enn Nr ae ae eae Diagnosing Machine Faultssesiope eo Symptoms: High near 0 Hz, decaying down across the spectrum Ski slope (bad measurement or very high frequency /amplitude) 9 10 Orders If you see that the spectrum begins at a high level at the low frequency end of the graph, and slowly decays across the graph, then there has either been or the sensor experienced a shock/transient during the measurement process. The transient ma sensor was bumped, or very high vibration), sensor was placed on a very hot or called su electrical. thermal (the rface), or The spectrum will have a ski-slope and a raised noise-floor at the high frequency end of the spectrum if the transducer becomes "saturated". This typically occurs when there is a source of high vibration at high frequency. PageD-3 Copyright © 2016 Mobius Institute a problem with the sensor, 'y be mechanical (the No Unauthorized Copies May Be Made. 9 3 i o a 3° 2 3 9 = 3 a Raised Noise Floor Symptoms: Bottom of spectrum raised ~ If the entire noise floor is raised, it is possible that you have extreme bearing wear: Bearings: Stage six ncies HFD/Shock IgSE/PeakVue If the noise is biased toward the higher frequencies, then you may have process or flow noise, with cavitation possible: Cavitation 40 Orders Page D- 4 Copyright © 2016 Mobius Institute No Unauthorized Copies May Be MadeSmaller "humps" may be due to resonances, or closely spaced sidebands. A high resolution measurement (or graphical zoom and a log scale) may reveal whether the Source is sidebands or @ resonance. If you can change machine speed, the resonant frequency will not move - but the other peaks will. Sidebands will typically be symmetrical around a dominant peak, for example 1X, 2X, 100/120 Hz, etc. Resonance (at 1X) 70 ee Orders eae No Unauthorized Copies May Be Mace 1 Copyright © 2016 Mobius Institute Raised Noise Floor8 e 2 3S a — A 4 & s ec 5 a Dynamic Imbalance Symptoms: 1X radial (V & H) Levels highest in horizontal axis (due to greatest flexibility). 0-180° phase difference across machine. 90° +40° between vertical and horizontal. Imbalance (dynamic) 0. 1X 90°430° between vertical and horizontal The technical way to describe unbalance is as a condition where "a shaft's geometric centerline and mass centerline do not coincide", or where "the center of mass does not lie on the axis of rotation". In other words, there is a heavy spot somewhere along the shaft. Dynamic imbalance-is a combination of static and couple imbalance. 1X RPM will dominate, but will be highest in the direction the machine can move most freely - typically in the horizontal axis. The phase difference from one end of the machine to the other could range between O and 180° out of phase. There will be 90° +40° between vertical and horizontal readings. The difference between vertical and horizontal readings taken from each bearing should be approximately equal. Page D- 6 Copyright ¢ 2016 Mebus Institute No Unauthorized Copies May Be MadeImbalance Sta toms: 1X radial (V & H) eee In phase across machine - 90° +30° between vertical and horizontal. Imbalance (static) If a machine were out of balance we would expect to see a sinusoidal time waveform, with a frequency of the running speed, and a large peak in the spectrum at the running speed (1X). The simplest type of imbalance is equivalent to a heavy’ spot at a single point in the rotor. This is called a static imbalance because it will show up even if the rotor is not turning - if placed in frictionless bearings the rotor will turn so the heavy spot is at the lowest position. Static imbalance results in 1X forces on both bearings of the rotor, and the forces on both bearings are always in the same direction. The vibration signals taken at each end of the machine (in the same direction) are in-phase. There will be 90° +30° between readings taken in the vertical and horizontal directions. Page D-7 a 25 94 43 13 33 ae} NA 2B = sat Copyright © 2016 Mobius Institute No Unauthorized Copies May Be Made Static Imbalance2 Q C & 3S a I 4 is a 3 2 9 Couple Imbalance Symptoms: 1X radial (V & H) : " Out of phase across machine. 