Monitoring Gear Boxes with

PeakVue
Presentation at Niagara Falls
Vibration Institute Chapter

January 20, 2005

1
WHAT I S A STRESS WAVE?

2
Hertz Theory Prediction for Various Size
Metal Balls

3
 Frequencies Excited by 0.5”,
1.0”. And 1.5” D Balls Impacting
CENT - OFF ROUTE EQUIPMENT
OFF ROUTE - (25-Feb-99)

Max Amp 1.5" D Ball

.84 25-Feb-99
14:54:52
Plot
Scale
0.9
RMS Acceleration in G-s

1.0" D Ball

25-Feb-99
14:54:02

0.5" D Ball

25-Feb-99
14:52:13
0 10 20 30 40 50 60 70 80
Frequency in kHz

4
Impacting and Friction: 1.0 +” D
Roller CENT - OFF ROUTE EQUIPMENT
OFF ROUTE -
0.024
Analyze Spectrum
28-Feb-01 15:07:31

RMS = .0892
0.020 LOAD = 100.0
RPM = 696. (11.60 Hz)

0.016
RMS Acceleration in G-s

0.012

0.008

0.004

0
0 10000 20000 30000 40000
Frequency in Hz
Label: OFFROUTE-A-1 /

5
 Analysis of Stress Waves
• Capture with accelerometer
• High-pass filter
• Capture time block of data
(peak values)
a) Spectral Analysis
b) Autocorrelation analysis

6
Example Time Waveform
Select Fmax
Delta t = 1/(2.56 × Fmax )
Sequentially insert in each Delta t the
Peak Value observed over that time increment

7
PeakVue Waveform Indicates Defective Rolling Elements
(Rollers pass in and out of load zone at rate of Cage Freq.)

8
PeakVue Spectrum Derived from PeakVue Waveform
(Cage Freq. = 3.43 Hz; BSF = 40.6 Hz)

9
Autocorrelation Coefficient Function Identifies
Dominant Impact Sources in PeakVue Data

10
Computation of Autocorrelation

A(τ j ) = ∑ x (t i ) x (t i + τ j )
1 N /2
A(0 ) i =1

t i = i∆t ; i = 1 , N

τ j = j∆t ; j = 1 , N 2
11
 Measurement Setup
Parameters
FHP ≥ Fmax
• Select Fmax Based on Fault Frequencies
Bearings: Fmax > 4 × BPFI
Gearing: Fmax > 2 × GMF
• Select Resolution (# Lines) Based on
Lowest Fault Frequency
Bearings: Cage
Gearing: Slowest shaft for gear pair in Mesh

12
Measurement Setup Parameters
(cont.)
• Cage - requires 12+ shaft revs
# lines
# Revs =
Fmin orders

• Shaft - Requires 5+ shaft revs

• FHP (High-Pass Filter)
– Same (highest) over a machine (structure with
continuous housing).
– FHP greatest for bearings or gears on machine
– Fmax can be varied, but same FHP must be used
on all points on component (i.e., throughout
Gearbox) 13
Guidelines for setting Pk-Pk PeakVue
Time Waveform
Alert Alarm Levels for an inner race Recom m ended P-P Tim e Wavefor m Aler t Lim its

fault 10.000

(Set Fault Alarm = 2 X Alert Alarm)

4.743
Acceleration in g's (p-p)

3.000 3.000

1.000
0.577

0.100
0.103
1 10 100 1000 10000
Speed (RPM)

0.75
 RPM 
g's =   × 3 for RPM < 900
 900 
g’s = 3 , for 900 < RPM ≤ 4000 ,
0.5
 RPM 
g's =   × 3 for 4000 < RPM ≤ 10000 ,
 4000 

g’s = 5 , for RPM > 10000 ,

14
 Gear Box

• Case Study # 1
– A) Cracked Tooth on post rebuild gear
box
– B) Cracked Tooth on Precision Tension
Bridle

