Vibration Measurement &testing Experiment: 432 Dynamics of Engineering Systems

LAB3 PATAMSETTI GANESH KUMAR
CONDITION MONITORING EXPERIMENT S296378
432 Dynamics of Engineering Systems
VIBRATION MEASUREMENT &TESTING

EXPERIMENT
Laboratory Report 3
Group Members (4th Group)

Ganesh kumar Patamsetti (296378)
Jahid Anwar Mollik (295715)
Preeth Patel (286016)
Submitted by: - Submitted to:-

Patamsetti Ganesh Kumar Dr. Stefanija Klaric
S296378
Date of Experiment Date of submission

25th - Apr-2018 08th-May-2018
COLLEGE OF ENGINEERING, IT & ENVIRONMENT

ASSESSMENT COVER SHEET
Student Name Patamsetti Ganesh Kumar
Student ID S296378
Assessment Title Multiple degree of freedom experiment
Unit Number and Title ENG432 -Dynamics of Engineering Systems

Lecturer/Tutor Dr. Stefanija Klaric
Date Submitted 08th -May-2018
Date Received
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Signed…….PATAMSETTI GANESH KUMAR……...Date……..-08th -May-2018……..…….

Contents
INTRODUCTION: ............................................................................................................................................ 4
OBJECTIVES: .................................................................................................................................................. 4
APPARATUS USED: ........................................................................................................................................ 4
EXPERIMENT SETUP: ..................................................................................................................................... 4
CONDITIONAL MONITORING BEARING1(SET2) ............................................................................................ 5
MATLAB CODE: ......................................................................................................................................... 5
PLOTS: ....................................................................................................................................................... 6
SAMPLE EXPLANATION: ............................................................................................................................ 7
CONDITIONAL MONITORING BEARING2(SET3): ........................................................................................... 9
MATLAB CODE: ......................................................................................................................................... 9
PLOTS: ..................................................................................................................................................... 10
DETERMINING THE FAULT OF THE BEARINGS: ........................................................................................... 11
DISCUSSION QUESTIONS:............................................................................................................................ 11
Monitoring principle for cooling facility ................................................................................................. 11
Describe one method of monitoring ...................................................................................................... 11
Image1 (Picture of thermal imaging gun taken during the lab visit) ...................................................... 12
Other methods used to monitor the bearing condition ......................................................................... 12
Purpose of having vibration isolators in the facility ............................................................................... 12
Image2(Picture of isolator (spring &damper) connected to the floor)................................................... 13
Image3(Picture of isolator with mechanical linkage connected to ceiling) ............................................ 13
Working of data acquisition system ....................................................................................................... 13
Conditions to valid for NFFT> number of samples ................................................................................. 13
Purpose of having higher value of NFFT ................................................................................................. 13
Purpose of collecting more samples ....................................................................................................... 14
Purpose of having short sample time ..................................................................................................... 14
Reasons for why it is difficult to find the inner race faults compared to outer race faults .................... 14
CONCLUSION............................................................................................................................................... 14
REFERENCES: ............................................................................................................................................... 15
INTRODUCTION:
The conditions of the machine-like temperature, vibrations should be observed continuously or
periodically to reduce the failures of machines. This monitoring helps in detecting the faults at a very
early stage and thereby providing us a chance to correct the faults as early as possible for the best
functioning of the machine. Humans can detect the faults by visual inspection and by the change of
sound that the machine normally produces. There is also a chance of the parts are enclosed, heavy and
big. This proves that the faults cannot be detected at starting stage by humans. Hence, we need a
system to monitor the functioning of the parts of machine at regular intervals. As most of the machines
are costly, utmost care should be taken in the form of preventive maintenance. This monitoring is
mainly useful for rotating objects like shafts, bearings, motors, pumps. Coming to this experiment, the
condition monitoring is done on the 2 different bearings to detect the faults each bearing has using
vibration analysis.
OBJECTIVES:
• Plot the accelerometer data in the time domain for each bearing
• Perform an order analysis on the accelerometer data for each bearing
• Plot the magnitude of the order analysis corresponding to bpfo and bpfi harmonics
• Find out the defects/faults in each bearing
• Answer the discussion questions
APPARATUS USED:
• PLC Controller and Monitor
• Accelerometer
• Tachometer (digital)
• UC 205 bearings with shaft
• Single phase induction motor
EXPERIMENT SETUP:
The single-phase induction motor is started which helps to rotate the shaft as well as the bearings. The
shaft speed is measured using the digital tachometer. An accelerometer is connected to the bearing
casing where the eddy current transducers carry the bearing acceleration data collected to the PLC
controller and the monitor. The sample was adjusted for 2 seconds at a sampling rate of 5000 per
second.
CONDITIONAL MONITORING BEARING1(SET2):

