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Mechanical Vibrations

Fifth Edition in SI Units


Singiresu S. Rao
Chapter 10
Vibration Measurement and Applications

3 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10
Chapter Outline

10.1 Introduction
10.2 Transducers
10.3 Vibration Pickups
10.4 Frequency-Measuring Instruments
10.5 Vibration Exciters
10.6 Signal Analysis
10.7 Dynamic Testing of Machines and Structure
10.8 Experimental Modal Analysis
10.9 Machine-Condition Monitoring and Diagnosis

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10.1
Introduction

5
10.1
© 2011 Mechanical Vibrations Fifth Edition in SI Units
10.1 Introduction

• Why we need to measure vibrations:


– To detect shifts in ωn which indicates possible failure
– To select operational speeds to avoid resonance
– Measured values may be different from theoretical values
– To design active vibration isolation systems
– To identify mass, stiffness and damping of a system
– To verify the approximated model

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10.1 Introduction

• Type of vibration measuring instrument used will depend on:


– Expected range of frequencies and amplitudes
– Size of machine/structure involved
– Conditions of operation of the machine/structure
– Type of data processing used

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10.2
Transducers

8
10.2
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10.2 Transducers

• A device that transforms values of physical variables into electrical


signals

• Following slides show some common transducers for measuring


vibration

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10.2 Transducers

• Variable Resistance Transducers

Mechanical motion changes electrical resistance, which cause a


change in voltage or current

Strain gage is a fine wire bonded to surface where strain is to be


measured.

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10.2 Transducers

• Variable Resistance Transducers

Surface and wire both undergo same strain.

R / R r L
Resulting change in wire resistance: K   1  2v   1  2v
L / L r L

where K = Gage factor of the wire


R = Initial resistance
ΔR = Change in resistance
L = Initial length of wire
ΔL = Change in length of wire
v = Poisson’s ratio of the wire
r = Resistivity of the wire
Δr = Change in resistivity of the wire ≈ 0 for Advance

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10.2 Transducers

• Variable Resistance Transducers


L R
Strain:   
L RK

The following figure shows a vibration pickup:

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10.2 Transducers

• Variable Resistance Transducers

ΔR can be measured using a Wheatstone bridge as shown:

 R1 R3  R2 R4 
E V
  R1  R2  R3  R4  

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10.2 Transducers

• Variable Resistance Transducers

Initially, resistances are adjusted so that E=0

R1R3 = R2R4

When Ri change by ΔRi,

 R1 R2 R3 R4  R1 R2 R3 R4


E  Vr0      where r0  
 R1 R2 R3 R4   R1  R2  2  R3  R4  2

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10.2 Transducers

• Variable Resistance Transducers

If the leads are connected between pts a and b, R1=Rg, ΔR1,= ΔRg,
ΔR2= ΔR3= ΔR4=0
Rg E
  K or E  KVr0
Rg Vr0
where Rg is the initial resistance of the gauge.

Hence E can be calibrated to read ε directly.

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10.2 Transducers

• Piezoelectric Transducers

Certain materials generate electrical charge when subjected to deformation


or stress.

Charge generated due to force:

Qx  kFx  kAp x
where k =piezoelectric constant
A =area on which Fx acts
px =pressure due to Fx.

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10.2 Transducers

• Piezoelectric Transducers

E=vtpx

v = voltage sensitivity
t = thickness of crystal

A piezoelectric accelerometer is shown.

Output voltage proportional to acceleration

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10.2 Transducers

Example 10.1
Output Voltage of a Piezoelectric Transducer

A quartz crystal having a thickness of 2.5mm is subjected to a


pressure of 50psi. Find the output voltage if the voltage sensitivity is
0.055 V-m/N.

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10.2 Transducers

Example 10.1
Output Voltage of a Piezoelectric Transducer
Solution

E = vtpx =(0.055)(0.00254)(344738) = 47.4015V

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10.2 Transducers

• Electrodynamic Transducers

Voltage E is generated when the coil moves in a magnetic field as


shown.
E = Dlv
E F
Dl  
v I
where D = magnetic flux density
l = length of conductor
v = velocity of conductor
relative to magnetic field

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10.2 Transducers

• Linear Variable Differential Transformer Transducer

Output voltage depends on the axial displacement of the core.

