BTD2223 MECHANICAL VIBRATION

LAB REPORT 2
TITLE: VIBRATION FAULT DIAGNOSIS

GROUP 3

LECTURE: DR.CHE KU EDDY NIZWAN

NO NAME ID

4 HAMERLIA EDRYNA BINTI MUHAMMAD HANUAR TM21008

INTRODUCTION
Vibration analysis is crucial for identifying and troubleshooting faults in rotating machinery. In
mechanical systems, vibration is frequent, especially in rotating equipment like motors, pumps,
and turbines. Excessive vibrations can result in malfunctioning equipment, poor performance,
and safety risks. Therefore, it's crucial to quickly detect and fix vibration problems. The methods
and results of our investigation on vibration fault diagnostics are presented in this publication.

OBJECTIVE

● To investigate and diagnose vibration faults in a mechanical system.

SCOPE OF TESTING

● Acquire the vibration signatures using a vibration data acquisition system.

● Set the unbalance and mechanical looseness defect

● Observe the vibration response in time and frequency domains.

APPARATUS

1. Sensor

2. National Instrument Data Acquisition System

3. Data analyzer and display

4. Basic Facilities.
METHODOLOGY

Before starting the experiment, we divided the process into system arrangement and software
setup.

System Arrangement:

- Connect the sensor to the data acquisition system and then connect the data acquisition
system to the PC. This will allow the NI-DAQmx Software and DasyLab Software to
read the data easily. Also, place the Uniaxial accelerometer on top of the Rotating fault
simulator.

Software Setup:

1. Open the NI-DAQmx software after connecting the data acquisition sensor to the PC.
Create a new task called "myaccelerationtask_1" for measuring vibrations. Select analog
input from the Acquire Signal menu.
2. Choose acceleration as the type of input signal and link it to the corresponding input
channel. Adjust the sensitivity value to 2.25 mV/g based on the sensor used. Set the
acquisition mode to continuous sample.
3. Set up DasyLab to work synchronously with the NI-DAQmx software. Go to the
Measurement menu, select Hardware Setup, choose NI-DAQmx, and synchronize it with
MAX.
4. The modules in DasyLab are arranged and connected as shown in Figure 7. The sampling
rate is set to 2048 and the block size is set to 4096, as seen in Figure 8.
Data Measurement:

i. Attach the accelerometer to the rotating fault simulator.

ii. Run the rotating simulation rig under normal conditions and start the measurement when the
system reaches a steady state.

iii. Record the root mean square (RMS) value of velocity, time waveform, and frequency
spectrum.

iv. Introduce faults to the rotating fault simulator:

- For unbalance, add an unbalanced mass (screw + nut) to the disc rotor.

- For mechanical looseness, loosen the screw on the bearing holder.

v. Repeat steps (i)-(iii) under the faulty conditions.

Software Setup.
- Firstly, we must open the NI-DAQmx software.
- Create a new task for vibration measurement and select analog input from the Acquire
Signal menu.
- Next, select acceleration as a type of input signal and link it with the corresponding input
channel.
- Set ‘Continuous Sample’ under Acquisition Mode and click ‘Run’ to verify the
connection between sensor and software. If the response is according to the input signal,
click ‘save’ and close the window.
- Hold the sensor and move it in the same direction to create a harmonic signal at the
amplitude vs acceleration graph. So, we can assume that our sensor works very well.
- Next, we moved to the DASYLab setup. For this step, we must Synchronous DASYLab
with NI-DAQmx software.
- Click on Measurement menu > Hardware Setup > NI-DAQmx > Synchronization with
MAX.
- After that, set the sampling rate and block size. Click on Measurement > Time Bases >
All Setting. Preferable sampling rate within the range of 1024-8192 Hz and block size
should be two (2) or four (4) times greater than the value of sampling rate.
- We chose 5000 Hz for the sampling rate and10000 for the block size.
- Now, we create a module layout for Data Acquisition. We need one Task Data
Acquisition, two pairs of Y/t Chart, one Data Window, one FFT, one digital filter, one
digital meter, and a derivative module. The module layout is as following:
RESULT / DISCUSSION & ANALYSIS

A set of tests were conducted to examine two fault circumstances. A three-phase, inverter-duty,
AC electric motor was used in each of these tests. A GS1-10P2 AC drive running at 40, 50 and
60 RPM was used to drive this motor. The sound and vibration assistant, which was also bought
from National Instruments, was used to analyze vibration data obtained from an accelerometer
mounted in the vertical axis of the motor.