15
16
Fault under Meas Point G5

17
18
Cracked Tooth Highlighted

19
Cracked Teeth in Precision Tension Bridle
GearBox

- Based on Pk-Pk Level of 41 g’s in TWF

- Pronounced Impact Pulses in TWF
(2/Rev)
- No Real Indication of Problem in
Vibration Data

20
Plan view of precision tension bridle
gearbox (single speed reduction with
two output shafts)

21
 Velocity spectral and acceleration waveform
data (Fmax=2000 Hz) from the bearing on the
input shaft of the precision tension bridle
SM - Precision Tension Bridle

gearbox
0.04
GM 1
PT BRIDLE -GV3
ROUTE SPECTRUM

350.68
14-Apr-97 07:59:17
PK Velocity in In/Sec

OVERALL= .0812 V-DG

0.03 PK = .0808
LOAD = 100.0
RPM = 526.
0.02 RPS = 8.77
GM 2
201.59

0.01

0
0 500 1000 1500 2000
Frequency in Hz
2.0
WAVEFORM DISPLAY
1.5 14-Apr-97 07:59:17
Acceleration in G-s

1.0 RMS = .3687

PK(+) = 1.59
0.5 PK(-) = 1.86
CRESTF= 5.06
0
-0.5
-1.0
-1.5
-2.0
-2.5
Freq: 351.25
0 50 100 150 200
Ordr: 40.07
Time in mSecs Spec: .02589

22
 PeakVue spectral and waveform data
(Fmax=200 Hz) from the bearing on the input
5
SM - Precision Tension Bridle
PT BRIDLE -GV3
ANALYZE SPECTRUM
RMS Acceleration in G-s

shaft of the precision tension bridle

4
PeakVuegearbox 14-Apr-97 08:28:16
(Filtr- HP 500 Hz)
RMS = 6.50
LOAD = 100.0
3 RPM = 216.
RPS = 3.60
2

0
0 50 100 150 200
Frequency in Hz
40
WAVEFORM DISPLAY
14-Apr-97 08:28:16
30
Acceleration in G-s

RMS = 7.16
PK(+) = 36.54
PK(-) = 4.82
20 CRESTF= 5.10

10

-10
Freq: 3.625
0 0.5 1.0 1.5 2.0
Ordr: 1.008
Time in Seconds Spec: 3.288

23
PeakVue spectral and (Fmax=100 Hz but
with a 5000 Hz HP filter) from the bearing
on the input shaft of the precision tension
bridle gearbox
GM 2

24
 Gearbox
• Case Study # 2
– Eccentric gear on post rebuild gear box

25
26
27
Defective Gear Placed in Separate Gear Box

28
 Gear Box
• Case study #3
– Worn spline on post rebuild gear box

29
30
31
32
 Bearing-Outer Race
• Case Study #4
• BPFO in Pinion Stand Gearbox
– Speed of shaft=360 RPM
– Peak g-level=37 g’s
– Fault=6.3 g’s

33
 Velocity spectral and acceleration
waveform data (Fmax=800 Hz) from
the bearing on the input shaft of the
gearbox (Sept 15)
1X GMF Velocity

2X GMF
BPFO

4.13 g’s

34
 Peakvue spectral and waveform data
(Fmax=1000 Hz) from the bearing on the
input shaft of the gearbox (Sept 15)
PeakVue
BPFO = 64.38 Hz = 10.75 X RPM

1/BPFO

36.96 g

35
 Peakvue spectral and waveform data
(Fmax=1000 Hz) from the bearing on the
input shaft of the gearbox before and after
bearing replacement