Insensitive to temp and high output.

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10.3
Vibration Pickups

10.3
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10.3 Vibration Pickups

• Most common pickups are seismic instruments as shown

• Bottom ends of spring and dashpot have same motion as the cage

• Vibration will excite the suspended mass

• Displacement of mass relative to cage: z = x – y

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10.3 Vibration Pickups

• Y(t) = Ysinωt

• Equation of motion of mass m:

mx  c x  y   k  x  y   0 or
mz  cz  kz  my
 mz  cz  kz  m 2Y sin t
• Steady-state solution:

z  t   Z sin  t   

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10.3 Vibration Pickups

Y 2 r 2Y
Z 
 k  m  2 2
c  2 2
1  r    2r 
2 2 2

 c  1  2 r 
  tan  1
2 
 tan  2 
 k  m  1 r 
 c
r , 
n 2mn

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10.3 Vibration Pickups

• Vibrometer

Measures displacement of a vibrating body

Z/Y ≈ 1 when ω/ωn ≥ 3 (range II)


r2
z  t   Y sin  t    if 1
1  r    2r 
2 2 2

In practice Z may not be equal to Y as r may not be large, to


prevent the equipment from getting bulky

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10.3 Vibration Pickups

Example 10.2
Amplitude by Vibrometer

A vibrometer having a natural frequency of 4 rad/s and ζ = 0.2 is


attached to a structure that performs a harmonic motion. If the
difference between the mximum and the minimum recorded values is
8 mm, find the amplitude of motion of the vibrating structure when its
frequency is 40 rad/s.

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10.3 Vibration Pickups

Example 10.2
Amplitude by Vibrometer
Solution

Amplitude of recorded motion:


Y 10
2
Z  1.0093Y  4 mm
1  10    2 0.210 
2 2 2

Amplitude of vibration of structure:


Y = Z/1.0093 = 3.9631 mm

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10.3 Vibration Pickups

• Vibrometer

Measures acceleration of a vibrating body.

 Y 2 sin  t   
 z  t n2 
1  r    2r 
2 2 2

1
If  1,
1  r    2r 
2 2 2

  z  t n2  Y 2 sin  t   

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10.3 Vibration Pickups

• Vibrometer
1
If 0.65< ζ < 0.7, 0.96   1.04 for 0  r  0.6
1  r    2r 
2 2 2

Accelerometers are preferred due their small size.

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10.3 Vibration Pickups

Example 10.3
Design of an Accelerometer

An accelerometer has a suspended mass of 0.01 kg with a damped


natural frequency of vibration of 150 Hz. When mounted on an engine
undergoing an acceleration of 1 g at an operating speed of 6000 rpm,
the acceleration is recorded as 9.5 m/s2 by the instrument. Find the
damping constant and the spring stiffness of the accelerometer.

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10.3 Vibration Pickups

Example 10.3
Design of an Accelerometer
Solution 1 Measured value 9.5
   0.9684
1  r    2r 
2 2 True value
2 9.81

or 1  r    2r   1 / 0.9684  1.0663


2 2 2 2
(E.1)
6000 2 
Operating speed    628.32 rad/s
60
d  1   2 n  150 2   942.48 rad/s
  r 628.32
Thus     0.6667
d 1   n
2
1  2 942.48

 r  0.6667 1   2 or r 2  0.4444 1   2   (E.2)


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10.3 Vibration Pickups

Example 10.3
Design of an Accelerometer
Solution

Substitute (E.2) into (E.1): 1.5801ζ4 – 2.2714ζ2 + 0.7576 = 0

Solution gives ζ2 = 0.7253, 0.9547


d 942.48
n    1368.8889 rad/s
Choosing ζ= 0.7253 arbitrarily, 1  2
1  0.7253 2

k  m n2   0.011368.8889  18738.5628 N/m


2

Damping constant
c  2m n  2 0.011368.8889  0.7253
 19.8571 N - s/m
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10.3 Vibration Pickups

Example 10.3
Design of an Accelerometer
Solution

Measures velocity of vibrating body: y  t   Y cos t


r 2Y
Velocity: z  t   cos t   
1  r    2r 
2 2 2

r2
If  1, then
1  r    2r 
2 2 2

z  t   Y cos t   
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10.3 Vibration Pickups

Example 10.4
Design of a Velometer

Design a velometer if the maximum error is to be limited to 1% of the


true velocity. The natural frequency of the velometer is to be 80Hz
and the suspended mass is to be 0.05 kg.

