VIBRATION ENGINEERING 312

VIBRATION TESTING
CHAPTER 4

MEMBERS:

PINEDA, JEREMIAH F.

PINEDA, RALPH ANDREW G.

PINEDA, CHARLES D.

PINGUL, JOHN PAUL G.

PRUNA, JOHN HARRY S.

QUIAMBAO, EJ F.

QUIBOLOY, HARRY
Vibration Testing
Vibration testing is the application of mechanical motion to a component, product,
system, or structure in order to observe its response or degradation over time. Also a method
used to assess the durability and reliability of mechanical and electronic systems by simulating
the stresses and strains they would experience in real-world environments.
Vibration testing is crucial because it simulates real-world situations that a machine,
product, or structure can encounter throughout the course of its lifetime, including operational
and transit-related circumstances. Therefore, vibration testing detects possible problems with
performance even before they begin or manifest.

Sinusoidal or Sine Vibration Testing

The most typical and simple type of vibratory motion. This traditional motion changes
position in a steady, circular way as time passes. A sine wave would appear on a plot of
position, velocity, or acceleration over time. This is the oldest technique for examining the
behaviour of products under extreme conditions and verifying their quality. Compared to
random vibration testing, this method of testing is less accurate to actual environmental
circumstances.

As seen in Figure, a sine wave is the shape of a sinusoidal or sine vibration. The
following terms or parameters are used to describe sinusoidal vibration testing: frequency,
sweep rate, number of sweeps, and amplitude (often acceleration or displacement).
Typical Sinusoidal Vibration Test

Some parameters of a sine vibration test:

Frequency: Frequency is defined as cycles per second. Its’ units are Hertz (Hz).
Amplitude: The amplitude for a sine vibration test is usually specified as displacement or
acceleration.
G: One G is equal to the acceleration produced by earth’s gravity.
Octave: The interval between one frequency and another.
Resonance: A frequency at which an amplitude magnification occurs in the device under test
when compared to the vibration table amplitude.
Sweep and Sweep Cycles: A sweep is defined as a travel from one frequency to another.
Sweep Rate: The rate at which the frequency range is travelled.

Types of Sinusoidal Vibration Testing:

Sine Sweep Vibration Testing
Travels or sweeps between a low and high frequency. The G levels and displacements
can be constant or variable. It allows the engineer to quickly observe a product’s response in
the frequency range of the operational environment. By comparing response vibrations of the
product to vibrations on the shaker table, it is effective for finding resonances. Additionally,
many test use sine sweep vibration testing, which needs multiple sweeps, to show the
durability of the items under examination.
Sine Resonance Track and Dwell Vibration Testing
Involves vibrating at a specific frequency and G level amplitude. Run a dwell test at
resonance frequencies for a certain period of time or sine wave cycles after determining
transmissibility peaks. Sine resonance track and dwell (SRTD) stimulates the recognized
resonance until failure or until a predetermined amount of time has passed without failure. A
Sine software add-on is SRTD.
Sine-on-Random Vibration Testing
A vibration test that uses both sine and random vibration. The control system
simultaneously produces signals to the shaker table while one or more sinusoids are
superimposed on a random test profile.
Random Vibration Testing
Vibrations found in everyday life scenarios (a vehicle on a typical roadway, the firing of a
rocket, or an airplane wing in turbulent airflow) are not repetitive or predictable like sinusoidal
waveforms. Consider the acceleration wave form for the dashboard vibration of a vehicle
traveling on Chicago Drive near Hudsonville, Michigan. Note that the vibrations are by no
means repetitive. So, there is an important need for tests that are not repetitive or predictable.
Random vibration testing accomplishes this.

Types of Random vibration Testing

Narrow band
Narrow-band analysis identifies specific machine faults where broad-band only
identifies overall vibrations levels which encompass a wide range of frequencies. To determine
machine health and identify problems, vibration data from each measurement point will be
taken in three directions.
Broadband
Broadband: Vibrations (or other signals) which are unfiltered. Signals at all frequencies
contribute to the measured value. Calibration: (As applied to vibration sensors) An orderly
procedure for determining sensitivity as a function of frequency, temperature, altitude, etc.

Advantages of Random Vibrations Testing

The goals or uses of random vibration testing in industry usually is to evaluate the
durability of the DUT and to check if a DUT will either work or fail under extreme conditions
which it might be exposed to during its lifecycle.
 For instance, a manufacturer may want to see how their product may fail on account of
various environmental vibrations it will probably encounter during its life. The manufacturer
will simulate these vibrations on a shaker and operate their product under those conditions.
Testing the product to failure will inform the manufacturer of several attributes of their
product’s weaknesses and the best way to improve it.

The Power Spectral Density Function (PSD)

To perform random testing, a random test spectrum needs to be defined. Real-time
data acquisition utilizes spectrum-averaging to create a statistical approximation of the
vibration spectrum. Generally, the random vibration spectrum profile is defined as a power
spectral density (PSD) plot.
The form of a PSD plot defines the average acceleration of the random signal at any
frequency. The area under this curve is called the signal’s mean square and its square root is
equal to the acceleration’s overall root-mean-square (RMS) value often abbreviated.
The Probability Density Function (PDF)
An examination of the acceleration waveforms of Figures 4 and 5 will indicate that much
of the random vibration acceleration values are nearly the same (±5g). However, some of the
acceleration values are quite large compared to the most common values. To help illustrate the
range of acceleration values, another statistic, the probability density function (PDF) is
required. A PDF is an amplitude histogram with specific amplitude scaling. Each point in the
histogram is a count of the number of times the measured signal sample was found to be within
a corresponding small range (an amplitude “bin”) of amplitude.