BPFO PeakVue Before Bearing Replacement

PeakVue After Bearing Replacement

36
Closeup picture of the outer race of the
defective bearing showing significant
spalling over an area of 5 in. x 5 in.

37
 Bearing Outer Race
• Case Study #5 BPFO
– Early stage fatiguing
– Shaft speed=650 RPM
– Alert=4.7 g’s

38
A
Alert=4.7 g’s
l
e WDT - GBOX
r 0.07
GBOX -P4 Measurement Pt4
Routine Spectrum
0.06 C C C C C C C C
RMS Acceleration in G-s

t 0.05
03-Feb-03 09:04:17
(PkVue-HP 2000 Hz)
RMS = .1353
= 0.04
LOAD = 100.0
RPM = 538. (8.97 Hz)
>skf nj2332EC
4 0.03

0.02
C=BPFO

. 0.01

7 0
0 10 20 30 40 50
Frequency in Orders
1.4
Routine Waveform
g 1.2 03-Feb-03 09:04:17
(PkVue-HP 2000 Hz)
Acceleration in G-s

’ 1.0

0.8
RMS = .2671
PK(+) = 1.15
CRESTF= 4.32
s 0.6

0.4

0.2

0
Ordr: 5.253
0 3 6 9 12 15 18 Freq: 47.12
Revolution Number Spec: .06017

39
Impacting Sporadic

WDT - GBOX
GBOX -P4 Measurement Pt4

.33
02-Feb-03 18:30
.0963

.92
Acceleration in G-s

02-Feb-03 16:22
.0899

.93
02-Feb-03 15:17
.0959

1.15
03-Feb-03 09:04
.0892

0 3 6 9 12 15 18
Revolution Number

40
 Bearing (Inner Race)
• Case Study #6
– BPFI on bearing on output shaft
– Severity ascertained from trending

41
Trend (2 years) of the maximum peak
amplitude (g’s) from the Peakvue
waveform and a Peakvue spectrum on
May 25

BPFI with 1X RPM sidebands

2X BPFI
1X
RPM

42
Trend (2 years) of the bearing frequency
band from the velocity spectrum and a
Velocity spectrum on May 25

Velocity
2X GMF

No indication of a bearing fault

GMF

43
 Picture of the defective bearing with a
significant inner race defect identified by
Peakvue trends

44
PeakVue Trend Before & After Bearing was Replaced
(Trend of Digital Overall)
RFPD - HOT MILL-F5 PINION STAND 200
HMF5PINSTD-P4H BOT BRG OUTPUT SIDE HORIZ.PK-VUE

05/18/00
0.6
Trend Display
of
OVERALL VALUE

02/01/00

06/28/00
0.5

-- Baseline --
Value: .04003
RMS Acceleration in G-s

0.4 Date: 01/07/99

10/19/99
0.3

0.2
03/25/99
11/06/98

08/17/00
0.1

0
Date: 08/17/00
0 100 200 300 400 500 600 700 800
Time: 13:03:27
Days: 07/31/98 To 08/17/00 Ampl: .01550
Label: Trend After Bearing Replaced

45
 Bearing Inner Race
• Case Study # 7
– BPFI (mechanical plus lubrication)

46
47
Data acquired outer bearing re input

IGB - Roller Mill Peak Vue

RM-PV -G2 Gearbox Point 2
0.18

129.49
Route Spectrum

14.87
RMS Acceleration in G-s 0.15 09-Jan-02 12:43:10
(PkVue-HP 1000 Hz)
BPFI
0.12 OVERALL= .4408 A-DG
RMS = .4387

258.98
0.09 LOAD = 100.0
RPM = 892. (14.87 Hz)

388.47
0.06

0.03

0
0 50 100 150 200 250 300 350 400
Frequency in Hz
4.0
Route Waveform
3.5 09-Jan-02 12:43:10
3.0 (PkVue-HP 1000 Hz)
Acceleration in G-s

RMS = .8999
2.5 PK(+) = 3.58
2.0 CRESTF= 3.94

1.5
1.0
0.5
0
Freq: 114.63
0 200 400 600 800 1000 Ordr: 7.709
Time in mSecs Spec: .09612
Dfrq: 14.86