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10.3 Vibration Pickups

Example 10.4
Design of a Velometer
Solution
r 2Y
We have z  t   cos t   
1  r    2r 
2 2 2

r2 Recorded velocity
R  (E.1)
1  r    2r 
2 2 2 True velocity

 1
Maximum r  r  (E.2)
1  2 2

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10.3 Vibration Pickups

Example 10.4
Design of a Velometer
Solution

Substitute (E.2) into (E.1),

 1 
 
2 
 1  2  R
2
  1  2 1 
1     4 
2 

2 
  1  2   1  2 
1
 R
4  4
2 4

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10.3 Vibration Pickups

Example 10.4
Design of a Velometer
Solution

R = 1.01 or 0.99 for 1% error

ζ4 – ζ2 + 0.245075 = 0 and ζ4 – ζ2+ 0.255075=0


ζ2 = 0.570178, 0.429821 or
ζ = 0.755101, 0.655607

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10.3 Vibration Pickups

Example 10.4
Design of a Velometer
Solution

Choosing ζ = 0.755101 arbitrarily,


n  80 2   502.656 rad/s
k  mn2   0.05 502.656  12633.1527 N/m
2

c  2 n m  2 0.755101 502.656 0.05


 37.9556 N - s/m

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10.3 Vibration Pickups

• Phase Distortion

All vibrating-measuring instruments have phase lag.

If the vibration consists of 2 or more harmonic components, the


recorded graph will not give an accurate picture – phase distortion

Consider vibration signal of the form as shown:

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10.3 Vibration Pickups

• Phase Distortion

Let phase shift = 90° for first harmonic


Let phase shift = 180° for third harmonic
Corresponding time lags: t1= 90°/ω, t2 = 180°/ω
Output signal is as shown:

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10.3 Vibration Pickups

• Phase Distortion

In general, let the complex wave be


y(t) = a1sinωt + a2sin2ωt + …

Output of vibrometer becomes:


z(t) = a1sin(ωt – Φ1) + a2sin(2ωt – Φ2) + …

where   
2  j 
 n 
tan  j  2
, j  1,2,...
  
1   j 
 n 
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10.3 Vibration Pickups

• Phase Distortion

Φj ≈ π since ω/ωn is large.


z(t) ≈ – [a1sinωt + a2sin2ωt + …] ≈ -y(t)
Thus the output record can be easily corrected.

Similarly we can show that output of velometer is z  t    y  t 

Accelerometer: Let the acceleration curve be


y  t   a1 2 sin t  a2  2  2 sin 2t  

Output of accelerometer:
z t    a1 2 sin  t  1   a2  2  2 sin  2t  2   
43 © 2011 Mechanical Vibrations Fifth Edition in SI Units
10.3 Vibration Pickups

• Phase Distortion

Since Φ varies almost linearly from 0° to 90° for ζ = 0.7, Φ ≈ αr =


α(ω/ωn) = βω where α and β are constants.

 
Time lag t      is independent of frequency.
 
  2 z t   a1 2 sin  t     a2  2  sin  2t  2   
2

 a1 2 sin   a2  2  sin 2   where   t  


2

Thus output of accelerometer represents the true acceleration being


measured.

