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1 Introduction
A developing fault in a machine or a structural component will always show up as an
increasing vibration at a frequency associated with the fault; however the fault might
be well developed before it affects either the overall vibration level or the peak level
in the time. Noise signals measured at regions in proximity to, and vibration signals
measured on the external surfaces of machines contain vital information about a ma-
chines running condition [1.5]. When machines are in a good condition, their noise
and vibration frequency spectra have characteristic shops. As faults begin to develop,
D.-S. Huang et al. (Eds.): ICIC 2008, LNCS 5226, pp. 696703, 2008.
Springer-Verlag Berlin Heidelberg 2008
Machinery Vibration Signals Analysis and Monitoring for Fault Diagnosis 697
the frequency spectra change. This is the fundamental basis for using noise and vibra-
tion measurement and analysis in condition monitoring [2]. A frequency analysis of
the vibration will give a much earlier warning of the fault, since it is selective, and
will allow the increasing vibration at the frequency associated with the fault to be
identified. Machine condition, machine faults and on-going damage can be identified
in operating machines by fault symptoms [3.4]. Therefore vibration analysis can iden-
tify developing problem before they become too serious and cause breakage, using
vibration and noise analysis, the condition of a machine can be constantly monitored
and more detailed analyses can be made to determine the health of a machine and
identify any faults that may be arising or that already exist.
Comprehensive equipment condition-monitoring program is essential for ensuring
maximum utility of assets in most industries. To effectively monitor large numbers of
assets of various types, a scalable, flexible and usable approach to condition monitor-
ing is warranted. It is becoming increasingly apparent that condition monitoring of
machinery reduces operational and maintenance cost and provides a significant im-
provement in plant availability. The obtained complex information from the meas-
urement signals has to be reduced to the trend of few characteristic values to forecast
the development of damages in the near future respectively to allow feedback to the
process control.
Table 1. Typical Faults Can Be Detected With Noise and Vibration Analysis
Item Fault
Gears tooth meshing faults, Eccentric gears
Cracked and/or worn teeth
Rotors and shafts Unbalance, Bent shafts
Eccentric journals, Loose components
Critical Speeds, Cracked shafts
Rolling element bearings Pitting of race and ball/roller
Other Rolling Element
Journal/bearing rub
Journal Bearing Defects, Oil whirl
Oval or barreled journals
Flexible couplings Misalignment, Unbalance
Electrical machines Unbalanced magnetic pulls
Broken/damaged rotor bars
Air gap geometer variations
Miscellaneous Structural and foundation faults
2
(1)
And,
x (t ) = X ( )e i t d . (2)
Because classical Fourier theory is only valid for functions which are absolutely in-
tegrable and decay to zero, the transform X () will only exist for a random signal
which is restricted by a finite time interval. Thus, the concept of a finite Fourier trans-
form, X (, T) is introduced. The finite transform of a time signal (t) is given by,
F {x (t )} = X ( , T ) = x (t )e
1 T
i t
dt . (3)
2 0
F{x (t) represents a forward Fourier transform, and F -1
x (t) represents an in-
verse Fourier transform [5].
x
Microphones
1 f Q ap
cos + C PA sin
2 0
Ix = df , (4)
f
where Q pa the quadrature spectrum (imaginary part of the one-sided cross-spectral
density), C pa is the coincident spectrum (real part of the one-sided cross-spectral
density), and is the phase shift between the two signals due to the instrumentation
Machinery Vibration Signals Analysis and Monitoring for Fault Diagnosis 701
and due to the separation distance between the microphone and the accelerometer.
This phase shift has to be accounted for in the analysis. The time lag phase shift can
be evaluated for each measurement point and the instrumentation phase shift has to be
evaluated during the calibration procedure.
n
( f ,
)
n
=
j =1
Q cos + C
i =1
pa sin A
j pa ij
(5)
j i
2 f j
where n is the number of data points in the frequency domain, N is the number of area
increments (Ai)on the whole surface, and f is the frequency resolution (i. e. f =
f/n ). The main advantage of the surface intensity is that information is not required
about the radiation ratio of a vibrating surface. It is also useful in highly reverberant
spaces where a reverberant field exists very close to the surface of a machine. It is
main disadvantage is that the phase difference between the microphone and the accel-
erometer has to be accurately accounted for.
The vibration intensity measurement technique is used to identify free-field energy
flow due to bending waves in a solid body. It can be shown that the vibration inten-
sity, Iv, in a given direction is
(B ) 1
2
(a 1 + a 2 )
(a 2 a 1 )d dt ,
T
Iv = (6)
Ps
2 f x 0
2
where B is the bending stiffness of the structure, Ps is the mass per unit area, x is
the separation between the two accelerometers, and a1 and a2 are the two accelerome-
ter signals. It is noted that the scaling factor is frequency dependent.
running condition. The vibration condition monitoring system of the mill machines
can select various levels of response when registering anomalies or impending failure.
Figure 4 is a typical frequency spectrum vibration signals with different degrees of
bearing housing looseness on the mill machine. This setup can alert the maintenance
supervisor immediately for diagnosis or repair. The visualized signatures in time and
frequency domains have to be summarized to obtain an actual condition classifiers of
normal operation to get an automatically feedback for process regulation.
Fig. 4. Frequency spectra under different degrees of bearing housing looseness on mill machine
6 Conclusion
The experiment results show that vibration, sound and acoustic emission combined
with intensity technique like sound intensity and vibration intensity measurement
Machinery Vibration Signals Analysis and Monitoring for Fault Diagnosis 703
techniques are more convenient and reliable for condition monitoring in complex
machinery and quality control than most of the standard methods, like heat, current,
force and normal vibration measurements as well as power consumption, used in
commercially available systems. The proposed monitoring system presents using
fewer sensors and takes less measure and analysis time. The obtained information
from the measurement signals is able to forecast the development of damage. The
proposed techniques have a great potential to improve industrial production lines
utilization rate and product quality by machines condition monitoring. As a result,
lower in running operation and maintenance costs and increased in productivity and
efficiency can be achieved, further application allow feedback to the process control
on production line.
Acknowledgments
This research is supported by the P.R. China Ministry of Education and the authors
acknowledge financial support The China Scholarship Council (C.S.C).
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