48
Typical BPFI pattern in Autocorrelation

IGB - Roller Mill Peak Vue

RM-PV -G2 Gearbox Point 2
1.0
Route ACorr(Wf)
09-Jan-02 12:43:10
(PkVue-HP 1000 Hz)

RMS = .0860
LOAD = 100.0
0.5 RPM = 892. (14.87 Hz)

PK(+) = .4534
PK(-) = .1173
CRESTF= 5.27
Correlation Factor

-0.5

-1.0
0 100 200 300 400 500 600
Time in mSecs

49
Trended Peak g-level from G2
Peak g Trend Data For Measurement Point G2

90

80

70

60 Peak G's

Alert
50
g's Peak

Fault

40

30

20

10

0
0 50 100 150 200 250 300 350
Days

50
51 g’s on Point G2 on February 6, 2002

IGB - Roller Mill Peak Vue

RM-PV -G2 Gearbox Point 2
7

129.67
Route Spectrum
6
RMS Acceleration in G-s
06-Feb-02 12:43:59
(PkVue-HP 1000 Hz)
5 BPFI OVERALL= 8.28 A-DG

259.35
RMS = 8.28
4
LOAD = 100.0
3 RPM = 893. (14.89 Hz)

389.02
14.89

0
0 50 100 150 200 250 300 350 400
Frequency in Hz
60
Route Waveform
50 06-Feb-02 12:43:59
(PkVue-HP 1000 Hz)
Acceleration in G-s

40 RMS = 12.87
PK(+) = 51.09
30 CRESTF= 3.92

20

10

0
Freq: 114.78
0 200 400 600 800 1000 Ordr: 7.709
Time in mSecs Spec: 1.034
Dfrq: 14.89

51
25 g’s on Point G1 on February 6, 2002.

IGB - Roller Mill Peak Vue

RM-PV -G1 Gearbox Point 1
3.2

129.68
Route Spectrum
RMS Acceleration in G-s 2.8 06-Feb-02 12:43:19
2.4 (PkVue-HP 1000 Hz)
OVERALL= 3.76 A-DG
2.0 RMS = 3.74

259.36
1.6 LOAD = 100.0
RPM = 893. (14.89 Hz)
1.2
14.89

389.05
0.8
0.4
0
0 50 100 150 200 250 300 350 400
Frequency in Hz
24
Route Waveform
20 06-Feb-02 12:43:19
(PkVue-HP 1000 Hz)
Acceleration in G-s

16 RMS = 6.71
PK(+) = 24.21
12 CRESTF= 3.62

0
Freq: 114.80
0 200 400 600 800 1000 Ordr: 7.709
Time in mSecs Spec: .475
Dfrq: 14.88

52
Note metal removal on inner race downstream of fault

53
 Gear Fault in Planetary Gear
• Planetary Gearbox

• Carrier turning at approximately 20 RPM

54
 Dominant activity at 3x: 0.34 g’s on
October 23, 2002
WDT - GBOX
GBOX -P2A Measurement Pt2A
0.020
Routine Spectrum
RMS Acceleration in G-s

23-Oct-02 13:16:58
0.015 (PkVue-HP 2000 Hz)
RMS = .0401
LOAD = 100.0
0.010 RPM = 20. (.33 Hz)

0.005

0
0 10 20 30 40 50
Frequency in Hz
0.40
Routine Waveform
0.32 23-Oct-02 13:16:58
Acceleration in G-s

(PkVue-HP 2000 Hz)

RMS = .1352
0.24 PK(+) = .3424
CRESTF= 2.53
0.16 DCoff = .2176

0.08

0
Freq: 1.000
0 4 8 12 16 20 24 28 32
Ordr: 3.006
Time in Seconds Spec: .01473

55
 Autocorrelation on October 23, 2002

WDT - GBOX
GBOX -P2A Measurement Pt2A
1.0
Routine ACorr(Wf)
23-Oct-02 13:16:58
(PkVue-HP 2000 Hz)