90° 30° between vertical and horizontal. 90°+30° between vertical and horizontal If a machine were out of balance we would expect to see a sinusoidal time waveform, with a frequency of the running speed, and a large peak in the spectrum at the running speed (1X). A rotor with couple imbalance may be statically balanced (it may seem to be perfectly balanced if placed in frictionless bearings). But when rotated, it will produce centrifugal forces on the bearings. The vibration signals taken at each end of the machine (in the same direction) are 180° out-of-phase. There will be 90° 30° between readings taken in the vertical and horizontal directions. Copyright © 2016 Mobius Institute Page D-8 No Unauthorized Copies May Be Made een i ONE Z a) ) Ty) a “Cbddad Wewdddy Sb bb wb ow wd us Imbalance: Overhung Machines Symptoms: High 1X axial, 1X radial (V & H) Axial phase readings in-phase. z 2 3 3 3 3 | 2 10 Orders In an overhung or cantilevered machine, you will see a high 1X vibration level in the axial direction, as well as the vertical and horizontal. Measurements in the axial direction will be in- phase. The difference between vertical and horizontal readings taken from each bearing should be approximately equal. We see the high 1X in axial because the imbalance creates a bending moment on the shaft, causing the bearing housing to move axially. Examples of overhung rotors are close-coupled pumps, axial flow fans, and small turbines. PageD-9 Copyright © 2016 Mobius Institute No Unauthorized Copies May Be Made ry Q = = o 6 = o| ie 3 £ o > ° 3 c & 3s a Ee 47 Imbalance: Vertical Machines Symptoms: 1X radial (horizontal) ; ‘ Phase readings similar in same direction at different points on machine. Imbalance (Vertical) Orders The spectrum again will show a strong 1X peak when measured in the radial direction (horizontal or tangential). To isolate motor imbalance from pump imbalance, it may be necessary to break the coupling and run the motor solo while measuring 1X. If the 1X level is still high, the problem is the motor; otherwise it is the pump. Imbalance: Vertical Machines Copynght © 2016 Mobius Institute DDC No Unauthorized Copies May Be Madeaf aa Wy Ibo bb MMe y Eccentric Rotor or Gear Symptoms: 1X radial (V and H) Eccentricity 1X Fan 1X Motor 3 Orders Eccentricity occurs when the center of rotation is offset from the geometric centerline of a gear, bearing, or rotor. Eccentric rotors/gears will generate strong 1X radial components, especially in the direction parallel to the rotor/ gear. This condition is very common, and mimics imbalance. s: Eccentricity & backlash Eccentric Rotor or Gear P Page D- 11 Copyright € 2016 Mobius Institute No Unauthorized Copies May Be MadeEccentric Sheaves Eccentric Sheaves Symptoms: 1X radial (V and H) Levels highest in direction of greatest belt tension. Phase between vertical and horizontal axis could be 0° or 180° Eccentricity '1X Fan 1X Motor 3 Orders Eccentricity occurs when the center of rotation is offset from the geometric centerline of a sheave (pulley). Eccentric sheaves will generate strong 1X radial components, especially in the direction parallel to the belts. This condition is very common, and mimics imbalance. In belt driven machines, there will be a high 1X vibration level on both components (motor and fan for example), however due to the change in speed, these will be at two different frequencies. Eccentricity in belt driven machines can be checked by removing the belt(s) and checking again for the 1X peak on the motor. Phase readings between the vertical and horizontal axis could either be in-phase or 180° out of phase. Page D-12 Copyright © 2016 Mobius Institute No Unauthorized Copies May Be MadeMisalignment Frequency: 1X and 2X (and 3X and 4x...) Axial and radial (V & H) Severe Misalignment 3 3 iS s % 2 In short, misalignment is a condition where the centerlines of coupled shafts do not coincide. If the misaligned shaft centerlines are parallel but not coincident, then the misalignment is said to be parallel (or offset) misalignment. If the misaligned shafts meet at a point but are not parallel, 3 then the misalignment is called angular misalignment. = Most misalignment cases are a combination of parallel and angular misalignment. Diagnosis, as a general rule, is based = upon dominant vibration at twice the rotational rate (2X) with increased rotational rate (1X) levels acting in the axial and in 33 _ either the vertical or horizontal directions. 