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10.4
Frequency-Measuring Instruments

10.4
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10.4 Frequency-Measuring Instruments

• Single-reed instrument or Fullarton Tachometer

 Clamped end pressed against vibrating body


 Adjust l until free end shows largest amplitude of vibration
 Read off frequency

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10.4 Frequency-Measuring Instruments

• Multi-reed Instrument or Frahm Tachometer

 Clamped end pressed against vibrating body


 Frequency read directly off strip whose free end shows largest
amplitude of vibration

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10.4 Frequency-Measuring Instruments

• Stroboscope

 Produces light pulses


 A vibrating object viewed with it will appear stationary when
frequency of pulse is equal to vibration frequency

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10.5
Vibration Exciters

10.5
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10.5 Vibration Exciters

• Used to determine dynamic characteristics of machines and


structures and fatigue testing of materials

• Can be mechanical, electromagnetic, electrodynamic or hydraulic


type

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10.5 Vibration Exciters

• Mechanical Exciters

Force can be applied as an inertia force

Force can be applied as an elastic spring force


for frequency <30 Hz and loads <700N

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10.5 Vibration Exciters

• Mechanical Exciters

The unbalance created by two masses rotating at the same speed


in opposite directions can be used as a mechanical exciter.

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10.5 Vibration Exciters

• Electrodynamic Shaker

The electrodynamic shaker can be considered as the reverse of an


electrodynamic transducer.

2 resonant frequencies are shown below.

F  DIl

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10.6
Signal Analysis

10.6
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10.6 Signal Analysis

• Acceleration-time history of a frame subjected to excessive


vibration:

• Transformed to frequency domain:

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10.6 Signal Analysis

• Spectrum Analyzers

Separates energy of signal into various frequency bands

Real-time analyzers useful for machine health monitoring

2 types of real-time analysis procedures: digital filtering method


and Fast Fourier Transform method

Basic component of spectrum analyzer: Bandpass filter

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10.6 Signal Analysis

• Bandpass Filter

Permits passage of frequencies over a band and rejects all other


frequency components

Response of a filter:

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10.6 Signal Analysis

• Bandpass Filter

fu and fl are upper and lower cutoff frequencies respectively


fc is centre (tuned) frequency

Ripples within band is minimum for a good bandpass filter

2 types of bandpass filters: constant percent bandwidth filters and


constant bandwidth filters

Constant percent: (fu – fl)/fc is a constant


E.g. octave, one-half-octave filters
Constant bandwidth: fu – fl is independent of fc

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10.6 Signal Analysis

• Constant Percent Bandwidth and Constant Bandwidth


Analyzers

Spectrum analyzer with a set of octave and 1/3-octave band filters


can be use for signal analysis

Lower cutoff freq of a filter = upper cutoff freq of previous filter.


Filter characteristics as shown

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10.6 Signal Analysis

• Constant Percent Bandwidth and Constant Bandwidth


Analyzers

Constant bandwidth analyzer used to obtain more detailed analysis


than constant percent bandwidth analyzer

Wave or heterodyne analyzer is a constant bandwidth analyzer with


a continuously varying centre frequency

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10.7
Dynamic Testing of Machines and Structures

10.7
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10.7 Dynamic Testing of Machines and Structures

• Involves finding the deformation of machines/structures at a critical


frequency

• Approaches:
 Operational Deflection Shape measurements
 Modal Testing

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10.7 Dynamic Testing of Machines and Structures

• Using Operational Deflection Shape Measurements

Forced dynamic deflection shape measured under steady-state


frequency of system.

Valid only for forces/frequency associated with operating


conditions.

If a particular location has excessive deflection, we can stiffen that


location.

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10.7 Dynamic Testing of Machines and Structures

• Modal Testing

Any dynamic response of a machine/structure can be obtained as a


combination of its modes.

Knowledge of the mode shapes, modal frequencies and modal


damping ratio will describe completely the machine dynamics.

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10.8
Experimental Modal Analysis

10.8
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10.8 Experimental Modal Analysis

• When a system is excited, its response exhibits a sharp peak at


resonance

• Phase of response changes by 180°as forcing frequency crosses the


natural frequency

• Equipment needed:
 Exciter to apply known input force
 Transducer to convert physical motion into electrical signal
 Signal conditioning amplifier
 Analyzer with suitable software

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10.8 Experimental Modal Analysis

• Necessary Equipment

Exciter
Can be an electromagnetic shaker or impact hammer

Shaker is attached to the structure through a stringer, to control the


direction of the force

Impact hammer is a hammer with built-in force transducer in its head

Portable, inexpensive and much faster to use than a shaker

But often cannot impart sufficient energy and difficult to control direction of
applied force

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10.8 Experimental Modal Analysis

• Necessary Equipment

Transducer
Piezoelectric transducers most popular

Strain gauges can also be used

Signal conditioner
Outgoing impedance of tranducers not suitable for direct input into
analyzers.

