Campbell Diagram

The calculation of the Campbell diagram is available when dynamic

analyses are performed in entire shaft systems. The shaft system's
eigenfrequencies are calculated for an operating speed range on one of the
shafts. The results are output together with the shaft's excitation frequencies
and the toothing as a plot, a report and in a table.

A Campbell Diagram is a graphical tool used to analyze and visualize the relationship between the natural
frequencies of a rotating system (e.g., a gearbox shaft) and its operating speeds. It is particularly helpful in
determining critical speeds, where resonance may occur, and is commonly used in vibration analysis of
rotating machinery such as turbines, compressors, and gearboxes.

Key Components of a Campbell Diagram:

1. Y-Axis (Frequency): Represents the natural frequencies of the rotating system, typically in Hertz
(Hz) or cycles per minute (CPM).
2. X-Axis (Speed): Represents the operating speed of the system, typically in revolutions per minute
(RPM).
3. Natural Frequency Lines: These lines show how the natural frequencies of the system change with
respect to the operating speed. The system can have multiple natural frequencies (modes of
vibration), and each one will be represented by a separate line.
4. Excitation Lines (Harmonics): Diagonal lines that represent the harmonics of the system’s rotational
speed. These are usually straight lines with slopes corresponding to multiples of the operating speed
(1x, 2x, 3x, etc.). For example, the first harmonic (1x) is a straight line where the frequency is equal
to the operating speed. Higher harmonics represent multiples of the operating speed and are plotted
as steeper lines.
How to Read a Campbell Diagram:

 Resonance: Occurs when one of the natural frequency lines intersects with an excitation line (such as 1x, 2x
harmonics, etc.). At this intersection, the system’s natural frequency coincides with an excitation frequency,
potentially leading to large vibration amplitudes, which is undesirable.
 Critical Speeds: The critical speeds are the operating speeds at which these intersections occur. These are
speeds to avoid during normal operation because of the risk of resonance.

Example of What You Would See:

 If your gearbox shaft has a natural frequency of 1000 Hz at a certain speed and this intersects with the 1x
excitation line at 10,000 RPM, then 10,000 RPM would be a critical speed.
 If the 2x harmonic intersects a different natural frequency at, say, 20,000 RPM, that would be another critical
speed.

Purpose of a Campbell Diagram:

1. Identify Critical Speeds: It helps you pinpoint speeds at which the natural frequencies match the
excitation frequencies, leading to resonance.
2. Design Adjustments: By analyzing the Campbell Diagram, you can modify the design (e.g., change
shaft dimensions, bearing locations, material properties) to shift natural frequencies away from the
operating speed range.
3. Predictive Maintenance: Helps engineers plan maintenance schedules by understanding the
vibration behavior at different operating speeds.

Example Campbell Diagram Structure:

1. Frequency vs. Speed Plot: Shows various natural frequencies as a function of the shaft’s rotational speed.
2. Excitation Harmonics: Straight diagonal lines representing 1x, 2x, 3x, etc., multiples of the running speed.

If any natural frequency curve crosses these diagonal lines, there’s a potential for resonance at those speeds.
Therefore, this helps in determining the critical speeds and avoiding operational risks.

Campbell Diagram in KissSoft:

When using KissSoft, after running the Critical Speed Analysis, the software will generate a Campbell
Diagram showing the relationship between the natural frequencies and the operating speed. You can then
identify where the critical speeds occur and take necessary design steps to prevent resonance issues.

In summary, a Campbell Diagram is a powerful tool for analyzing and avoiding dangerous critical speeds in
rotating systems. It is a standard output for critical speed analysis in software like KissSoft.

1. Reference Shaft

A reference shaft is the main shaft under analysis for its dynamic and vibration behavior. It is the primary
rotating element in the gearbox or mechanical system that you are evaluating. When conducting critical
speed analysis, the geometry, material properties, loads, and boundary conditions (such as supports or
bearings) of the reference shaft are all defined in detail.