MATLAB CODE:
close all;
clear all;
clc
%% accelerometer data
load labdata1_1.txt
ShaftHz = 1478/60;
Fs = 5000;
%sampling frequency adjusted in PLC controller
plot(labdata1_1(:,1),labdata1_1(:,2))
%plotting accelerometer data(2nd column values) with samples(time 2 sec)
title('Time domain');
legend('Bearing1');
xlabel('Samples(2 sec)');
ylabel('Magnitude');
% Time is 10000 samples (5000 for 1 sec)
% Magnitude is 2nd column values of accelerometer data collected
%% bearing data
B1_bpfo =3.5853; %bpfo 1st harmonic value of UC205 bearing(from manual)
B1_bpfi =5.4147; %bpfi 1st harmonic value of UC205 bearing(from manual)
%
B1_bpfoH = B1_bpfo:B1_bpfo:100;
% limiting the value of bpfo harmonics till it reaches 100
B1_bpfoMag = 10*ones(size(B1_bpfoH));
%best describes the location of '*' and '+' in Y axis of magnitude vs order
graph
B1_bpfiH = B1_bpfi:B1_bpfi:100;
B1_bpfiMag = 10*ones(size(B1_bpfiH));
%% fft
L=length(labdata1_1(:,2))% length of sample
NFFT = 2^(nextpow2(length(labdata1_1(:,2))))
%length is 10000 and it should be greater than 2^x where x=14 gives 16384
BFFT = fft(labdata1_1(:,2),NFFT);
%Converting time to Fourier transform limiting to values of NFFT
f = Fs*(0:NFFT-1)/NFFT;
%sampling frequency multiplied from 0,1,2..... till NFFT and divided with
NFFT
B1_orders = f./ShaftHz(1);%converting frequency to order
figure
plot(B1_orders, abs(BFFT(:,1)),B1_bpfiH,B1_bpfiMag ,'*', B1_bpfoH,B1_bpfoMag
,'+');
%plotting order vs magnitude graph
%bpfo represented with "+";,and bpfi represented with "*";
title('Bearing1 Order Analysis');
legend('fft output','BPFI','BPFO');
xlabel('Order');
axis([0,30,0,50000]);%best magnified for close observance of defects
PLOTS:
SAMPLE EXPLANATION:
close all;
clear all;
clc
load labdata1_1.txt
**Load the text file created using the 2nd column values of accelerometer data
and 1st column replaced with the samples (1 to 10000)
ShaftHz = 1478/60;
**Determined shaft speed using tachometer while experiment (converting rpm to
Hz)
Fs = 5000;
%plotting accelerometer data (2nd column values) with samples (time 2 sec)
legend('Bearing1');
% Time is 10000 samples (5000 for 1 sec)
% Magnitude is 2nd column values of accelerometer data collected
%% bearing data
B1_bpfo =3.5853; %bpfo 1st harmonic value of UC205 bearing (from manual)
B1_bpfi =5.4147; %bpfi 1st harmonic value of UC205 bearing (from manual)
%
**The manual given for experiment was with 10 harmonics, so it is better to limit
the value of harmonics to 100. Lower the value lower the harmonics.
%best describes the location of '*' and '+' in Y axis of magnitude vs order graph
**magnitude values are in the range of 10^4 . Size of bpfoH is 27. This shows that
there are 27 harmonics and their positions on Y axis are at 10. If we increase the
value of 10 to 10000 we can observe that the ‘+’ and ‘*’ are moving upwards.
%% fft
NFFT = 2^(nextpow2(length(labdata1_1(:,2))))
**nextpow2 of Matlab implies that the length is 10000 and 2^13 gives only 8192
which is lower than the 10000 so the next power value to be taken is 2^14 which
is 16384.
%Converting time to Fourier transform limiting to values of NFFT
%sampling frequency multiplied from 0,1,2..... till NFFT and divided with NFFT
**frequency at every sample point is determined till the NFFT
B1_orders = f./ShaftHz(1);%converting frequency to order
figure
,'+');
xlabel('Order');
CONDITIONAL MONITORING BEARING2(SET3):

MATLAB CODE:
close all;
clear all;
clc
load labdata2_1.txt
ShaftHz = 1469/60;
Fs = 5000;
%plotting accelerometer data(2nd column values) with samples(time 2 sec)
legend('Bearing2');
% Time is 10000 samples(5000 for 1 sec)
% Magnitude is 2nd column values of data collected
%% bearing data
B1_bpfo =3.5853; %bpfo 1st harmonic value of UC205 bearing(from manual)
B1_bpfi =5.4147; %bpfi 1st harmonic value of UC205 bearing(from manual)
%best describes the location of '*' and '+' in Y axis of magnitude vs order
graph
%% fft
NFFT = 2^(nextpow2(length(labdata2_1(:,2))));
%Converting time to fourier transform limiting to values of NFFT
%sampling frequency multiplied from 0,1,2..... till NFFT and divided with
NFFT
B1_orders = f./ShaftHz(1);
%converting frequency to order
figure
,'+');
xlabel('Order');
PLOTS:
DETERMINING THE FAULT OF THE BEARINGS:

Close observing of the plots of order analysis, we can observe some peaks of magnitude on Y axis
coinciding with ‘+’ and ‘*’ signs of the order on X axis. These coinciding peaks constitute the faults at
their respective positions (inner or outer race) of bearings. The peaks are repeated with different
magnitudes at regular intervals as if they are harmonics which are multiplied by 2,3, 4... Limiting the
inner and outer race values to 100 helps to reduce the harmonics and gives a good chance for close
watching of the peaks.
For bearing 1, the major faults are at ball pass frequency outer race because the peaks are high when ‘+’
sign is on X axis. The inner race faults are less comparative to outer faults. The first harmonic at 3.5853
on X axis shows a peak and second peak can be observed at 2nd harmonic which is 7.1707.
For bearing 2, the major faults are at ball pass frequency outer race because the peaks are high when ‘+’
sign is on X axis. The inner race faults are less comparative to outer faults and can be observed at ‘*’
signs on X axis but are little high comparative to 1st bearing. The first harmonic of inner race faults is at
5.41 on X axis shows a peak and second peak can be observed at 2nd harmonic which is 10.82.
DISCUSSION QUESTIONS:
Monitoring principle for cooling facility
The monitoring principle used in the lab facility visited is based on the thermal analysis of the
components connected in the BMS (building management system) using various sensors. Measuring the
temperatures at operation of the components depending on the load and intensity and comparing them
with the desired manual temperatures. The temperature at the source is called the fault temperature
and the temperature difference between the two ideal and real temperatures is called temp diff. There
are 4 priority warnings given depending on the temp diff and the fault temperatures. There is also
temperature sensors (thermostats) located all over the chillers, inflow pipes, external pipes, motors,
tank and at every important point. These temperatures collected are cross checked with the manual
temperatures in the software and a warning is issued if the difference is altered more.
Describe one method of monitoring

One method of monitoring the temperature rise is by using the thermal imaging gun. Every machine
emits heat in the form of infrared energy. This infrared energy is captured by the lens attached to the
gun and it forwarded to the infrared sensor which forms an impulse. These impulses are processed and
collected as digital form to monitor on the screen depending on the intensity of IR denoted with
different colours to distinguish. These are mostly used on the bearings, contactors, switch board panels,
fuses, transformers to detect the faults.
Image1 (Picture of thermal imaging gun taken during the lab visit)
Other methods used to monitor the bearing condition

It is very difficult to find the faults of the bearings in the beginning stage of their usage. The faults are
mainly due to uneven wear caused by misalignment, poor lubrication or over lubrication, fatigue due to
continuous constant load application. The methods that can be used to detect the faults in bearings are-
Vibration analysis-using accelerometer studying the frequency and the time domain of the impulses.
Acoustic analysis-using stethoscopes and decibel meters to check the change in sound of bearing.
Temperature measurement analysis- Measuring the temperature using thermal imaging guns which
uses Infra-red thermography to record the temperature and comparing with the manual.
Wear debris analysis- Mostly by visual inspection and by using Vernier callipers.
Purpose of having vibration isolators in the facility

The vibration or shock isolators are located under the motors and the chillers to eliminate the excess
vibration created by the machines transmitting to the floor and the environment to maintain a certain
legal and acceptable terms. The chiller pipes (both inflow and return) that are located close to the top
floor are also provided with the isolators connecting to the ceiling of the floor. The vibration isolators
used in this lab facility are springs and the dampers mounted with mechanical linkages. These isolators
can be viewed in the images below.
Image2(Picture of isolator (spring &damper) connected to the floor)
Image3(Picture of isolator with mechanical linkage connected to ceiling)
Working of data acquisition system

The main components of data acquisition system are accelerometer sensors with eddy current
transducers, Data collection device, computer with vibration analysis software and monitor. As most
sensors are MEMS (micro electro mechanical sensors), the accelerometer is connected to the outer
casing of the bearing. When acceleration is applied on the device (means that the motor is started, and
the bearing is moving), a force is created which helps to move the piezo electric materials to generate an
electric pulse. This movement is directly proportional to the force acting on the piezo electric material.
These movements are recorded in vibration analysis software in the computer. The output is in the
form of volts and converted into digital signal to display it in the monitor.
Conditions to valid for NFFT> number of samples