Charge or voltage amplifiers are used to match and amplify the


signals before analysis

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10.8 Experimental Modal Analysis

• Necessary Equipment

Analyzer
FFT analyzer commonly used

Analyzed signals used to find natural frequencies, damping ratios


and mode shapes

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10.8 Experimental Modal Analysis

• Necessary Equipment

General arrangement for experimental modal analysis:

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10.8 Experimental Modal Analysis

• Digital Signal Processing

x(t) represents analog signal, xi = x(ti) represents corresponding


digital record.

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10.8 Experimental Modal Analysis

• Digital Signal Processing


a0 N / 2  2it j 2it j 
We have x j  x t j      ai cos  bi sin ; j  1,2,, N
2 i 1  T T 
1 N 1 N 2it j 1 N 2it j
where a0   x j , ai   x j cos , bi   x j sin
N j 1 N j 1 T N j 1 T

N is fixed for a given analyzer and equations can be expressed as


  
d   A X where X   x1 x2  x N  ,
1 T


d   a0 a1a2  a N / 2b1b1 bN / 2 
T

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10.8 Experimental Modal Analysis

• Analysis of Random Signals

Input and output data usually contain random noise.

If x(t) is random signal, its average is


1 T
x  t   lim  x t  dt
T  T
0

For digital signal, x  lim  x  t j 


1 N
N  N j 1

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10.8 Experimental Modal Analysis

• Analysis of Random Signals

Define a new variable x(t) as x t   y  t   y  t 

Mean square value


1
x  t   lim x 2  t  dt
T

2

T  T
0

 x t 
N
1
For digital signal, x 2  lim j
N  N j 1

Root mean square value xRMS  x 2

74 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Analysis of Random Signals

Autocorrelation function

1
R t   x  lim  x    x    t  d
T
2
T  T 0

1 N n
For digital signal, R n, t    x j x jn
N  n j 0

If x(t) is purely random, R(t)  0 as T  ∞


If x(t) is periodic, R(t) will also be periodic.

75 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Analysis of Random Signals

Power spectral density (PSD):


1 
S     R  e i d
2 

x  
2

Digital form : S    
Nt
Cross-correlation function:
1
Rxf  t   lim  x    f    t  d
T

T  T 0

Cross-PSD:
1 
S xf      Rxf   e i d
2 

76 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Analysis of Random Signals

If f(τ+t) is replaced by x(τ+t), we get Rxx(t) which leads to Sxx(ω).

Frequency response function H(iω) is related to PSD as

S xx     H    S ff   
2

S fx     H  i  S ff   
S xx     H  i  S xf   

77 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Analysis of Random Signals

Coherence function:

 S fx     S xf     S xf   
2

      
 S     S     S    S   
 ff  xx  xx ff

β = 0 if x and f are pure noises.


β = 1 if x and f are not contaminated at all.

Typical coherence function:

78 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Determination of Modal Data from Observed Peaks

Let the graph of H(iω) be as shown below.

4 peaks suggesting a 4-DOF system.

79 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Determination of Modal Data from Observed Peaks

Partition into several frequency ranges.


Each range is consider a 1-DOF system

Damping ratio corresponding to peak j:


 j2    j1
j  where  j1 and  j2  satisfy
2 j
H  i j 
H  i j  1
  H  i  
 2
j
2
When damping is small, ωj ≈ ωn

80 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

Example 10.5
Determination of Damping Ratio from Bode Diagram

The graphs showing the variations of the magnitude of the response


and its phase angle with the frequency of a single DOF system
provides the frequency response of the system.

Instead of dealing with the magnitude curves directly, if the


logarithms of the magnitude ratios (in decibels) are used, the
resulting plots are called Bode diagrams. Find the natural frequency
and damping ratio of a system whose Bode diagram is as shown.

