Vibration Analysis with FFT Analyzer

Name: Sudipta Pal

Roll no: ME1418
Subject: AMV
Date: 05-
05-05-
05-2017
Content

Basics of Vibration
Vibration Characteristics
FFT Process
Vibration Transducer
Vibration Standards
Data Acquisition
Vibration Alarming Methods
What is Vibration?
What is Vibration ?
Vibration is the motion of a body about a
reference position caused by a force
In simple terms vibration is :-
A response to some form of excitation

The free movement of the shaft in a

journal bearing will cause it to vibrate
when a forcing function is applied
 Principle of Vibration Analysis

Mechanical faults generate Mechanical Defects detected

unique vibration with vibration analysis
Belt drive faults
Geometry of the machine Imbalance
diameter of the shaft, Misalignment
Bent shaft
number of bearing Looseness
elements, etc. Machine resonance
Cavitation
Turning speed (e.g. RPM) Shaft Rub
Bearing Defects including:
cage defect
outer race defect
inner race defect
rolling element defect
Gear defects
Electrical faults
Basic Terminology in Vibration
How Vibration is measured & described
Vibration Characteristics
Amplitude

Amplitude is the magnitude of vibration expressed in terms of

signal level (millivolts or milliamps) or in engineering units
There are many ways of measuring vibration amplitude levels,
the most common are: peak to peak, zero to peak, root mean
square (RMS), average and crest factor.
Zero to peak or peak is the measurement from the zero line to
the top of the positive peak or the bottom of the negative peak.
Vibration Characteristics
Frequency

Measure of the number of cycles of vibration that occur

in a specific period of time
Tells us at what rate the vibration is occurring
CPM relates directly to machine RPM
The time required to complete one full cycle of
vibration

Frequency = 1 1 = Cycles
=
Period T Second
Vibration Characteristics
Significance of Frequency

Essential to pinpoint the cause of a machine problem

most vibration problem will have frequencies that
directly related to the rotational speed.
Vibration frequency is an analysis or diagnostics tool

Consider a motor has a rotational speed of 1485RPM, in terms of frequency this

equates to:

1485 CPM (1rpm = 1cpm)

24.75 Hz (1485/60) (minutes to seconds)
1 Orders (1 x revolution of the shaft)
Time Waveforms
There are multiple sources of forcing functions that can emit from a
machine or component.

A8 - Example 15
The plot shown on the right 0.4
Ex15 -F2V Fan Outboard Vertical
Route Waveform

is a complex time 0.3

22-Aug-02 11:33:16

waveform. 0.2
PK = .1495
LOAD = 100.0
RPM = 832. (13.86 Hz)
Los - Example 8
EX 8 -P2V Pump Outboard Vertical PK(+) = .3263
1.0

Amplitude versus Time Analyze

PK(-) =Spectrum
.3572

Acceleration in G-s
0.1 15-Nov-95 10:00:16
CRESTF= 3.38

RMS = 1.27
0.0
0.8 LOAD = 100.0

This is just one format RPM = 737.

RPS = 12.28

RMS Velocity in mm/Sec

(domain) for analysing -0.1

0.6
vibration data. -0.2

-0.3

Data can also be analysed

0.4

in a Spectrum (Amplitude -0.4

0 50 100 150 200 250 300 350
Time: 120.44
Ampl: -.07595

Vs Frequency) through a 0.2 Time in mSecs

process known as the FFT

0
Freq: 736.86
0 6000 12000 18000 24000 30000 Ordr: 1.000
Frequency in CPM Spec: .245
Label: Looseness
Frequency Domain
This data is derived from the time domain mathematical manipulation of the time
waveform.

Recall the waveform and spectrum from the previous slide. If you tried to determine all
the frequencies from the waveform plot, you would need all day just to analyse one
point of data.

As the FFT plots the frequencies from the waveform for you the analysis of this data
becomes easier and reduces the amount of time needed for analysis of each point.