2 Phase relationships are very important as described below. a E | a Page D - 13 ls Copynght @ 2016 Mobius Institute (No Unauthorized Copies May Be Made a2 ie @ — c | 3 Pal = . = 3 5 iS < Angular Misalignment Symptoms: High axial vibration: 1X strong but 2X and 3X can also be strong : 2 180° across coupling in axial direction Angular Misalignment De 1x If the misaligned shafts meet at a point but are not parallel, then the misalignment is called angular misalignment. Angular misalignment produces a bending moment on each shaft, and this generates a strong vibration at 1X and some vibration at 2X and even 3X in the axial direction at both bearings. There will also be fairly strong radial (vertical and horizontal) 1X and 2X levels, however these components will be in phase. The vibration is 180° degrees out of phase across the coupling in the axial direction, and in-phase in the radial direction. wyrght ¢ 2016 Mobius Institute Page D-14 5 ,Parallel Misalignment : Symptoms: 2X radial, smaller 1X radial (V & H) 180° across coupling in radial direction Parallel Misalignment 2x 10 Orders If the misaligned shaft centerlines are parallel but not coincident, then the misalignment is said to be parallel (or offset) misalignment. Parallel misalignment produces both a shear force and bending moment on the coupled end of each shaft. High vibration levels at 2X as well as 1X are produced in the radial (vertical and horizontal) directions on the bearings on each side of the coupling. Most often the 2X component will be higher than 1X. Depending upon the coupling type, there can be 3X, 4X all the way up to 8X peaks, particularly when misalignment is severe. In this case, the noise floor is not raised (unlike rotating looseness) and the harmonics do not continue to higher frequencies (as they do with rotating looseness). Axial 1X and 2X levels will be low for pure parallel misalignment. The vibration is 180° degrees out of phase across the coupling in the radial and axial directions. Parallel Misalignment Page D - 15 Copyright © 2016 Mobius Institute No Unauthorized Copies May Be MadeJ - |Bent Shaft : Symptoms: 1X axial Close to 180° phase difference between bearings Bent Shaft 8 z Orders A bent shaft predominantly causes high 1X axial vibration. The dominant vibration is normally at 1X if the bend is near the center of the shaft, however you will see 2X vibration if the bend is closer to the coupling. Vertical and horizontal axis measurements will also often reveal peaks at 1X and 2X, however the key is the axial measurement. Phase is also a good test used to diagnose a bent shaft. The phase at 1X measured in the axial directions at opposite ends of the component will be 180° degrees out of phase. Bent Shaft Page D- 16 Copyright © 2016 Mobius Institute No Unauthorized Copies May Be MadeGZAkLKChAK AY Cocked Bearing Symptoms: 1X, 2X, and 3X axial 180° phase difference on either side of the shaft Cocked bearing ax 2X 9 10 Orders A cocked bearing, which is a form of misalignment, will generate considerable axial vibration. Peaks will often be seen at 1X, 2X, as well as 3X. Given that there is such a strong axial vibration, it too can be confused with misalignment, and with imbalance in an overhung pump or fan. The presence of peaks at 2X and 3X would indicate a cocked bearing condition over imbalance however. Due to the twisting motion, there will be 180° phase difference on either side of the shaft on the bearing (i.e. between measurements taken above and below the shaft or left and right of the shaft). Cocked Bearing Page D-17 Copyright © 2016 Mobius Institute No Unauthorized Copies May Be MadeLooseness : 1X harmonics Structur 1X horizontal : 1X, 2X, and 3X vertical Pedestal beari oseness is caused by excessive clearance between he machine such as in a Symptoms: Rotating