RMS = .1256
LOAD = 100.0
0.5 RPM = 20. (.33 Hz)

PK(+) = .5790
PK(-) = .2883
Correlation Factor

CRESTF= 4.61

-0.5

-1.0
0 4 8 12 16
Time in Seconds 56
 Dominate activity at 1x: 2.1 g’s on
December 30, 2002
WDT - GBOX
GBOX -P2A Measurement Pt2A
0.07
Routine Spectrum
RMS Acceleration in G-s

0.06 30-Dec-02 12:46:34

0.05 (PkVue-HP 2000 Hz)
RMS = .1177
0.04 LOAD = 100.0
RPM = 20. (.33 Hz)
0.03

0.02

0.01

0
0 4 8 12 16
Frequency in Orders
2.4
Routine Waveform
2.0 30-Dec-02 12:46:34
Acceleration in G-s

(PkVue-HP 2000 Hz)

1.6 RMS = .2261
PK(+) = 2.10
1.2 CRESTF= 9.27
DCoff = .2427
0.8

0.4

0
Ordr: 1.010
0 10 20 30 40 50 60 70 80
Freq: .338
Time in Seconds Spec: .04590
57
 Autocorrelation on December 30, 2002
Dominate activity at 2.47 orders
WDT - GBOX
GBOX -P2A Measurement Pt2A
1.0
Routine ACorr(Wf)
30-Dec-02 12:46:34
Dela orders=2.472 (PkVue-HP 2000 Hz)

RMS = .1682
LOAD = 100.0
0.5 RPM = 20. (.33 Hz)

PK(+) = .8097
PK(-) = .2306
Correlation Factor

CRESTF= 4.81

-0.5

-1.0
Time: 16.94
0 5 10 15 20 25 30 35 40
Ampl: .220
Time in Seconds Dtim: 1.209
Freq: .827

58
 Activity Highlighted at 2.47 Orders

WDT - GBOX
GBOX -P2A Measurement Pt2A
0.07
Routine Spectrum
RMS Acceleration in G-s

0.06 30-Dec-02 12:46:34

89/36=2.472
0.05 (PkVue-HP 2000 Hz)
RMS = .1177
0.04 LOAD = 100.0
RPM = 20. (.33 Hz)
0.03

0.02

0.01

0
0 4 8 12 16
Frequency in Orders
2.4
Routine Waveform
2.0 30-Dec-02 12:46:34
Acceleration in G-s

(PkVue-HP 2000 Hz)

1.6 RMS = .2261
PK(+) = 2.10
1.2 CRESTF= 9.27
DCoff = .2427
0.8

0.4

0
Ordr: 2.472
0 10 20 30 40 50 60 70 80
Freq: .826
Time in Seconds Spec: .04985

59
 2.47 activity gone on February
3, 2003
Dominate activity at 3x: 0.75 g’s

WDT - GBOX
GBOX -P2A Measurement Pt2A
0.016
Routine Spectrum
02-Feb-03 15:16:20
RMS Acceleration in G-s

3.00

15.00
0.012 (PkVue-HP 2000 Hz)
RMS = .0312
LOAD = 100.0
0.008 RPM = 20. (.33 Hz)
6.00

12.00
2.47

18.00

21.00

27.00
24.00
9.00

0.004

0
0 5 10 15 20 25 30
Frequency in Orders
0.8
Routine Waveform
0.7 02-Feb-03 15:16:20
(PkVue-HP 2000 Hz)
Acceleration in G-s

0.6 RMS = .3252

PK(+) = .7509
0.5 CRESTF= 2.31

0.4

0.3

0.2
Ordr: 2.471
0 3 6 9 12 15 18 21 24 27 Freq: .825
Revolution Number Spec: .00484

60