THE

basics of setting up
a Vibration Test
SETUP, TESTING, AND COMPLETION

2022 EDITION

THE INNOVATOR IN

SOUND & VIBRATION

TECHNOLOGY
1 TO 5………PREPARING TO RUN A TEST
6 TO 7………SYSTEM SETUP AND RUNNING THE TEST
8…………………COMPLETING THE TEST
9…………………APPENDIX

EDITOR’S NOTE
The Basics of Setting Up A Vibration Test by Cherie Stoll, MA in Science Writing, was originally published in
2022 on VibrationResearch.com. The eBook is also located on VRU.VibrationResearch.com.
 Preparing to
run a test
SECTION 1

WHY AM I RUNNING THIS TEST?

Vibration affects many aspects of our lives, even if at first we do not recognize it. The vehicles we drive, the
roads we travel on, and the buildings we pass all experience vibration. Packages delivered to our doors,
satellites orbiting overhead, and cellphones in our pockets also feel a vibrational impact. While it may often go
unnoticed, engineers know that consistent shock or vibration can significantly impact the quality of items we
use every day.

From a production and manufacturing standpoint, the prevalence of vibration prompts several questions.
How does the item experience vibration, and how is it affected? Are the issues an immediate risk, or have they
built up over many years? How can I minimize vibrational damage or failure?

To determine where to begin, a test engineer will first determine why they are running a test. Does the
industry require it, or have they identified a failure during manufacturing? Often, the purpose of the test will
help drive the type performed. Common reasons include:

■ To meet a specification
■ To determine product resonance
■ Fatigue analysis
■ Production verification
■ Research and development

WHAT PRODUCT AM I TESTING?

The goal of vibration testing is to reproduce the service environment as close as possible. Therefore, the
product type will help guide you to a suitable test selection. For items exposed to transient events, an
engineer may select a short-term, high-acceleration shock test. Those that fatigue due to long-term random
vibration would call for a random test.

The most common way to determine the characteristics of a service environment is to record data while the
product is in use. Engineers can analyze the recordings to pinpoint areas of damage and fatigue. They can
also use them to develop a vibration test reflective of the service environment. If recording is not an option,
historical data often functions as the reference point.

The product type also helps determine the system setup. An oversized item might require many transducers
or multiple shakers. If an item is mounted at several points in the service environment, the test setup should
reflect such. Examining the product in its service environment can reveal details that will improve the quality
of your tests.

vrsupport@VibrationResearch.com THE BASICS OF SETTING UP A VIBRATION TEST 1

SECTION 1
preparing to run a test

WHAT TYPE OF TEST DO I WANT TO RUN?

The standard vibration test types are sine, random, and shock. For some test engineers, these three tests are
sufficient to meet the specifications necessary for their industry. Others apply more complex innovations to
develop highly customized test profiles. The route you choose will depend on necessity and experience.

STANDARD
SINE
A sine test outputs a single-frequency signal at a defined amplitude for a set duration. Engineers most
often use it to identify resonances or expose a device under test (DUT) to a known resonant frequency
until failure. Sine sweeps and sine resonance track and dwell (SRTD) fall under the category of a sine
test.

Select sine for:

■ Identifying resonances
■ Identifying issues with the shaker system (cracked armature, loose bolts, etc.)
■ Validating fixtures
■ Qualifying a product if product failure arises from the excitation of a known resonance

RANDOM
A random test excites all the frequencies in a defined spectrum for any given time. Exciting multiple
resonances helps engineers to determine the interaction between them.

Select random for:

■ Testing a product with a profile close to the operational environment
■ Determining a DUT’s response to the excitement of multiple resonances simultaneously
■ Testing a product to failure

SHOCK
A shock test tests a DUT’s capability to survive a drop, hit, impact, fall, explosion, or other sources of
potential transient vibration. Classical shock tests generate a reliable and understandable response for
product evaluation and durability testing.

Select classical shock for:

■ Fulfilling requirements from a test standard
■ Generating a unipolar shock pulse
■ Employing a pre-determined change in velocity

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 SECTION 1
preparing to run a test

MIXED-MODE
SINE-ON-RANDOM (SoR)
An SoR test profile includes sinusoidal vibration superimposed on a random background. The sine and
random vibrations are performed simultaneously to simulate an environment where both modes are
present. An SoR test should be selected instead of random when sine vibration affects the underlying
background random vibration.