lo rotating and stationary elements of tl bearing, while non-rotating looseness is a looseness between jonary parts, such as a foot and a foundation, two normally stati or a bearing housing and a machine. etween a machine and its Structural looseness, or looseness b ent in the foundation, will increase the 1X vibration compon direction of least stiffness. This is usually the horizontal direction, but it depends on the physical layout of the machine. Page D- 18 No Unauthorized Copies May Be Made Copyright © 2016 Mobius Institute PeMEMe tT? tm mmmRotating Looseness Symptoms: 1X harmonics radial (0.5X harmonics when severe) Looseness: Rotating 1x 2x Hee aeaAeCK BK ee ih “& Excessive clearance in journal (sleeve) and rolling element bearings (bearing looseness) will produce harmonics of 1X that can extend, in some cases, above 10X. Excessive journal bearing clearance can produce harmonics of 0.5X as shown below. They are called half order components or sub harmonics. They can be produced by rubs and severe impacting. Even 1/3 order harmonics are possible. bw ww a 3 € 6 3 3 8 4 | & = 8 3 2 Page D- 49 5 unauthorized Copies May Be Made Copyright © 2016 Mobius InstituteStructural Looseness Symptoms: Structural: 1X horizontal Looseness: Structural Orders Looseness between a machine and its foundation will increase the 1X vibration component in the direction of least stiffness. This is usually the horizontal direction, but it depends on the physical layout of the machine. Low-order 1X harmonics are also commonly produced if the looseness is severe. It is often hard to tell imbalance from foundation looseness or flexibility, especially in vertical machines. If 1X horizontal is much greater than 1X vertical, looseness is suspected. If 1X horizontal is lower than or equal to 1X vertical, then imbalance is suspected. Foundation flexibility or looseness can be caused by loose bolts, corrosion, or cracking of mounting hardware. Note: If a machine has resilient mounts, then the vibration will always be greater in the horizontal axis. Phase can be used to verify this condition. There will be a 180° degrees phase difference between the machine and the base in the vertical direction. \ Copyright @ 2016 Mobius tnstitute a G20 No Unauthorized Copies May Be Made y WD HR mm Mm WW 2 fm ‘a ‘Je UE WE ww)ed ee ee ere Pedestal Bear ng Looseness Symptoms: 1X, 2x, and 3X radial Looseness: Pillow block The spectrum will have components at 1X, 2X and 3X (but often no more harmonics), with a 0.5X peak in more severe cases. Phase can again be used to verify this condition. There will be a 180 degrees phase difference between'the bearing and the base. 4 Page D- 21 Copynght © 2016 Mobius Institute ag No Unauthorized Copies May Be Made a uv g § a ° ° 4 | £ = s o a S gs a a 3 Q oO! Rotor Rub 1X harmonics radial (0.5X harmonics when Symptoms: severe) A rub will show similar characteristics to rotating looseness. You will see harmonics of 1X, and often half-order harmonics. Often one or more resonances will be excited by the rub. Rotor Rub Copynght © 2016 Mobius Institute Page ae tt No Unauthorized Copies May Be MadeA A ZA A A Journal Bearing Clearance : Symptoms: 1X harmonics Journal bearing wear When there are clearance problems in sleeve (journal) bearings, the spectrum will show very similar characteristics to rotating looseness. There will be strong harmonics of shaft speed. In most cases, the vertical axis of vibration will have higher levels than horizontal. In more severe cases, half-order and even one-third order harmonics will be present in the spectrum. Journal Bearing Clearance Page D - 23 Copyright © 2016 Mobius Institute No Unauthorized Copies May Be Made3] Symptoms: 0.38-0.48X in radial Journal bearing oil whirl ia lie laa Tf Oil Whirl is a condition in which a strong vibration occurs at between 0.38X and 0.48X. It never shows up at precisely 0.5X, but is always a little lower in frequency. It is caused by excessive clearance and light radial loading, which results in the oil film building up and forcing the journal to migrate around in the bearing at less than one-half RPM. No Unauthorized