TORQUE AND TORSIONAL

VIBRATION MEASUREMENTS

Torsional vibration causes oscillatory angular stresses which add to normal rotational motion resulting in
drive shaft torsion. Torsional vibration can produce:
¾ High gear noise
¾ Faster wearing of gears
¾ Gear failure
¾ Coupling damage
¾ Deformation of keys
¾ Slippage of coupling hubs
¾ Accelerated wear of electric motor
windings
¾ Shaft fatigue failure at 45°
¾ Power surges
High torsional vibration can therefore have
disastrous effects, causing damage to
equipment, endangering plant personnel and
negatively impacting production.
Unfortunately, this vibration may go unnoticed when installing a machine and be stable in normal
operating conditions excepting transient conditions and on change of harmonic.
In the latter conditions the standard measurement systems used for analysing lateral vibration, such as
accelerometers and proximity probes, are not able to make this diagnosis which can only be done with a
full-bridge strain gage system. Such a system makes it possible to establish the modes of torsional
vibration peculiar to the machine concerned. This latter aspect is of interest especially when it is
necessary to determine the gap between the natural torsional frequency and the harmonics of the
systems (linked with the operating conditions in which the system is running).
An analysis of these components may therefore prevent degenerative phenomena from arising by
gauging possible resonances and eliminating them. Generally, it is possible to:
¾ Calculate overload phenomena
¾ Isolate the causes of frequent faults and consequently cut mainte-
nance costs to the minimum
¾ Colve lower-than-expected performance issues
¾ Determine the distribution of loads
¾ Check the specified performance of the machine
¾ Consider and validate new prototypes
SINT Technology has developed an integrated telemetric acquisition
system for measuring torque and torsional vibration. The specially
developed software makes it possible to carry out time and spectrum
analyses, as well as three-dimensional waterfall processing versus time
and velocity.
The fact the system is quick to install (can be
adapted to any size of shaft) and the accuracy of
signal transmission and reprocessing
(guaranteed by a wide range of amplifications
which can be set by hardware to handle small
signals) make it highly adaptable to all
requirements. Acquisition of signals in time
followed by reprocessing in frequency enables
not only analysis of steady state conditions but
also assessment of transient phenomena which
make it possible to highlight the natural torsional
frequencies of the system and therefore any
resonance phenomena.
Analysis of stationary phenomena
Analysis of stationary phenomena is essential for gauging the normal operating conditions of mechanical
drive. Particularly, it is possible to determine the harmonic components of a system and related
amplitudes, alternating torque and average torque which can be used to calculate machine output.
7000
Armonics Acquired
1xREV 16.8457
10000 6000 2xREV 32.95898
3xREV 49.80469
4xREV 66.65039
5000 5000 5xREV 82.76367
6xREV 99.60938
7xREV 116.4551
4000 8xREV 133.3008

Torque [Nm]
0
9xREV Not found
10xREV 166.2598
Torque [Nm]

3000
11xREV 183.1055
-5000 12xREV 199.2188
13xREV Not found
14xREV 232.9102
2000
15xREV Not found
-10000
16xREV 265.8691
1000

-15000

0
'T 1x 20 2x
0 40 3x 60 4x 80 5x 100 120 140
-20000 Frequency [Hz]
3 3.05 3.1 3.15 3.2 3.25 3.3 3.35 3.4
Time [sec]

Analysis of static operating conditions is also fundamental for analysing transients and considering
corrective action to eliminate resonance phenomena.

Analysis of transient phenomena

An analysis of transient phenomena is carried out whenever machine operating conditions change, for
instance startups, shutdowns, changes in load and operating conditions.
Signals acquired in time are then processed
120
by a FFT and analysed with three-
100
dimensional charts.

80
Torque [KNm]

60

40

20
4

0 3
0 1 2 3 4 5 6 7 8 9 10 11
1 2
-20
time [s]

The change in speed of a system enables

harmonics to excite the natural frequencies
detecting any critical operating conditions.
By crossing the spectra with velocity it is possible to accurately establish a system’s natural frequencies
and identify any resonances, also shown up by analysis of harmonic components in static conditions.
Finally, analysis of alternating components during transients is fundamental for defining any resonance
phenomena which are critical for a machine and hard to analyse being present only for short periods of
time.