Healthy Condition:

(gmbr)

The healthy condition of The Rotating Fault Simulator is that there is no unbalanced and
looseness observation on it. By monitoring the condition of an ideal motor, comparisons can be
made between motors under fault conditions and that of an ideal motor. There 3 types of speed
have been tested in this test. 40, 50, and 60 RPM

Motor speed = 40 RPM

(gambaq result RPM 40 healty)

Motor speed = 50RPM
(gmabaq result)

Motor speed = 60 RPM

(result pic)
Unbalanced Condition:
(gmabar wth screw)

A steel bolt is fastened to one end of the flywheel of a three-phase induction motor in order to
analyze the rotor's unbalanced state. At one operating speed, a motor with an unbalanced rotor
will have a significant amplitude peak. A data capture device was used to record motor vibration
data, which was then graphed in MATLAB using FFT.

Motor speed= 40 RPM

(result pic)
Motor speed= 50 RPM
(result pic)

Motor speed= 60 RPM

Result pic)
Looseness Condition:
(gmbr yg longgar skru)

The patterns of vibration brought on by mechanical relaxation are also investigated. A three-
phase electric motor's body can move more freely by removing the mounting nuts, which alters
the motor's vibration pattern. It is believed that mechanical relaxation-related frequency peaks on
the spectrum look like multiples of motor operating speed. Additionally, this peak has an
unpredictable amplitude and occurs on the elevated noise floor. Using a data collection tool, it is
captured.

Motor speed = 40 RPM

(reslt pic)

Motor speed= 50 RPM

(result pic)

Motor speed= 60 RPM

(reslut pic)
Comparison between healthy and faulty conditions in terms of vibration intensity (VRMS)
and frequency spectrum.

In healthy conditions, the frequency spectrum can often be broad and continuous, but the
vibration intensity (VRMS) tends to be low and stable. It follows that there are several different
frequencies present and that none of them dominate the signal. Additionally, the power
distribution of these signals is considerably more evenly distributed across all frequencies, and
the power tends to be lower at higher frequencies than at lower ones.

Contrarily, unhealthy situations show extremely distinct traits from defective ones. The vibration
intensity (VRMS) will often be greater than average with peaks at specific frequencies or
frequency ranges. These peaks reveal the presence of defective or out-of-balance components
inside the system that is causing the vibrations. Similar to how it is under healthy conditions, the
frequency spectrum will not be as wide and continuous, but rather may be more focused on a few
key frequencies or bands of frequencies, with very little energy elsewhere in its range. If these
peak frequencies fall inside the system's essential operating limits, they might interfere with
surrounding gear or possibly seriously harm the system itself.

In order to correctly analyse any potential fault situations, it is crucial to evaluate both
parameters precisely. It's also critical to bear in mind that the frequency spectrum and vibration
intensity (VRMS) might change depending on a range of elements, including load levels,
operating conditions, and material characteristics. Additionally, each reading should be
thoroughly examined to look for any trends or anomalies that could indicate future issues before
they have a chance to spiral out of control.
CONCLUSION AND RECOMMENDATION

The three experiments' results all backed supported the use of vibration analysis in preventative
maintenance. The patterns corresponding to each damage event are identified by comparing the
vibration data for each damaged instance to a healthy motor. This serves as an example of how
vibration analysis may be used to find numerous defects in rotating mechanical systems.

The experiments that follow will examine vibrational trends. To put it another way, the aim of
this study is to identify the causes and timing of rotating machinery failure. The motor may be
used for the longest period of time before needing to be fixed by creating a time-dependent
approach for evaluating motor damage, which lowers total maintenance costs.