Copies May Be Made oe eae le leResonance Symptoms: "Hump" in spectrum typically in one direction only Resonance (at 1X) Resonance is an operating condition where an excitation frequency is near a natural frequency of the machine structure. A natural frequency is a frequency at which a structure will vibrate if deflected and then let go. There will typically be a high amplitude peak sitting on a “hump" in the spectrum in only one axis. Or example, the pump vane rate peak at 6X may be elevated in the horizontal direction only. If you increase (or reduce) the frequency so that the resonance is not longer excited, the amplitude will drop significantly. Resonance Page D - 25 x Copyright © 2016 Mobius Institute No Unauthorized Copies May Be Madeg Element Bearing Wear olling Element Bearing Wear Symptoms: Peak (with harmonics) at non-synchronous frequencies a Faults associated with rolling element bearings follow a classic oH pattern, beginning with a high frequency "ringing" of the bearing. Tools such as HFD, Spike Energy, SEE and others detect the bearing at this stage. Demodulation (envelope detection) and "Peakvue" can also be used to detect bearing faults. Bearings: Stage one Natural frequencies HFD/Shock IgSE/PeakVue As the fault progresses the spectrum will change in characteristic ways. There will be peaks at non-synchronous frequencies (e.g. 3.9X, 6.45X, et.), typically with harmonics, and often with sidebands of running speed (1X) or the cage frequency. Bearings: Stage two Natural frequencies HFD/Shock IgSE/PeakVue Copyright © 2016 Mobius Institute pepo Rize) No Unauthorized Copies May Be MadeBearings: Stage three I I Fault jrequencias Natural frequencies HFD/Shook 1g8E/PeakVue Bearings: Stage four { | al Fault irequencies Natural frequencies HFD/Shock Ig3E/PeakVue Searings: Stage five TE Natural frequencies HFD/Shock IgSE/PeakVue Bearings: Stage six Cola ae Element Bearing Wear HED/Shock 19SE/PeakVue Page D - 27 sav Ca¥ pol G Mobius Institute a No Unauthorized Copies May Be MadeThere are four forcing frequencies of interest: ball pass inner race (BPI), ball pass outer race (BPO), fundamental train (also called the cage rate) (FT), and ball spin (BS). Given the following information: Ball diameter (d) Pitch diameter (D) Number of balls (n () Contact angle (a) The forcing frequencies can be calculated as follows: Defect on Inner Race (BPI) = 3 n (1 + a cos a ) Defect on Outer Race (BPO) = + n (1 - ¢ cos a ) Defect on Cage (FT) = ; 1- £ cos a) Defect on Ball (BS) = oe [1 -(¢ Jcos*a] Where: d = Ball Diameter D = Pitch Diameter n = Number of Balls A= Contact Angle Alternatively, the following rule of thumb may be used: BPI = 0.6 x # balls/rollers BPO = 0.4 x # balls/rollers - 5 3 3 | i § o a € S e s a 2 £ 3 e Page D- 28 2016 Fotis Institut Na Unauthorized Copies May Be MadePumps/Fans Blade/Vane Pass Symptoms: Peak at vane pass or blade pass frequency Blade/vane pass All pumps, fans and compressors will normally have a peak in the spectrum at the "blade pass" or "vane pass" frequency. This is the number of blades or vanes multiplied by the shaft speed. The amplitude of the peak can increase if the gap between the blades or vanes and the stationary diffusers is not kept equal. It is also caused by obstructions and sharp bends in the flow path, in this case at the edge of the volute where it meets the discharge passage. Vane pass = Number of vanes x RPM Blade pass = Number of blades x RPM w a « o @ & > Ss o 3 s a rr c G a ~ a a E 3 a Page D - 29 Copyright © 2016 Mobius Institute 9 No Unauthorized Copies May Be MadeFlow Turbulence Flow Turbulence oH Symptoms: Random vibration in the range 50 to 2000 CPM Flow turbulence 1x Flow turbulence is due to variations in pressure or velocity of the air passing through the fan or blower. This phenomenon generates random, low frequency vibration. It will typically be observed in the range of 50 to 2000 CPM. Copyright © 2016 Mobius Institute tepbon) No Unauthe Jo Unauthorized Copies May Be ModeSymptoms: High frequency "noise' Cavitation normally creates random, higher frequency vibration or "noise". It is often observed as a "hump" in the vibration spectrum. Cavitation normally indicates insufficient suction pressure or starvation - i.e. low inlet pressure. If you listen to the waveform, it can often sound like gravel in the pump. Page D- 31 Copyright © 2016 Mobius Institute No Unauthorized Copies May Be Made CavitationReciprocating Machines oH Symptoms: 0.5X peak for a four-stroke engine a two-stroke engine 1X peak for The vibration level on recipro: very high. If you have a four: other rotation, which will res' In the case of a two-stroke e! engine will fire for every stro 1X peak. Copyright © 2016 Mobius Institute pode Two-stroke Engines cating machinery is commonly -stroke engine, then the engine fires every ult in a strong peak at 0.5X. ngine, such as many diesels, the ke; therefore you will see a strong D-32 No Unauthorized Copies May Be Made mlStator Eccentricity, Loose Iron _or Shorted Laminations 5 Orders blems will generate high vibration at twice the line r eccentricity produces an that Stator pro frequency (100 or 120 Hz). Stato uneven stationary air gap between the rotor and stator produces a very directional source of vibration. 2 c = 5 § $ 3 a 2 & 4 Page D - 33 Copyright © 2016 Mobius Institute No Unauthorized Copies May Be Madetat ll Symptoms: Twice line frequency (100 or 120 Hz) radial Soft foot and warped bases can produce an eccentric stator. Altering the tension on the hold down bolts, or repairing the foundation can resolve this problem. Copyright © 2016 age D - 34 ‘ght © 2016 Mobius Institute panther M No Unauthorized Copies May Be Made —a oom &CC CCC ee a aA aA KY Symptoms: Pole pass sidebands around 1X and 100/120 Hz Eccentric rotor Eccentric rotors produce a rotating variable air gap between the rotor and the stator, which induces a pulsating source of vibration. You will see the twice line frequency component, however this time there will be pole pass sidebands around this frequency and the 1X peak. frequency times the quency is the slip e between The slip frequency is the difference he synchronous speed. The pole pass fret number of poles. the actual RPM and t Page D-35 — yo unauthorized Copies May Be Made Eccentric RotorSymptoms: 1X radial Thermal Rotor Bow Uneven heating of the rotor due to unbalanced rotor bar current distribution causes the rotor to warp, or "bow", and rotor bow results in an imbalance condition with all its usual symptoms. It can be detected by the fact that it goes away when the motor is cold. Local heating can be so severe in motors that the offending bar can actually melt and lodge in the air gap. Rotor Bow Page D - 36 Copyright © PyFight © 2016 Mobius Institute ‘No Unauthorized Copies May Be MadeCracked or Broken Rotor Bars Symptoms: Pole pass sidebands around 1X and harmonics Broken/cracked rotor bars Cracked rotor bars will generate pole pass frequency sidebands around 1X and its harmonics (2X, 3X, and so on). You will often see a very busy spectrum with harmonics of 1X, each with "skirts" of pole pass sidebands. The pole pass frequency is the slip frequency times the number of poles. The slip frequency is the difference between the actual RPM and the synchronous speed. An induction motor with defective rotor bars will produce a vibration signature that slowly varies up and down in amplitude at twice the slip frequency of the motor. This phenomenon is called beating, and can often be heard as well as measured. The amplitude and frequency of the beats are dependent on the load on the motor (because that affects the slip frequency). Motor current analysis is very helpful when assessing the damage to rotor bars. Page D - 37 Copyrignt = 2016 Mobius Institute No Unauthorved Copies May Be Mage 2 a a . $s 9 “ © o = ° a . 