22
Rolling Element Bearings Vibration Monitoring
1. Wear:
Wear
• Lifetime exceeded
• Bearing overload
• Incorrect assembly
• Manufacturing error
• Insufficient lubrication
Wear
23
Rolling Element Bearings Vibration Monitoring
2. Race Damage:
4
3
Roller bearing geometry and damage frequencies: 1 - Outer race damage
2
2 - Inner race damage
3 - Rolling element damage
Z n d Rollover frequencies
Ball pass frequency, outer race: BPFO = ( 1- cos ) Dimensions
D
260
Z d BPFO = n / 60 4.0781 = 203.77 Hz
Ball pass frequency, inner race: BPFI = ( 1+ cos ) d =77.50 mm
n D
260 d 2 D =14.29 mm BPFI = n / 60 5.9220 = 295.90 Hz
Ball spin frequency: BSF = D n ( 1- cos )
D
d60n 2.fw = n / 60 5.2390 = 261,77 Hz
) Z
d = 10
Fundamental train frequency: TFT = ( 1- cos
2 60 D
= 0 fK = n / 60 0.4079 = 20.38 Hz
24
Rolling Element Bearings Vibration Monitoring
fn
BPFO 2 BPFO 3 BPFO 4 BPFO
Sidebands at intervals of 1X
25
Rolling Element Bearings Vibration Monitoring
26
Rolling Element Bearings Vibration Monitoring
Lubrication Problems:
Major fluctuation in
• Race damage level of shock pulses
Lubricant contamination and damage
• Defective sealing frequencies
• Insufficient lubricant
Insufficient lubrication
• Underrating
Subsequent
small temperature
increase
27
Rolling Element Bearings Vibration Monitoring
Incorrect mounting.
Shock pulse
Air gap
Bearing rings out of round, deformed.
Dirt
• Incorrect installation
• Wrong housing calculation
• Manufacturing error in bearing Fixed
housing Floating
Severe vibration
bearing bearing Bearing temperature
increases
Cocked bearing.
Axial 1X, 2X
and 3X.
• Incorrect installation
28
Blade and Vanes Vibration Monitoring
MP
A blade or vane generates a signal frequency called
blade pass frequency, fBP:
MP f BP =B n N Bn = # of blades or vanes
N = rotor speed in rpm
fBPF
29
Aerodynamics and Hydraulic Forces Vibration Monitoring
MP MP
There are two basic moving fluid
problems diagnosed with vibration
analysis:
• Turbulence
• Cavitation
Cavitation: Turbulence:
1X fBPF Random
Random 1X
30
Belt Drive Faults Vibration Monitoring
MP MP
Belt transmission a common drive system in
industry consisting of:
• Driver Pulley
• Driven Pulley
MP MP • Belt
Belt frequency:
Ø
Ø1 ω 1
2
ω2 fB
3,1416 ω1 Ø1
l
l: belt length
31
Belt Drive Faults Vibration Monitoring
Belt Worn:
fn
Pulley Misalignment:
32
Belt Drive Faults Vibration Monitoring
Eccentric Pulleys:
Belt Resonance:
33
Gear Faults Vibration Monitoring
Spur Gear:
Worm Gear:
gear wheel
Driving gear
Gear
Driven gear
gear wheel pair
gear train
Planet Gear:
Bevel Gear:
Ring (cone) Bevel gear
Sun gear
Bevel gear
Planet gear
Carrier
34
Gear Faults Vibration Monitoring
Gear Meshing:
Pitch surface
35
Gear Faults Vibration Monitoring
MP
fz fz 2 fz 3 fz 4 fz
fn1
z2
z1
MP
fn2
Wear
fz 2 fz 3 fz
MP MP Detail of X:
X
fz
36
Gear Faults Vibration Monitoring
MP
Tooth break-out
MP MP fz and
X Detail of X: harmonics
z2 Sidebands
z1
fz
fn1 fn2
37
Gear Faults Vibration Monitoring
fz and
MP MP Detail of X:
harmonic
X
sidebands
fz
Gearwheel being
manufactured
Cutting tool
zM
38
Electrical Motors Vibration Monitoring
fL : line frequency
Bar meshing frequency: fbar = fn nbar
nbar: number of rotor bars
p: number of poles
Synchronous frequency: fsyn = 2 fL / p
• Stator eccentricity
• Eccentric rotor
• Rotor problems
• Loose connections
39
Electrical Motors Vibration Monitoring
Stator Eccentricity:
Loose iron
Shorted stator laminations
Soft foot
MP MP
1X 2X
40
Electrical Motors Vibration Monitoring
Eccentric Rotor:
Rotor offset
Misalignment
Poor base
MP MP
fp 1X 2X
Tslippage
R
adial
2 fL
t [ms]
fp, 1X, 2X and 2fL signals.
Modulation of the vibration time signal with the slip
1X and 2fL with sidebands at fP. frequency fslip
Radial predominant. Tslip 2-5 s
High resolution needed.
41
Electrical Motors Vibration Monitoring
Rotor Problems:
Radial
f [Hz]
2. Broken or cracked rotor bars:
1X 2X 3X 4X 1X and harmonics with sidebands at fP
Radial High resolution spectrum needed
Possible beating signal
42
Electrical Motors Vibration Monitoring
Radial
fbar and 2fbar with 2fL sidebands
2fbar can be higher
1X and 2X can appear
fn 2f L
2fL excessive signal with sidebands at 1/3 fL
Radial Electrical phase problem
Correction must be done immediately
43