Where are Vibration AI Programs Taking Us

• Present state as I understand it;

• Monitoring Overall In/sec
• Alarm based on actual set points or changes from historical
levels
• Monitoring Overall G,s
• Alarm based on actual set points or changes from historical
levels
• Some Monitor Bands
• Very few from what I am seeing are using Band Alarms and
when asked why some are not using them here are some
common responses;
• It takes a lot of time to enter the data.
• We don’t have the data.
• We don’t have the manpower.
• AI tells us we don’t need that information they can do everything with algorithms
and modeling.
 Overall Trends
• Trend of the overalls on a machine;
Plot of Trend at 36X to Fmax

Peak Related to Electrical Frequency

New Motor

Bearing Defect Developing

Actual Spectrum waterfall
Stacked Plot
Overall Level Examples
Overall Level Examples
Overall Level Examples
Its All About The Numbers
Example
 Programed fault frequencies
• We currently can enter fault frequencies,
but they are typically locked into a
location. The frequencies can show up
better at times on other locations because
they may not have to compete with other
vibration issues at those locations.
 Stock Exchange
• Think about the
stock market ticker.
All it is doing is
tracking numbers
and plotting the
changes.
 How Many Defect Frequencies
are there to monitor
• Running Speed
• Bearing Frequencies
• Gear Mesh Frequencies
• Belt Frequencies
• Coupling Frequencies
• Vane Frequencies
• Sprocket Frequencies
 Gearbox Bearing and Gear Mesh Frequencies
57 different frequencies in this example SKF 32322
BPFO : 5,265.0 cpm
O ut Put Speed BPFI: 7,567.6 cpm
10.0 cpm Base Natural Frequency FTFI: 375.8 cpm
3 rd Inter Shaft Gear
3450 cpm BSF: 2,407.9 cpm
Mesh
SKF 22330E
3616.2 cpm BPFO : 1,639.3cpm
16 Teeth SKF 22322E-C3
BPFI: 2,350.9 cpm
79 Teeth BPFO : 11,784.4 cpm
SKF 23084C FTFI: 109.3 cpm
BPFI: 16,909.9cpm
BPFO : 122.3 cpm BSF: 703.3 cpm
Final Gear Mesh FTFI: 737.0 cpm
BPFI: 147.6 cpm
732.4 cpm INA SL192344 BSF: 4743.5 cpm
FTFI: 4.5 cpm
16 Teeth BPFO : 271.9 cpm
BSF: 52.1 cpm
73 Teeth BPFI: 390.7 cpm SKF NU322E-C3
FTFI: 17.8 cpm BPFO : 10,147.0 cpm
BSF: 97.7 cpm BPFI: 14,960.5 cpm
FTFI: 724.5 cpm
BSF: 4503.2 cpm

SKF Q J322N2
BPFO : 8,841.4 cpm
BPFI: 12,679.3 cpm
FTFI: 735.2 cpm
BSF: 3981.3 cpm

Input S peed
1793.4 rpm
2nd Inter
S haft S peed
Input Shaft
916.62 cpm
Gear Mesh
3rd Inter S haft 41248.2 cpm
S peed 23 Te e th
45.7 cpm 2 nd Inte r Shaft 45 Te e th
SKF 29352E SKF 23084C SKF 22344C Gear Mesh
BPFO : 105.5 cpm BPFO : 122.3 cpm BPFO : 303.8 cpm SKF 22330E S haft S peed 16499.2 cpm SKF 32322
BPFI: 124.4 cpm BPFI: 147.6 cpm BPFI: 427.3 cpm BPFO : 1,639.3cpm 18 Te e th
226.0 cpm BPFO : 5,265.0 cpm
FTFI: 4.5 cpm FTFI: 4.5 cpm FTFI: 18.9 cpm BPFI: 2,350.9 cpm 73 Te e th
BPFI: 7,567.6 cpm
BSF: 38.8 cpm BSF: 52.1 cpm BSF: 128.4 cpm FTFI: 109.3 cpm FTFI: 375.8 cpm
BSF: 703.3 cpm BSF: 2,407.9 cpm
 Currently
• With AI Platforms;
• When an alarm trips it throws up a flag. Then someone either
digs into all the data or sends someone out to the machine to
collect more data or start the Look, Listen and Feel process of
trouble shooting.
 Currently cont.
• Without AI;
When we are collecting the data we see, hear or feel
something out of the ordinary. If we have a good data collector, it
will tell us what band in in alarm. We make a note, maybe collect
some additional vibration data then look at the information closely
after it is dumped.
When we dump the data with no notes, we allow our band
alarms to screen the data for us and alert us to possible issues. If
we have bearing information or other frequency information if there
is an alarm, we can manually activate those peaks. If the peaks
match up, then we can start the process to determine how bad the
problem is.
Define the frequencies and build
a library
• Develop your library
• Many facilities have a lot of like equipment.
• Over time as these libraries are developed you will
not have to do the research repeatedly. It becomes
Cut & Paste.
• Components can be the same across different
machines. Example Gearbox or Motor or Pumps.
Gearbox Info Example
Motor Info Example
Machine Data Sheet
 AI and Resolution comes into play
• If we go back to slide #9 and think about the 57 different
frequencies. If we took the time to program all those frequencies into
our vibration program and let AI monitor them for changes. Instead
of collecting 30 readings and going though all that data maybe we
only need 3 sensors on this machine to allow us the resolution we
need to track and scan all those frequencies for us.
• On the machine on slide #15, I only collected 2 readings on the
gearbox with 3 axis. 1 at input speed and 1 at output speed.
Between the 2 readings the resolution was good enough to look at
all the frequencies in the 4-shaft gearbox set up to be able to ID the
frequencies and changes. It was also good enough to watch the
frequencies of the drive chain sprockets and the internal drag chain
head sprocket.
 AI Program Value
1. What's changing.
2. What's the rate of change.
3. Do I physically have to go to the machine
to trouble shoot or can I send a
maintenance tech or operator.