3 3 @ 2 S & 5oi Loose Rotor Bars Symptoms: 100/120 Hz sidebands around rotor bar pass frequency Bo Loose Rotor Bars 40 50 Orders If there are loose rotor bars there will be a peak at the rotor bar pass frequency (RBF - the number of rotor bars times the RPM), with sidebands of twice line frequency (100 or 120 Hz). Even if you do not know the number of rotor bars, if you see a high frequency with twice line frequency sidebands, you can be somewhat confident that this fault condition exists. Rotor bar pass frequency = Number of rotor bars X Running speed Loose Rotor Bars Conran @ ome ty D6 Mobius Instat Page D- 38Loose Rotor Symptoms: High 1X and harmonics Loose Rotor on the Shaft 5 Orders Sometimes the rotor can slip on the shaft, usually intermittently depending on temperature, and this causes severe vibration at 1X and harmonics. Abrupt changes in load or line voltage can instigate this condition. Loose Rotar Page ~ 39 No Unauthorized Copies May Be Made 6) 2016 Mobius Institute Copyright— 2 3 £ 5 & 3 : 3 sg s a o 8 8 § Loose Stator Windings Symptoms: High 100/120 Hz radial High Coil Pass Frequency 1X sidebands (AC Synchronous Motors) a If the electrical windings of the motor stator are even a little loose, the vibration level at twice line frequency will be increased. This condition is very destructive because it abrades the insulation on the wire, leading to shorted turns and eventual short circuits to ground and stator failure. High Coil Pass Frequency = Number of Stator Coils x RPM Number of Stator Coils = Number of Poles x Number of Coils per Pole Copyright © 2016 Mobius Institute Page D - 40 No Unauthorized Copies May Be MadeLamination Problems Symptoms: High 100/120 Hz radial Stator Eccentricity, Loose Rotor Bars or Shorted Laminations € motors are made of thin laminations other, If the laminations are The rotor and stator of Al d resultant thermal warping that are isolated from eac! shorted together, local heating an will occur. also cause higher twice line frequency warping can cause the 1X level to Shorted laminations le pass sidebands are observed. vibration levels. The increase, and often pol e slip frequency times the The pole pass frequency is th number of poles. The slip frequency is the difference between he synchronous speed. the actual RPM and t Lamination Problem Ss PageD= 41 41, ypauthorzed Copies May Be Made| [toose connections | Symptoms: High 100/120 Hz with 16.67/20 Hz sidebands Orders Phasing problems due to loose connectors can cause excessive vibration at twice line frequency (100 or 120 Hz), with sidebands of one-third line frequency (16.67 or 20 Hz). Loose Connections Copyright © 2016 Mobius institute Page D- 42 ee No Unauthorized Copies May Be Made| You will normally find peaks at the shaft speeds and the gear mesh frequency, however they will be low level. There may be a 2X and 3X GM peak, and there may be sidebands of shaft speed around the gear mesh frequency. There may also be a Peak at the natural frequency of the gears. These frequencies will be most prominent in the radial | = | direction for spur gears, and in the axial direction for helical gears. Gear mesh = Number of teeth x Shaft speed Output speed = Input speed x Input teeth/ Output teeth Time waveform analysis is a powerful tool when it comes to analyzing measurements from gearboxes. As each tooth meshes you will see a pulse in the waveform. You can typically study the time waveform and count the teeth. Depending upon the nature of the fault, you may see one of the impacts/pulses per cycle at a higher amplitude, or lower amplitude (if it were: ‘Gear Tooth Wear Symptoms: 1X sidebands around the gearmesh frequency Harmonics of gearmesh frequency Gears: Tooth wear When teeth begin to wear, two things will happen. The first is that the sidebands of gear mesh will increase in level. The sidebands will correspond to the speed of the gear with the wear. The second thi the gear is & as a naturaGear Tooth Load Symptoms: High gearmesh frequency Gears: Tooth Load 3GM 32 36-40 Orders The level of the tooth mesh frequency is dependent on the alignment of the shafts carrying the gears, and the load on the gear. A high peak at the gear mesh frequency does not necessarily indicate a problem. Gear mesh = Number oi Output spee = InputsGear Backlash 1X sidebands around the gearmesh frequency Symptoms: High gear natural frequency Gears: Eccentricity & backlash 2BG2E 365 40 Orders Gear backlash wll generate shaft speed sidebands around the gearmesh fre The jear mesh peak and the gear natural freq! increased load when this pr% IS [Eecenvicears w WV Symptoms: 1X sideband around the gearmesh frequency Gears: Eccentricity & backlash a . 