81 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

Example 10.5
Determination of Damping Ratio from Bode Diagram

82 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

Example 10.5
Determination of Damping Ratio from Bode Diagram
Solution

ωn = 10Hz, ω1 = 9.6 Hz, ω2 = 10.5 Hz, Peak response = -35 dB

Damping ratio:

2  1 10.5  9.6
    0.045
2n 210.0 

83 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Determination of Modal Data from Nyquist Plot

Real parts of frequency-response function of 1-DOF system plotted


along horizontal axis

Imaginary parts of frequency-response function of 1-DOF system


plotted along vertical axis
1 
Frequency-response function:   i    u  iv where r 
1  r  i 2r
2
n
1 r2  2r
u , v
1  r 
2 2
 4 r
2 2
1  r 
2 2
 4 2 r 2

84 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Determination of Modal Data from Nyquist Plot

85 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Determination of Modal Data from Nyquist Plot

Properties of Nyquist Circle:


• u and v are large when r=1
• 1-r2 = (1+r)(1-r) ≈ 2(1-r) and 2ζr ≈ 2ζ

1 r 
u

2 1 r 
2 2
 2
 , v

2 1 r 
2 2
 2 
2 2
 1   1 
u 2   v     
 4   4 

86 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Determination of Modal Data from Nyquist Plot

Once H(iω) is measured, use least square approach to fit a circle.

Intersection of circle with –ve Im axis corresponds to H(iωn)

Bandwidth is the difference of the frequencies at the 2 horizontal


diametral points
  2     1
Damping ratio:  
2n

87 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Measurement of Mode Shapes

 
Undamped multi-DOF system:  m x   k  x  f


 
Free harmonic vibration:  k     m yi  0  i
2

Orthogonal relations for mode shapes: Y T  mY   diag M 


Y T  k Y   diag K 
Ki
i2 
Mi

88 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Measurement of Mode Shapes

When forcing functions are harmonic,

 
 ~i t 1  ~  ~i t
x  t   Xe   k     m Fe       Fe
 2 i t


     Y   K     M  2
 Y 
1 T

Xp
 pq          pq 
Fq
with F j  0; j 1, 2 ,, N ; j  q
 
N  yi  p  yi  q

i 1 Ki   2M i

89 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Measurement of Mode Shapes

Further normalized [Y] as


  

[ ]  1 2  N  Y  M 
1 / 2

N 
 pq      2
  
 
i p i q

i 1  i   2

90 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Measurement of Mode Shapes

 
Damped multi-DOF system:  m x   c  x   k  x  f

 

Assume proportional damping:  c   a k   b m

Undamped mode shapes of the system will diagonalize the damping


matrix:
Y T  cY   diag  k 

91 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Measurement of Mode Shapes



Frequency-response function when f is harmonic:

N
 
 yi  p  y i  q
 pq          pq  ~
i 1 K i   M i  i Ci
2

When mass-normalized mode shapes are used:

N
 pq      2
  

i
p i q
~
i 1 i    2 i  ii
2

92 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.8 Experimental Modal Analysis

• Measurement of Mode Shapes

Substituting ω=ωi into the equation, we get:

 pq  i   H pq  i  
  

i p

i q
~
    2 i  ii2
i
2 2

  
 
i p i q
or  pq  i   H pq  i  
2 ii2
  
 
or i p i q  2 ii2 H pq  i 

93 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9
Machine-Condition Monitoring and Diagnosis

10.9
94 © 2011 Mechanical Vibrations Fifth Edition in SI Units
10.9 Machine-Condition Monitoring and Diagnosis

• Machine operations will cause misalignments, cracks, unbalances


etc in machine parts

• Vibration level will increase until machine failure occurs

95 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Vibration Severity Criteria

Vibration severity charts can be used as a guide to determine


machine condition.

RMS value of vibratory velocity is compared against the criteria set


by the standards.

However the overall velocity signal used for comparison may not
give sufficient warning of the imminent damage.

96 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Machine Maintenance Techniques

Life of machine follows the bathtub curve:

97 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Machine Maintenance Techniques

Breakdown maintenance:
Allow the machine to fail and then replace it with a new machine.

