DALOG Training - Data Analysis

DALOG® Data Analysis
Dr. Franz Muschaweck

Sebastian Muschaweck
Date: 18. January 2010
DALOG® Diagnosesysteme GmbH, - 1 -

© Confidential. DALOG reserves all rights even in the event of industrial property rights.
We reserve all rights of disposal such as copying and passing on the third parties.
Why is Vibration Monitoring important?
We can hear vibration! 

 Vibration can generate sound!
We can sense vibration! 

 Vibration can generate heat!
We can see vibration! 

 Vibration can move objects!

What causes Machine Vibration?
Repeating Forces 
Looseness 
Resonance 

Repeating Forces
Repeating Forces in Machines are mostly
 Imbalanced
 Misaligned
 Worn
 Improperly Driven

Imbalanced Machine Components
Imbalanced
 Rotor, Coupling, Fan, Shaft, etc.
Static imbalanced
 Moment imbalanced

Misaligned Machine Components
Angular Misaligned Shaft
Parallel Misaligned Shaft

Worn Machine Components
Worn Rollers
Worn Teeth
Worn Belt

Improperly Driven
Misfiring Cylinder
Consistence of the Material
Defect Table

Looseness
Excessive Clearness
Loose Screws,
Bolts

Resonance – Resonance Frequencies
Most machines have more than

one natural oscillation rate.
The more complex –

the more natural oscillation rates.
Resonance frequencies should always

be avoided as it causes rapid and severe damages.

Resonance
Natural Oscillation Rate

How is Machine Vibration Described?
The most important numerical descriptors of
machine vibration are
 Amplitude
 Frequency

Amplitude and Frequency
Amplitude describes the severity of Vibration

 Amplitude is an indication of the severity of vibration
Frequency describes the oscillation rate of Vibration

 the size and the speed of the vibratory movement

What is Amplitude?
The amplitude of vibration is the magnitude of vibration.
Vibration amplitude
of an imbalanced fan!

How can a Time Signal be described?

Characteristic Values in the Time Domain I
RMS – Root Mean Square - Vibration Energy of the Signal

pure sinus wave RMS = 0.707 * Amplitude
PtP – Peak to Peak - Maximum Peak of the Signal

Characteristic Values in the Time Domain II
Cr Crest Value – Degree of peakedness of the Signal
Ku Kurtosis – Degree of peakedness of a

Distribution of the Signal
normal distribution of a signal Ku = 3

Acceleration Sinus Signal Curve
RMS = 1.72 [g]
PtP = 4.93 [g]
Cr = 1.48 [-]
Ku = 1.50 [-]

Acceleration Signal “normal” Signal Curve
RMS = 0.68 [g]
PtP = 3.60 [g]
Cr = 2.99 [-]
Ku = 2.52 [-]

Acceleration Signal with Spikes
RMS = 0.26 [g]
PtP = 2.80 [g]
Cr = 5.45 [-]
Ku = 4.97 [-]

Trend of the Characteristic Values
Trend RMS Value
Trend PtP Value

Trend of the Characteristic Values
Reason for a change in trend can be:
Process
Bearings
Gears
Coupling

Peakedness of a Signal - Broken Teeth

Peakedness of a Signal – Damaged Bearings

Peakedness, High Vibration of a Signal –
Damaged Mill Plate Rollers

What is a Frequency?
The rate at which a machine

component oscillates is called its
oscillation or vibration frequency!
Frequency is an indicator of the

condition of the machine!

What is a Frequency?

What is a Waveform?
A waveform shows how the vibration level

changes with the time!

What is a Spectrum?
A spectrum is a graphical display of the frequencies

at which a machine component is vibrating

What is a Spectrum?
Vibration amplitude
of an unbalanced fan!
The waveform is a pure Sinus Wave.

What is a Spectrum?
The waveform is a superposed Vibration amplitude of a

Sinus Wave. fan disturbed by a card!

What is a Spectrum?
Vibration amplitude of a
The waveform is a pure Sinus Wave.
fan disturbed by a card!

What is a Spectrum?
=
Sinus = fn
Sinus = 4 * fn
Add both sinus waves and you get the superposed signal.
What is a Spectrum?
Unbalance
Rub
Measured Vibration –
a combination of both
sources of vibration
Add both sinus waves and you get the superposed signal.
What is a Spectrum?
Fast Fourier Transformation FFT

from a time wave to a spectrum!
fn
4 * fn
FFT
What is a Spectrum?
Individual Frequencies
Individual Signals
fn
4 * fn
FFT

Waveform and Spectrum
Waveform displays the overall effect

Spectrum displays the machine frequencies

Imbalanced Coupling - Eccentricity
Shaft speed fs = 1 x rpm
Static imbalance

Static imbalance
What is the shaft speed of the following Sinus signal?
in Hz
fs = ???[Hz]
and in rpm
ns = ???[rpm]

Static Imbalance
What is the shaft speed of the following Sinus signal?
in Hz
fs = 12[Hz]
and in rpm
ns = 720[rpm]

Gear Boxes

Gear Faults – Tooth Problems
 Alignment  Single Pitch Error

 Cracked Tooth  Sum Pitch Error
 Broken Tooth  Radial Run Out
 Pittings, Spallings  Eccentricity
 Wear, Scratches