RANDOM-ON-RANDOM (RoR)
An RoR test outputs a complex test profile with two types of random signals: narrow-band signals
superimposed on a random background. It reflects operational environments where the DUT is
subjected to a broadband random signal and one or more random tones. The random vibrations are
performed simultaneously.

SINE-ON-SINE (SoS)
SoS (also known as multi-sine) runs sine tones at different rates simultaneously. It saves time for
engineers performing fatigue testing and allows for the excitation of multiple resonant frequencies at
once.

SPECIALIZED
KURTOSION®
Random Testing: control the Root Mean Square (RMS) and kurtosis of a random waveform to bring
your test profile closer to the real world.

FATIGUE DAMAGE SPECTRUM (FDS)

Random Testing: create a random test profile that is the damage equivalent to weighted time history
files reflective of the operational environment.

INSTANT DEGREES OF FREEDOM® (iDOF)

Random Testing: run a highly accurate random vibration test in a condensed period, ensuring that the
product is tested for just the right amount of time.

SHOCK RESPONSE SPECTRUM (SRS)

Shock Testing: evaluate a DUT’s response to a complex transient event likely to occur in the
operational environment.

vrsupport@VibrationResearch.com THE BASICS OF SETTING UP A VIBRATION TEST 3

SECTION 1
preparing to run a test

WHAT SHAKER CAN I USE?

Shakers apply force to the DUT. Engineers use the equation Force = Mass x Acceleration (F=M*A) as the basis
for sizing shakers. All shakers have a force rating that determines what combination of mass and acceleration
they can achieve.

The more mass on a shaker, the less acceleration the shaker can produce. Conversely, less mass allows for
more acceleration. Remember to include all the moving masses on the system, including the weight of the
shaker’s armature, slip table, head expander, etc .

Shakers also have other limits for velocity, displacement, and drive voltage. Double-check your manual for the
correct ratings or contact the manufacturer for clarification. VibrationVIEW will warn you when a test profile is
beyond your shaker’s capabilities.

DO I NEED A SPECIAL MOUNTING FIXTURE?

Rarely is a DUT simple enough to mount directly to the shaker. Therefore, engineers often require a
specialized fixture to attach the DUT to the shaker tabletop and transmit the forces of the shaker.

A well-designed fixture should:

■ Mount the DUT in the correct orientation

■ Transmit the forces from the shaker to the DUT without resonance or interference
■ Allow the engineer to quickly test multiple samples
■ Have minimal mass so the shaker can function with minimal force
■ Perform many tests without sustaining damage
■ Be void of independent motion in any axis

Mounting fixtures can range from simple to highly customized depending on factors such as DUT size, test
severity, and mounting orientation(s). They can be developed in-house or outsourced.

HOW WILL THIS FIXTURE AFFECT MY TEST?

A good fixture design should prevent unwanted test occurrences such as over/under-testing. However, some
DUTs—particularly oversized ones—may require adjustments in the software to address issues with mounting.

For instance, the hard mounting of a DUT can result in large base reaction forces at its resonances. The
conformity of motion at the attachment point(s) is not present in the actual environment, and the mechanical
impendence of the shaker can result in over-testing. To prevent such, engineers may set an upper limit with
vibration force limiting.

WHAT OTHER EQUIPMENT DO I NEED?

There is other equipment necessary to run a vibration test in addition to the controller and shaker, including
suitable transducers to monitor and collect data.

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 SECTION 1
preparing to run a test

TRANSDUCERS
A transducer is an electronic piece of equipment that converts the signal carried in a particular form
of energy to another form of energy. The three most common transducers for vibration testing are
acceleration, velocity, and displacement sensors.

