To Design And Develop Instrumentation And Perform Analysis of Mechanical/Electrical Fault Related Vibration signature

By: Muhammad Anees Akhtar

Advisors

Dr. Muhammad Rafiq Khan Mr. Afzal Hussain Mr. Mushtaq Ahmed
1

Project Objectives

To Study The Causes of Vibration in Rotating Machines. To Study The Effect of Vibration on Machine Condition. Instrumentation for Vibration Measurement. Vibration Analysis Techniques.

Instrumentation for Vibration Measurement

Displacement (proximity) Sensor. Velocity Sensor. Acceleration Sensor.

Transducer (Sensor) Selection Guide

Vibration Analysis Techniques

Time Domain Analysis. Frequency Domain Analysis. Time and Frequency Domain Analysis.

Time Domain & Frequency Domain Analysis

Block Diagram For Experimental Setup.

Induction Motor

Sensor

Recording

Inspection

Retrieval
7

Instrumentation Required For Vibration Measurement setup.

Vibration Sensor. Magnetic Recorder. Band Pass Filters. Oscilloscope. Power Supply. Function Generator.

Instrument Calibration & Testing

Proximity Switch. Oscilloscope. Recorder.

Testing Of Sensor
Technical specification

Proximity Switch was Tested to Ensure That it Confirms to The Specifications.

Type Supply Voltage Sensing Distance Aluminum Sensing Distance Copper Sensing Distance Mild Steel Switching Current Embeddable Housing-Body Material IP Rating Length Mounting

Inductive Proximity Sensors 10 to 30V(dc) 1.5mm 1.5mm 5mm 150mA Yes Nickel Plated Brass IP67 50mm Flush

Operating Temperature Range

Output Type Overload Protection Reverse Polarity Protection Termination Type

-25 to +70C
PNP N/O Yes Yes Pre-Wired

10

Testing of Oscilloscope

A Wave Function of Known Frequency was Produced from Function Generator. The Output was Seen on The Oscilloscope. Frequency of The Function was Measured. The Oscilloscope Gave the Same output as was Produced by the Function Generator.

11

Calibration of Recorder
Equipment used:

Tape recorder. Cassette. Oscilloscope. Function Generator. Power Supply(+15V) Operational Amplifier (IC 741). Bread Board. Banana Plug for Microphone and Headphone Sockets.

12

Calibration of Recorder
Function generator Magnetic Medium

FIGURE 1: Arrangement for Recording Signal

Magnetic Medium

Buffer

Oscilloscope

FIGURE 2: Arrangement for Viewing the Recorded Signal

13

Magnetic Recording of Function Waveforms.

3 2 1 0 -0.005
volts

2 1 0
0.001

-0.004

-0.003

-0.002

-0.001

-1 0 -2 -3 -4 -5 -6 -7

-0.005
volts

-0.004

-0.003

-0.002

-0.001

-1 0 -2 -3 -4 -5 -6 -7

0.001

time

time

2 1 0 -0.005 -0.004 -0.003 -0.002 -0.001 -1 0 -2 -3 -4 -5 -6 -7 -8 time 0.001

volts

14

Output of Recorder
0.8 0.6 0.4 0.2 0 -0.001 -0.2 0 -0.4 -0.6 -0.8 0.8 0.6 0.4 0.2 0 -0.2 0 -0.4 -0.6 -0.8

volts

-0.005

-0.004

-0.003

-0.002

0.001

volts

-0.005

-0.004

-0.003

-0.002

-0.001

0.001

time

time

0.6 0.4 0.2

volts

0 -0.005 -0.004 -0.003 -0.002 -0.001 -0.2 -0.4 -0.6 -0.8 time 0 0.001

15

Band Pass Filter and Filtered sine wave

0.12 0.1 0.08 0.06

volts

0.04 0.02 0 -0.01 -0.008 -0.006 -0.004 -0.002 -0.02 0 -0.04 -0.06 time 0.002

16

Vibration Measurement Setup

17

Analysis of Faults

Unbalance. Misalignment. Mechanical looseness.

18

Unbalance

19

Description

Sensor was Adjusted so That No Signal Arrives While Intact Condition When Motor is Started. Fault was Introduced While Attaching Load to Motor via Jubilee Clamp. When The Motor was Started in Unbalanced Condition Sensor Started Switching. The Output was Seen on The Oscilloscope and Saved in Floppy Diskette.
20

Results
unbalance
Observation no. 1 2 3

sensor

oscilloscope
Comparison 1xRPS 1xRPS 1xRPS

Reference frequency 24.3 24.3 24.3

Observed frequency 24.2 24.29 24.3

21

Graphical Output of Sensor

35 30 25
amplitude

20 15 10 5 0 -0.5 -0.4 -0.3 -0.2

time(sec)

-0.1

-5

0.1

22

Misalignment

23

Description

Motor was Loaded by Coupling a Pump to Motor. Shafts were Coupled Such That They are not in Line. Sensor was Adjusted Properly. Output of The Sensor was Saved on The Floppy Diskette.
24

Results
Misalignment

sensor

oscilloscope
Comparison 1xRPS

Observation Reference no. frequency 1 24.3

Observed frequency 23.6

2
3

24.3
24.3

23.9
23.7

1xRPS
1xRPS
25

Graphical Output of Sensor

18 16

14

12

amplitude(volts)

10

0 -0.1 -0.08 -0.06 -0.04 -0.02 -2 time(sec) 0 0.02

26

Mechanical Looseness

27

Results
Mech. Looseness
Observation no. 1

sensor
Reference frequency 24.3 Observed frequency 24.5

oscilloscope
Comparison 1xRPS

2
3

24.3
24.3

24.9
24.8

1xRPS
1xRPS
28

Graphical out put of sensor

18

16

14

12

10
amplitude(volts)

0 -0.1 -0.08 -0.06 -0.04 -0.02 -2

time(sec)

0.02

29

Thank you

30