Basically, NFFT is calculated based on the next power of 2 tools. The NFFT value should be exceeding the
2^k where k is an integer. For example, the sample rate for our experiment is 5000 and taking the
readings for 2 secs gave 10000 samples. Now, using the formula of next power of 2, 2^13=8192 which is
lesser than the samples. Using this value results in the non-usage of some values of sample (input).
Then using the next power of 2 gives 2^14=16384, gives us a better resolution and accuracy. The major
condition is the NFFT must be zero padded either in the beginning or at the ending if we use higher
value of NFFT.
Purpose of having higher value of NFFT

There is always a compromise between frequency resolution and temporal resolution (time resolution).
For a fixed sampling rate, if we change the frequency resolution the time resolution will change like vice-
versa. If the NFFT value is lower than the samples, the accuracy is lost because of omittance of some
values of the samples. The main purpose of having higher value of NFFT is to have a high frequency
resolution and with great accuracy. If we use the other tools other than next power of 2, it takes a lot of
time to collect the samples as the FFT bins should be run longer to get the short bins and the time it
takes for the computation using FFT.
Purpose of collecting more samples

The frequency resolution is the sample rate divided by the number of points. The more the sample
length the better is the accuracy of the plot. It is also helpful in determining the acceleration changes in
determining the faults of the bearings. Taking more samples by fixing the time and frequency increases
the frequency resolution gives a better plot to observe even the minute peaks in the plot.
Purpose of having short sample time

If we consider T as the sampling period, the sampling frequency will be 1/T which is equal to the number
of samples per second. So, for a fixed number of samples, the sampling frequency can be varied by
changing the sample time. Short sample time gives the higher sampling frequency which is much
desired for the accurate and precise plot.
Reasons for why it is difficult to find the inner race faults compared to outer
race faults
The defects in bearings are due to inner race fault, outer race fault, ball fault and the combination in the
attachment of all the 3. Reasons for the difficulty of finding the inner race faults are
• Sensing power of the accelerometer is more at the outer bearing as the accelerometer is placed
on the outer casing.
• The inner race bearing is far from the eddy current transducer which senses the acceleration of
the bearing.
• The transducer should pass the ball, oil film, casing before it reaches the inner race.
• The inner race faults are very difficult to find at a very early stage of wear or corrosion.
CONCLUSION:
The visit to the chiller lab facility helped to learn the real time scenarios and the emergencies in the
plant to be attended. Working of chillers, placement of different sensors, monitoring the sensors, using
of thermal imaging gun, fault detection of bearings using vibration analysis are well learned and
observed in this experiment. This experiment showed the importance of understanding the vibrations in
the machines helps us to reduce the cost of million dollars of equipment and work time. The functions of
MATLAB like nextpower2, NFFT, BFFT, size, ones are very learned by this experiment.
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LAB3 PATAMSETTI GANESH KUMAR

CONDITION MONITORING EXPERIMENT S296378

432 Dynamics of Engineering Systems

VIBRATION MEASUREMENT &TESTING

Group Members (4th Group)

Submitted by: - Submitted to:-

Date of Experiment Date of submission

COLLEGE OF ENGINEERING, IT & ENVIRONMENT

Student Name Patamsetti Ganesh Kumar

Assessment Title Multiple degree of freedom experiment

Unit Number and Title ENG432 -Dynamics of Engineering Systems

Date Submitted 08th -May-2018

Signed…….PATAMSETTI GANESH KUMAR……...Date……..-08th -May-2018……..…….

CONDITIONAL MONITORING BEARING1(SET2):

CONDITIONAL MONITORING BEARING2(SET3):

DETERMINING THE FAULT OF THE BEARINGS:

Describe one method of monitoring

Other methods used to monitor the bearing condition

Purpose of having vibration isolators in the facility

Image2(Picture of isolator (spring &damper) connected to the floor)

Image3(Picture of isolator with mechanical linkage connected to ceiling)

Working of data acquisition system

Conditions to valid for NFFT> number of samples

Purpose of having higher value of NFFT

Purpose of collecting more samples

Purpose of having short sample time

En.wikipedia.org. (2018). Condition monitoring. [online] Available at:

Au.mathworks.com. (2018). Exponent of next higher power of 2 - MATLAB nextpow2 - MathWorks

Sensorwiki.org. (2018). sensors:accelerometer · SensorWiki.org . [online] Available at:

Anon, (2018). [online] Available at: https://www.quora.com/How-does-the-sampling-rate-influence-the-

Azimadli.com. (2018). Bearing Tones. [online] Available at:

En.wikipedia.org. (2018). Sampling (signal processing). [online] Available at:

Ntnamericas.com. (2018). [online] Available at:

En.wikipedia.org. (2018). Vibration isolation. [online] Available at:

Fabreeka.com. (2018). [online] Available at: https://www.fabreeka.com/wp-

Thermoscan_13605 Charles Darwin University Casuarina Campus Thermoscan Inspection Report.pdf

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