ACCELEROMETER
An accelerometer measures an item’s rate of change of velocity.
Advantages:
■ Effective at middle and high frequencies
■ Can provide velocity and displacement data using integration
■ Small and sturdy construction is functional in many environments
Disadvantages:
■ Adds mass to the system

DISPLACEMENT SENSOR
This sensor measures an item’s relative position and change in position.
Advantages:
■ Effective at low frequencies
Disadvantages:
■ Measures relative position, not absolute
■ Ineffective at high frequencies due to small displacement values

VELOCITY SENSOR
This sensor measures an item’s relative linear speed or angular speed.
Advantages:
■ Effective at middle frequencies
■ Laser sensors do not add mass to the system
Disadvantages:
■ Ineffective below 10Hz and above 2,000Hz

Your selection will depend on the response you require for control and analysis and the application
of your vibration test. Other transducers provide measurements such as force, temperature, humidity,
pressure, voltage, current, and strain.

AUXILIARY EQUIPMENT
The necessity of additional equipment will depend on what you want to test and the measurements
you seek. For example, a temperature or humidity chamber controls the environmental conditions for
stable readings. A secondary data acquisition device collects additional recordings for a more in-depth
analysis.

There is also auxiliary equipment that supports the function of the main equipment. For example,
a power amplifier outputs an amplified version of the signal from the controller. Transducers may
also require a voltage or current source, a low-noise cable, an input charge amplifier, or other special
conditioners.

vrsupport@VibrationResearch.com THE BASICS OF SETTING UP A VIBRATION TEST 5

system setup
SECTION 2
system setup & running the Test
& running
the test
SECTION 2

BEFORE STARTING A TEST

IS MY SYSTEM SET UP CORRECTLY?
CONNECTIONS
A vibration testing system has many components that must be set up correctly every time. Vibration
lab technicians must be attentive during this process to avoid significant/irreparable damage to the
device under test.

While all equipment is off, check your cable connections. If you want to change cables, make sure to
turn the amplifier gain down for safety. Cable checks should include:

■ Controller network cable connected to the control PC

■ Controller drive cable connected to the amplifier input
■ Amplifier cable safely connected to the shaker
■ Transducer cables connected to the correct controller inputs

All cables should also be properly routed for the duration of the test, including any downtime. For
example, will a lift truck ride over your drive cable on the weekend?

TRANSDUCERS
In addition to checking the transducers’ cable connections, you should also tape down/secure these
cables to avoid unwanted noise. The transducers should be in the appropriate orientation for your test
set-up.

After you check the cable connections and transducers, you can turn on and check your equipment,
including:

■ Computer
■ Controller
■ Table (all objects securely affixed)
■ Amplifier (gain down)

Any connected auxiliary equipment should also be powered on and ready for testing at this time.

6 THE BASICS OF SETTING UP A VIBRATION TEST VibrationResearch.com

 PARAMETERS
After an equipment check, you should verify the parameters of your test setup. First, ensure that you
are connected to the correct hardware unit. Then, in the test software, you can:

■ Verify the shaker limits

■ Verify the input sensitivities
■ Enter the mass of the device under test
■ Verify that the system can run the test specifications
■ Verify that the safety (drive) limits are appropriate for the test
■ Check the channel aborts

Safety note: You should never bypass interlocks/safety locks.

Only after all the connections and parameters are verified should you turn on the amplifier gain. Never
change the amplifier gain while a test is running.

It is a good practice to note the pre-test conditions and log all preliminary data at this stage.

SYSTEM CHECK
A helpful feature of VibrationVIEW is the System Check test mode. It is an automated feature that
verifies the functionality of the accelerometer, amplifier, shaker, and control system. We recommend
you perform this function before performing any new testing operation.

CREATE AND OPEN A TEST PROFILE

A test profile consists of several parameters that define the controller’s output signal, including test
levels and schedule. Standards will usually provide the configuration, which will vary depending on
the test type. Often, vibration test software will display default parameter values that are helpful as a
starting point.

LIMITS AND TOLERANCES

A profile also includes additional limits and tolerances that correspond with the specific test.
Tolerances, aborts, and maximum outliers should provide reasonable certainty that the test can run.
Determine what constitutes a failure, then adjust the profile limits if necessary.

If you or another engineer in the building ran the test previously, you should also review any notes,
special requirements, or observations from previous tests.