This strategy is used when machine is inexpensive and no other


damage is caused by the breakdown.

98 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Machine Maintenance Techniques

Preventive maintenance:
Maintenance performed at fixed intervals.

Intervals determined statistically from past experience.

This method is uneconomical.

99 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Machine Maintenance Techniques

Condition-based/Predictive maintenance:
Replace fixed-interval overhaul with fixed-interval measurements.

Can extrapolate measured vibration levels to predict when they will


reach unacceptable values.

Maintenance costs are greatly reduced.

100 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Machine Maintenance Techniques

101 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Machine Condition Monitoring Technique

Following methods are used to monitor machine conditions:

Aural and visual – a skilled technician will listen and see the
vibrations produced by the machine

Operational variables monitoring – performance is monitored wrt


intended duty. Deviation denotes a malfunction.

102 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Machine Condition Monitoring Technique

Temperature monitoring – rapid increase in temperature is an


indication of malfunction.

Wear debris found in lubricating oils can be used to assess extent


of damage by observing concentration, size, shape and colour of
the particles.

Available vibration monitoring


techniques.

103 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Vibration Monitoring Techniques

Time domain analysis


E.g. following is an acceleration waveform of a gearbox. Pinion is
coupled to 2685 rpm motor.

Period of waveform same as period of pinion.


This implies a broken gear tooth on the pinion.

104 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Vibration Monitoring Techniques

Statistical Methods
Peak level, RMS level and crest factor may be used as indices to
identify damage.

Changes in Lissajous figures can be used to identify faults.

105 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine Condition Monitoring and Diagnosis

• Vibration Monitoring Techniques

Statistical Methods
Waveform corresponding to good components will have bell-shaped
probability density curve

Any deviations can be due to component failure

First 4 moments of the curve are called the mean, standard deviation,
skewness and kurtosis.
1 
Kurtosis is defined as k 4   x  x  4
f  x  dx

Increase in value of kurtosis can be due to machine component failure

106 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Vibration Monitoring Techniques

Frequency Domain Analysis


Vibration spectrum is unique to that particular machine. Its shape
changes as faults starts developing.

Nature and location of the fault can be detected by comparing the


frequency spectrum of the damaged machine with that of the
machine in good condition.

107 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Vibration Monitoring Techniques

Frequency Domain Analysis


Each rotating element generates identifiable frequency.

Thus changes in the spectrum at a given freq can be attributed to


the corresponding element.

108 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Vibration Monitoring Techniques

Quefrency Domain Analysis


Quefrency is the x-axis for cepstrum.

Cepstrum c(τ) is the inverse fourier transform of the log of the


power spectrum SX(ω).
T
1
S X     F  x t  where F  x t    x t  e it dt
2
2
T
T 
2

c   F 1 log S X   

Cepstrum can detect any periodicity in the spectrum caused by


component failure.
109 © 2011 Mechanical Vibrations Fifth Edition in SI Units
10.9 Machine-Condition Monitoring and Diagnosis

• Vibration Monitoring Techniques

Quefrency Domain Analysis


2nd gear was at fault although 1st gear was engaged.

110 © 2011 Mechanical Vibrations Fifth Edition in SI Units


10.9 Machine-Condition Monitoring and Diagnosis

• Instrumentation Systems

Quefrency Domain Analysis


3 types – basic system, portable system, computer-based system.

Basic system consists of vibration meter, stroboscope and headset.

Portable system consists of portable FFT vibration analyzer based


on battery power.

Computer-based system consists of FFT vibration analyzer coupled


with computer for maintaining centralized database and provide
diagnostic capabilities.
111 © 2011 Mechanical Vibrations Fifth Edition in SI Units
10.9 Machine-Condition Monitoring and Diagnosis

• Instrumentation Systems

Piezoelectric accelerometers are commonly used.

Can choose between acceleration, velocity and displacement to


monitor.

Velocity is commonly used as the parameter for monitoring the


machine conditions because the velocity spectrum is the flattest.

Any change in the amplitude can be observed easily in a flatter


spectrum.

112 © 2011 Mechanical Vibrations Fifth Edition in SI Units

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