 In KissSoft, the reference shaft would be the modelled shaft whose dynamic characteristics (like natural
frequencies, critical speeds, and mode shapes) are being analyzed.
 Other elements connected to the reference shaft, such as gears, couplings, or other rotating parts, may
influence its behavior.
2. Meshing Stiffness

Meshing stiffness refers to the stiffness of gear teeth during meshing, i.e., when they are in contact and
transmitting force. This stiffness is a measure of how much the gear teeth resist deformation when forces are
applied during operation. It is a crucial factor because it influences the dynamic behavior of the entire gear
train, including noise, vibration, and critical speeds.

 In the context of critical speed or dynamic analysis, the meshing stiffness between gear pairs can affect the
vibration response of the system, including the shaft.
 KissSoft can use gear meshing stiffness as part of its calculations to more accurately predict the system's
response and calculate the critical speeds considering the influence of the gears.

3. Speed Limits (Min/Max)

Speed limits represent the operating range of the system being analyzed, usually defined by a minimum and
maximum rotational speed in revolutions per minute (RPM).

 Minimum speed (Min): The lowest operating speed at which the shaft or gearbox will rotate. This is typically
where the system starts operating.
 Maximum speed (Max): The highest speed that the system will reach during operation.

These speed limits are crucial in critical speed analysis because they help define the range of speeds over
which the analysis will be performed. You want to ensure that no critical speeds fall within this operating
range, as resonance at any speed within this range could cause failure or excessive vibration.

4. Number of Calculation Steps

The number of calculation steps refers to the resolution of the analysis in terms of how many discrete
speeds the software will calculate and check for critical speeds between the minimum and maximum speed
limits.

 For example, if you are analyzing a shaft between 0 and 10,000 RPM, and you choose 100 calculation steps,
the software will analyze at 100 points across this speed range (e.g., 0, 100, 200, 300... up to 10,000 RPM).
 A higher number of steps gives more detailed results but increases the computational time.

Choosing the right number of steps ensures a balance between precision and efficiency, making sure critical
speeds are accurately identified.

5. Number of Eigenfrequencies

Eigenfrequencies (also called natural frequencies) are the specific frequencies at which the shaft or
system tends to vibrate naturally. In dynamic analysis, the number of eigenfrequencies refers to how many
of these natural frequencies are considered in the analysis.

 A typical system may have several natural frequencies, especially for a long or complex shaft with multiple
gears or components attached.
 The software will calculate the number of specified eigenfrequencies within the speed range. For example, if
you specify 5 eigenfrequencies, the system will output the first five modes of vibration and their associated
frequencies.

These eigenfrequencies are important because resonance occurs when the shaft’s operating speed coincides
with one of these natural frequencies, causing large vibrations.
6. Number of Resonance Curves

Resonance curves represent the relationship between rotational speed and vibration amplitude at different
natural frequencies. The number of resonance curves indicates how many such curves will be plotted or
calculated to visualize where resonance might occur.

 Typically, each resonance curve corresponds to a different harmonic or excitation order (e.g., 1x,
2x, 3x of operating speed). For instance:
o 1x curve: This curve shows where the system might resonate at the first harmonic (operating speed
matches the natural frequency).
o 2x curve: The second harmonic (twice the operating speed matches the natural frequency).

 By specifying the number of resonance curves, you determine how many harmonic orders (multiples
of the operating speed) will be considered in the analysis.

Putting It All Together in KissSoft

In KissSoft, when you're performing a critical speed or dynamic analysis of a shaft, these parameters allow
you to fine-tune the analysis to ensure accurate results. Here's how each fits into the process:

1. Reference Shaft: The shaft you’re analyzing, with all its geometric, material, and support conditions.
2. Meshing Stiffness: Includes the effect of gear interaction on the shaft dynamics.
3. Speed Limits (Min/Max): Defines the operating speed range for analysis, ensuring you identify any
resonance within the practical working range.
4. Number of Calculation Steps: Determines how finely the speed range is divided, providing a detailed picture
of potential critical speeds.
5. Number of Eigenfrequencies: Specifies how many natural frequencies (vibration modes) the software should
calculate.
6. Number of Resonance Curves: Helps you track how the system’s resonance behavior varies across different
harmonics of the operating speed.