START THE TEST

After you start the test, save a data file. You can use this information to compare changes from the
start of the test to completion. Additionally, observe the responses as the test runs and determine if
the profile requires any changes.

vrsupport@VibrationResearch.com THE BASICS OF SETTING UP A VIBRATION TEST 7

completing
a test
SECTION 3

PASS/FAIL
After the test is complete, you will need to determine if the test passed or failed. The pass/fail criterion is
pre-determined, but failure usually involves fatigue or damage to the DUT. Either way, you should note all
observations and responses of interest. Recording any changes or special notes for future testing will also
be helpful. Further investigation may also be beneficial if the test results were unexpected. Where did the
discrepancy occur?

POST-PROCESS AND DATA ANALYSIS

Some vibration data necessitates further analysis after testing. Evaluating recorded data can help
explain the results of a vibration test. It can answer questions such as:
■ At what frequency did the DUT fail?
■ How does the test compare to the standard?
■ What were the acceleration levels at a particular time/frequency?
■ What displacement level does the shaker need to run the test profile?

Vibration data are collected in the time domain. However, it is often advantageous to transform the
data into another domain to view different vibration patterns. In engineering, the frequency domain is
common for analysis.

FFT AND PSD

Fast Fourier transform (FFT) and power spectral density (PSD) mathematics are powerful tools for
analyzing the characteristics of a waveform. Engineers can also perform resampling or filtering on a
waveform.
■ Resampling: changes the sample rate to user specifications on a time waveform.
■ Filtering: removes frequency components from a time waveform.

Additionally, the engineer may adjust the data to display the information needed for a report. This may
include a simple graph adjustment to labels or a waveform edit such as cut, crop, or copy.

GENERATE A REPORT
Reports provide a test overview that a standard, customer request, or lab policy may require. Often, the
software program will include some reporting feature. With VibrationVIEW’s custom reports, you can
customize the report parameters to include details such as data vectors, graphs, screen images, test
notes, and company branding.

REPEAT THE TEST

Similar to any scientific process, you should repeat the test to confirm the validity of the results. The
number of times you perform a test will depend on the level of confidence you seek.

8 THE BASICS OF SETTING UP A VIBRATION TEST VibrationResearch.com

SOURCES
SECTION 1: PREPARING TO RUN A TEST
De Barros, Everaldo and Carlos d’Andrade Souto. “Evaluation of a Vibration Test Fixture.” International Journal
of Acoustics and Vibration 22, no. 3 (2017). https://doi.org/10.20855/ijav.2017.22.3480.

Reddy, T. Srinivas and K. Vijaya Kumar Reddy. “Design and analysis of vibration test bed fixtures for space
launch vehicles.” Indian Journal of Science and Technology 3, no. 5 (2010): 592-595.

GLOSSARY
DEVICE UNDER TEST | DUT RANDOM ON RANDOM | ROR
Manufactured product that is undergoing Mixed-mode test that runs a profile with
testing. random background vibration and random
narrow-band signals.

FAST FOURIER TRANSFORM FFT SHOCK

Computational algorithm that efficiently Test that runs a pulse to test a system’s
transforms time-domain data into the capability to survive transient vibration.
frequency domain.

FATIGUE DAMAGE SPECTRUM | FDS SHOCK RESPONSE SPECTRUM | SRS

Test development tool that replicates the Test development that evaluates a DUT’s
operational environment of a product. response to a complex transient event.

INSTANT DEGREES OF FREEDOM® | iDOF SINE

Patented random vibration test type that runs Test that outputs a single frequency sine tone
accurate vibration tests in a condensed period. at a defined amplitude and time.

KURTOSION® SINE ON RANDOM | SOR

Patented random vibration test type that Run mixed-mode tests with sine tones
controls the RMS and kurtosis of the waveform. superimposed on a random background.

POWER SPECTRAL DENSITY | PSD SINE ON SINE | SOS

Random test tool that represents the Mixed-mode test that runs multiple sine tones
distribution of a signal over a defined at different rates simultaneously.
frequency spectrum.

RANDOM SINE RESONANCE TRACK AND DWELL | SRTD

Test that excites all frequencies in a defined Sine test type that brings a product to failure
spectrum for any given time. by exciting a known resonance.

vrsupport@VibrationResearch.com THE BASICS OF SETTING UP A VIBRATION TEST 9

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