Characterization of mechanical systems

Drawing from years of experience in analysis and programming, SINT Technology has developed an
integrated software package for acquisition and reprocessing of real-time signals (Fast Data Logger and
Speed Time Waterfall).
This system is particulary effective in torque
analysis as it enables the highest signal quality in
the acquisition stage while allowing full
characterization of the mechanical system under
examination in reprocessing.

The three-dimensional waterfall

analysis, in time or speed,
pinpoints a system’s harmonics,
natural frequencies and resonan-
ce phenomena, automatically
calculating the damping factor.

Examples of services by SINT Technology

In addition to a telemetric system for signal transmission, a torsional analysis therefore requires a bridge
arrangement of four strain gages fitted at 45°. Such a configuration particularly compensates for any
flexural effects and temperature variations. The acquired signal is proportional to the strains, from which
the shear stress and torque are calculated.
In fact, when at rest the four strain gages have the same dimensions
as the grid (length/width) and consequently the same electrical
resistance. Under stress they are deformed modifying their geometrical
characteristics and electrical resistance.

The change in electrical

resistance is proportional
to the torque applied on
the shaft and can be
accurately measured with
a Wheatstone bridge
circuit.
Case I – Measurement of torsional vibration on two extension shafts in a metal works
TAF is the torque amplification factor and is the ratio between break-away torque and torque in steady state
conditions. It is used to judge design improvements to the extension shafts of a rolling mill.

The objective was to determine whether the new hollow ex-

tension design was better than its solid predecessor. The data acquisition campaign conducted by SINT
Technology therefore analysed the transient phenomenon, considering the system’s response to stress
produced by different types of flat blooms, verifying a real improvement.

Case II – Measurement of torque on a gas turbine starter motor

Validation of a starter motor comes under this class of MB
applications. In the specific case SINT Technology was
asked to check the output and torque delivered by a starter
motor, with a control system based on the torque
calculated on the basis of the motor’s electrical input.
The electric motor 1100

calculations matched the 900

1 6
measured values meaning
that the motors could be 700
2
3
4 3 5 1)
2)
Generator
Starting Motor
used in the customer’s
T o rq u e [N m ]

500 1100 9000.00

3) Coupling
4) Speacer with torquemeter
applications. 900
8000.00

7000.00
5) Gear Box
300

700
6000.00 6) Turbine

Revolution Speed [rpm]

5000.00
Torque [Nm]

100 500 4000.00

Torque
Torque
Shaft Speed
Turbine Speed

3000.00

10 1010 2010 3010 4010 5010 6010 7010 300

2000.00
-100
Revolution Speede [rpm] 1000.00
100

0.00

0 100 200 300 400 500 600 700 800 900 1000
-100 -1000.00
Time [sec]

Case III – Measurement of torsional vibrations on a reciprocating compressor

10000
The main causes of failures in couplings between an electric
2
1 3
motor and compressor are resonance phenomena. In many
5000
circumstances, however, such phenomena cannot be directly
identified as the system’s natural frequency does not coincide
0
with a harmonic and may be found only during transients.
Torque [Nm]

With SINT Technology’s software for torsional analysis such

-5000 phenomena can be calculated extremely accurately, enabling
manufacturers to establish the causes and consequently the
-10000 best solution at the onset of faults.
Collaboration between SINT Technology and manufacturers
-15000
0 0.4 0.8 1.2 1.6 2 2.4 2.8 3.2 3.6 4 4.4 4.8 5.2
is always an important step for diagnostics making it possible
Time [sec]
to achieve the best results, as in the case outlined above.
SINT Technology’s torque analysis services comprise:
¾ Measurement of torsional vibration on rolling mill extension shafts
¾ Measurement of torque on gas turbine starter motors
¾ Measurement of torsional vibration on reciprocating compressors
¾ Measurement of torque on centrifugal pumps and centrifugal compressors

Via Giusti 229 - 50041 Calenzano (FI)

tel +39 055 8826302 fax +39 055 8826303
e-mail: info@sintechnology.com
www.sintechnology.com