Broken Teeth

Pitting, Spalling

Calculating the fundamental Gear Frequencies
z1 = number of teeth bevel pinion fs1= input shaft frequency
z2 = number of teeth bevel wheel fs2= bevel wheel shaft frequency
zs = number of teeth sun wheel fzb1= gear mesh frequency bevel gear
zp = number of teeth planet wheel fp = planet frequency
zr = number of teeth ring gear fc = carrier frequency
np = number of planets fzp = gear mesh frequency planet gear
fds = defect frequency sun gear
fdp = defect frequency planet wheel
fdr = defect frequency ring gear

Calculating the fundamental Frequencies
Carrier Frequency
Gear Mesh Frequency

fs1
Planetary Stage
Input Shaft Frequency Bevel Wheel Shaft

Frequency
Gear Mesh Frequency
Bevel Gear Stage

Input Speed n = 990rpm
Input Shaft Frequency
Gear Mesh Frequency

Bevel Gear Stage
Bevel Wheel Shaft

What is the input speed? fs1 = ???[Hz] Frequency
What is the gear mesh frequency? fzb1 = ???[Hz]
What is the speed of the bevel wheel shaft? fs2 = ???[Hz]

Input Speed n = 990rpm
Input Shaft Frequency
Gear Mesh Frequency

Bevel Gear Stage
Bevel Wheel Shaft

What is the input speed? fs1 = 16.50[Hz] Frequency
What is the gear mesh frequency? fzb1 = 214.50[Hz]
What is the speed of the bevel wheel shaft? fs2 = 5.80[Hz]

Acceleration Time Signal
Typical normal
time signal curve

Frequency Spectrum
Typical normal
frequency curve

Waveform of beginning Gear Failure
time signal curve

beginning of gear
failure

Spectrum of a beginning Gear Failure
Frequency spectrum
beginning of gear failure

Waveform of a broken Tooth
time signal curve

massive gear failure

Spectrum of a broken Tooth
frequency spectrum
massive gear failure

Bearings

Ball Pass Frequency Outer BPFO
Ball Pass Frequency Inner BPFI
Ball Spin Frequency BSF
Fundamental Train Frequency FTF

Envelope Analysis
Original Signal Envelope
Outer Ring Frequency + Harmonics
• Band-Pass Filter (10- 20 kHz) > Rectifying > Low-Pass Filter

•Hilbert Transformation Analogue or Digital
• Peak-Hold Method
Amplitude Modulation

Envelope Signal

Roller Bearing with Inner Ring Failure

Roller Bearing with Inner Ring Failure (Envelope)

Roller Bearing with Outer Ring Failure

Roller Bearing with Outer Ring Failure (Envelope)

Roller Bearing with Ball Failure

Signal Analysis Bearing Failure

Signal Analysis Bearing Failure

THANK YOU
Maráming Salámat
Terima kasih
Do not hesitate to contact us:

Tel.: +49 821 7 47 77 10  Fax: +49 821 7 47 77 19
e-mail: [email protected]  www.dalog.net


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DALOG® Data Analysis

Dr. Franz Muschaweck

Date: 18. January 2010

DALOG® Diagnosesysteme GmbH, - 1 -

We can hear vibration! 

We can sense vibration! 

We can see vibration! 

DALOG® Diagnosesysteme GmbH, - 2 -

DALOG® Diagnosesysteme GmbH, - 3 -

Repeating Forces in Machines are mostly

DALOG® Diagnosesysteme GmbH, - 4 -

DALOG® Diagnosesysteme GmbH, - 5 -

Angular Misaligned Shaft

Parallel Misaligned Shaft

DALOG® Diagnosesysteme GmbH, - 6 -

DALOG® Diagnosesysteme GmbH, - 7 -

Consistence of the Material

DALOG® Diagnosesysteme GmbH, - 8 -

DALOG® Diagnosesysteme GmbH, - 9 -

Most machines have more than

The more complex –

Resonance frequencies should always

DALOG® Diagnosesysteme GmbH, - 10 -

DALOG® Diagnosesysteme GmbH, - 11 -

DALOG® Diagnosesysteme GmbH, - 12 -

Amplitude describes the severity of Vibration

Frequency describes the oscillation rate of Vibration

DALOG® Diagnosesysteme GmbH, - 13 -

The amplitude of vibration is the magnitude of vibration.

DALOG® Diagnosesysteme GmbH, - 14 -

DALOG® Diagnosesysteme GmbH, - 15 -

RMS – Root Mean Square - Vibration Energy of the Signal

PtP – Peak to Peak - Maximum Peak of the Signal

DALOG® Diagnosesysteme GmbH, - 16 -

Cr Crest Value – Degree of peakedness of the Signal

Ku Kurtosis – Degree of peakedness of a

DALOG® Diagnosesysteme GmbH, - 17 -

RMS = 1.72 [g]

PtP = 4.93 [g]

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RMS = 0.68 [g]

PtP = 3.60 [g]

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RMS = 0.26 [g]

PtP = 2.80 [g]

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Trend PtP Value

DALOG® Diagnosesysteme GmbH, - 21 -

Reason for a change in trend can be:

DALOG® Diagnosesysteme GmbH, - 22 -

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The rate at which a machine

Frequency is an indicator of the

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DALOG® Diagnosesysteme GmbH, - 27 -

A waveform shows how the vibration level

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