32. 36 «40 i a Orders j For eccentric gears and gears with bent shafts, you will see ! shaft speed (of the offendi sidebands of the on frequency, however si } rather than an enti 7 ! Gear mesh = Number Output spee = Input gMisaligned Gears 1X sideband around the gearmesh frequency Symptoms: Harmonics of gearmesh Gears: Misalignment 2GM Misaligned gears will generate high gearmesh frequencies with sidebands, however itis commen to have harmonics of gearmesh ith b times gear m your frequer frequenciesCracked or Broken Gear Tooth / Symptoms: High 1X radial Gear natural frequency 1X sidebands around the gearmesh frequency Gears: Cracked or broken tooth A cracked or/Bh at the turning natural freq turning spet ‘ nds of theHowever, the best way to see a cracked or broken tooth is via the time waveform. If there were twelve teeth, one of 12 pulses in the waveform will be very different to the other pulses. Naturally, the time difference between these pulses will be equal to the period of the turning speed of that gear (the tooth comes into mesh once per revolution). Gears: Cracked or broken tooth 1X 16 18 20 Orders Gear mesh = Number of teeth x Shaft speed d Output sone Input teeth/Output teeth® w Hunting Tooth Frequency | Symptoms: Hunting tooth frequency and 2xHT Gears: Hunting Tooth B 5 Orders The so-called "hunting tooth frequency" is the rate at which a tooth in one gear mates with a particular tooth in the other gear. If the gear ratio is an integer such a 1, 2 or 3, the hunting tooth frequency will be the RPM of the larger gear, and the same teeth will be in contact once per revolution. This will cause uneven wear on the gears - a small defect in one tooth will repeatedly contact the same: eo in the other cooy causing localized wear onvtl In practice, the hunting on both the gear and pill manufacturing or as a low frequency, and yoi gearbox. The hunting tooth fre mesh frequency divid numbers of teeth on | is often just the prod Copyright © 2016Coupling Faults Symptoms: 1X and 2X If the coupling is not true, i.e., has non-parallel flange faces, a vibration pattern similar to angular misalignment is produced. Coupling (non-parallel face) EB Coupling imbalance is also a common problem, and results in high 1X and 2X radial components. fs [oleae ales Lila aladaalad Coupling we and loosene — os an RAHeee ll ee Worn or Loose Belts | Symptoms: Belt rate with sidebands Gi Belt wear If a belt is worn or loose you will witness a peak at the belt rate, and harmonics, with twice this frequency (2BR) the highest - when there are two sheaves. . It is the rate at which a point on the belt it. It is always less that the spe It is calculated@ Driven RPM) Belt freq = PI x She Where PI For timing be consider,Eccent Sheaves/P eys Symptoms: High 1X radial Eccentricity 3 Orders Eccentric sheaves will generate a strong 1X radial peak, especially in the direction parallel to the belts. This condition is very common, and mimics imbalance. This condition can be s and repeating the eave will also @Misaligned Sheaves/ Pulleys Symptoms: High 1X axial ent of sheaves produces high vibration at 1x, ction. On occasion you will also e axial Misalignm predominantly in the axial dire see harmonics of belt rate (belt frequency) in th direction. Belt Misalignment 1X Fan/Motor__Belt Resonance Symptoms: High 1X radial Belt resonance 9 10 Orders =| Resonance in the belt can cause high amplitudes if the belt's natural frequency should happen to coincide with either the e RPI The natura Deer can be altered by eithe mS § ee ue ereExternal Noise Symptoms: Non-synchronous peak External Noise B You will often find a peak in a spectrum that is difficult to explain. Before you jump to conclusions, you may like to rule- out the possibility that the vibration is from another machine or process. The peak will typicall would be too much o same as your machi that the vibration is e Stop the mag vibration is ° Check local a If you find that it want to ignore it. for long periods 0 a process called b