Sine vs Random Vibrations

Sine vibration testing applies a single frequency to a test item and selectively excites
resonant structures within the device. In a swept sine test a vibration sine tone is ramped up
and down through a range of frequencies and for a specified rate and duration.
Random vibration testing is one comprised of vibration energy at all frequencies over a
specified range. The vibration frequency components that make up the input signal for a
random test combine in amplitude and phase to create a time waveform which appears on an
oscilloscope as random noise. The characteristics of the random waveform are constantly
updating and changing within the bounds of the programmed random input.
Shock Testing

Shock tests are a sharp transfer of energy into a mechanical system to test a system’s
capability to survive a drop, hit, impact, fall, explosion, or any other source of transient
vibration.

A. Classical Shock Testing

A shock pulse can be characterized by its peak acceleration, the duration, and the shape
of the shock pulse. An electrodynamic shaker can generate many classical pulse shapes and can
be a cost and time-efficient option for a routine test.

Types of Shock Testing

1. Half Sine Shock

impulse has the shape of a half-sine wave. This waveform represents a rapid rise in force
followed by a quick drop, simulating high-intensity, short-duration shocks.

2. Haversine shock
pulses are typically defined in terms of acceleration magnitude, pulse duration, and the
damping coefficient.
 3. Sawtooth shock
pulse is one of the classical pulse shapes used in shock testing. It is characterized by its
distinct triangular waveform with a gradual rise in acceleration followed by a sudden drop,
resembling the teeth of a saw.

4. Trapezoidal (rectangular or square) shock test

A trapezoidal shock test pulse also referred to as a rectangular or square pulse, is another
classical pulse shape used in shock testing. It is characterized by its flat, constant acceleration
level, followed by an immediate return to zero.
Types of Classical Shock Testing

1. Pyrotechnic shock
This method uses explosive devices to generate controlled shock waves. It is especially
relevant in aerospace and defense industries to assess how components and systems withstand
explosions and munitions shocks. Examples include testing the resilience of aircraft structures
to nearby missile strikes.

2. Drop Testing
A shock test that is performed in order to evaluate and observe the effects of shock on
the packaged or unpackaged product.
Two Types of Drop Testing

• Drop Tower Testing

• Package drop Testing

3. Free fall shock

also known as a drop test or drop shock test, is a method used to evaluate the impact
resistance and durability of products when subjected to the forces experienced during a free
fall.

B. Complex Shock Testing

Shock Response Spectrum (SRS)

SRS tests are designed to re-create complex pulses. Many synthetic pulses can represent
a complex transient waveform with a frequency response comparable to the operational
environment.

Resonate Testing
It uses SRS testing to recreate a pulse that is technically equivalent to the initial test
requirement in terms of damage potential to provide the same level of test assurance.

What is harmonic and transient testing?

Harmonic Testing:
o Harmonic testing assesses the behavior of a system or device when subjected to
harmonic distortion in the electrical waveform.
o Harmonics are non-sinusoidal components of an electrical signal that occur at
integer multiples of the fundamental frequency
 o This testing is crucial for devices like power converters, variable speed drives,
and sensitive electronics because harmonics can lead to increased heat
generation, reduced efficiency, and do interference with other equipment.
o Harmonic testing involves applying controlled harmonic waveforms to the
system and monitoring its response to assess how well it handles harmonics
without adverse effects.

Transient Testing:

o Transient testing involves evaluating the response of a system or device to

sudden, short-duration voltage or current changes, often referred to as
transients or surges.
o Transients can result from events like lightning strikes, switching operations, or
load changes and can cause equipment damage or malfunction if not adequately
managed.
o This testing is important for assessing the durability and reliability of electrical
equipment to ensure it can withstand and continue to operate correctly during
transient events.
o Transient testing typically involves subjecting the equipment to simulated
transient conditions and observing its response, including voltage spikes, current
surges, and recovery times.
Types of Harmonic and transient testing
Harmonic Testing:

Harmonic Distortion Analysis:

This involves measuring and analyzing the distortion of the voltage or current
waveforms caused by harmonic frequencies. It helps identify the presence and levels of
harmonics in a system.

Harmonic Load Flow Analysis:

This assesses the impact of harmonics on the power flow in a network. It helps
determine how harmonics affect voltage and current distributions.

Harmonic Filter Testing:

Verifies the performance of harmonic filters designed to mitigate harmonic distortion in
power systems. This includes testing their ability to suppress specific harmonics.
Harmonic Resonance Testing:

Identifies conditions where resonance between the system impedance and harmonic-
producing equipment can amplify harmonics, potentially causing damage.
Transient Testing:

Transient Response Analysis:

Evaluates how a system or device responds to sudden changes in voltage or current,
such as voltage spikes or surges. It helps ensure equipment can withstand and recover from
transients.

Lightning Surge Testing:

 Simulates lightning strikes or surges to assess how well equipment can withstand such
extreme transient events.

Switching Transient Testing:

Analyzes the effects of rapid switching operations on the power system. It helps ensure
that switching events don't cause damage or disruption.

Electromagnetic Pulse (EMP) Testing:

Assesses the resilience of critical infrastructure and electronics to electromagnetic
pulses, which can be caused by nuclear detonations or solar flares.
Short-Circuit Testing:
Evaluates how equipment and protection systems respond to short-circuit faults, which
can result in transient conditions.