A8 - Example 15 Los - Example 8

Ex15 -F2V Fan Outboard Vertical EX 8 -P2V Pump Outboard Vertical
0.4 1.0
Route Waveform Analyze Spectrum
22-Aug-02 11:33:16 15-Nov-95 10:00:16
0.3
PK = .1495 RMS = 1.27
LOAD = 100.0 LOAD = 100.0
0.8
RPM = 832. (13.86 Hz) RPM = 737.
0.2
RPS = 12.28
PK(+) = .3263

RMS Velocity in mm/Sec

PK(-) = .3572
Acceleration in G-s

0.1 CRESTF= 3.38

0.6

0.0

-0.1 0.4

-0.2

0.2
-0.3

-0.4
Time: 120.44 0
0 50 100 150 200 250 300 350 Ampl: -.07595 Freq: 736.86
Time in mSecs 0 6000 12000 18000 24000 30000 Ordr: 1.000
Frequency in CPM Spec: .245
Label: Looseness
Fast Fourier Transform FFT Process

Any waveform is actually just the sum of a series of simple sinusoids

of different frequencies, amplitudes, and phases.

A Fourier series is that series of sine waves; and we use Fourier

analysis or spectrum analysis to deconstruct a signal into its individual
sine wave components.

The FFT is a process that determines the frequency of a signal from

a time waveform.

The FFT is named after an 18th century mathematician named Jean

Baptise Joseph Fourier. He established:
Meaning if you take a time waveform and mathematically calculate the vibration
frequency, it can be converted to a more familiar format

Fourier analysis works by testing for the presence of each frequency

component.
Schematic Diagram of FFT analyzer
How the Vibration Spectrum is Created
FFT - Signal Processing
The Fast Fourier Transform (FFT) takes the complex waveform and breaks it down
into the component sine waves
 FFT Analysis of Car Engine

In the FFT there is clearly a dominate frequency at 30 Hz or 1,800 RPM

which tells us that at idle the crank shaft is rotating at 900 RPM (or 15
Hz) where there is also a peak in the FFT.
The use of an FFT in our vibration analysis gave clues on what was
causing the measured vibration.
Displacement, Velocity and Acceleration on a
Same Vibrating Machine
Vibration Transducer
Vibration Transducer
Vibration Transducer
Accelerometers
Velocity Sensors
Typical Uses of Vibration Transducers
Radial Shaft
Vibration & Position
Radial Casing
Vibration

Axial Shaft
Vibration & Position
Monitoring Techniques
Relative Amplitude
Useful Operating Ranges
100000000

10000000

1000000
Accelerometer
100000

10000

1000 Velocity Transducer

100

Prox. Probe
10

0.1 1 10 100 1000 10000 Hz

Monitoring Techniques
Vib Acceleration
accentuates HIGH frequencies,
and attenuates LOW frequencies.

Acceleration

Velocity
flat treats all frequencies equally.

Velocity

Displacement
accentuates LOW frequencies,
and attenuates HIGH frequencies.

Displacement

Freq
Measurement Parameter

Find the flattest spectrum

Normally velocity is used
Acceleration
For very slow running machine
(< 600 RPM) displacement is
preferred.

Velocity For High frequency diagnostics

use acceleration
Always use acceleration for
Envelope analysis.
Displacement
Vibration Pickups
Shaft
Rotating Rolling Element
Speed Bearings
Journal Blades
Bearings 2x Gear
instability 3x

1 KHz 3KHz 25KHz

Non Contact Displacement

Velocity Probe
Accelerometer
Vibration Fundamentals
How Much Vibration is Too Much ?
1. Use Absolute Vibration Levels
- Given by machine makers
- Published Vibration Severity Standards
eg. ISO 2372, VDI 2056, BS 4675

2. Use Relative Vibration Levels

Vibration standards are guidelines
ISO2372 ( BS 4675 , VDI 2056 )
45
Not 28
Not Permissible 18

2.5 times = 8dB

Not
Permissible Permissible
11.2

10 times = 20dB
Just Tolerable 7.1

Velocity mm/s RMS

Just
Tolerable 4.5
Just Tolerable Allowable 2.8
Allowable 1.8
Allowable Good 1.12
Good Large Machines
15 kW<
Medium Machines
with rigid and heavy 1.71
foundations whose
Good <75kW
natural Frequency
0.45
Small <300 kW on special exceeds 0.28
Machines< 15 kW foundations machine speed
0.18
Group K Group M Group G
Signal Data Acquisition
Detecting Faults Automatically
Vibration Alarming Methods
Overall Alarm
Overall Alarm
Frequency Bands
Establishing a Vibration Program
Step 1: Define program focus
Step 2: Determine Collection Method(s)
Step 3: Create database
Step 4: Collect Data
Step 5: Detect Developing Faults
Step 5: Detect Developing Faults
Step 6: Diagnose Nature of Fault
FFT Analyzer Mode Application

Diagnose
Nature of
Fault
Step 6: Automated Diagnosis
Examples of Orbits (Fault Detection)