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Machinery Vibration Signals Analysis and Monitoring

for Fault Diagnosis and Process Control

Juan Dai1, C.L. Philip Chen2, Xiao-Yan Xu3, Ying Huang4,


Peng Hu5, Chi-Ping Hu1, and Tao Wu1
1
The Faculty of Mechanical and Electrical Engineering, Kunming University of Science and
Technology, Kunming, 650091 China
jdkust@yahoo.com.cn
2
The Department of Electrical and Computer Engineering, University of Texas at San Antonio,
San Antonio, TX 78249 USA
3
The Electrical Engineering Department, Shanghai Maritime University,
Shanghai, 200135 China
4
Yunnan University of Traditional Chinese Madicine,
Kunming, 650021 China
5
The Faculty of Applied Technology, Kunming University of Science and Technology,
Kunming, 650091 China

Abstract. The vibration signals contain a wealth of complex information that


characterizes the dynamic behavior of the machinery. Monitoring rotating ma-
chinery is often accomplished with the aid of vibration sensors. Transforming
this information into useful knowledge about the health of the machine can be
challenging due to the presence of extraneous noise sources and variations in
the vibration signal itself. This paper describes applying vibration theory to de-
tect machinery fault, via the measurement of vibration and voice monitoring
machinery working condition, also proposes a useful way of vibration analysis
and source identification in complex machinery. An actual experiment case
study has been conducted on a mill machine. The experiment results indicate
that fewer sensors and less measurement and analysis time can achieve condi-
tion monitoring, fault diagnosis, and damage forecasting. Further applications
allow feedback to the process control on production line.

Keywords: Reliability, fault detection, condition monitoring, vibration analy-


sis, process control.

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.

2 Noise and Vibration Analysis Detected Typical Faults

Common machinery consists of a driver or a prime mover, such as an electric motor.


Other prime movers include diesel engineers, gas engineers, steam turbines and gas
turbines. The driven equipment could be pumps, compressors, mixers, agitators, fans,
blowers and others, at time when the driver equipment has to be driven at speeds
other than the prime mover, a gearbox or a belt is used. Each of these rotating parts is
further comprised or simple components such as stator, rotors, seals, bearings and so
on. When these components operate continuously at high speeds, wear and failure is
imminent [7]. When defects are developed in these components, they give rise to
higher vibration levels. It can be stated that whenever either one or more parts are
unbalanced, misaligned, loose, eccentric, out of tolerance dimensionally, damaged or
reacting to some external force, higher vibration levels will occur. The common noise
and vibration sources include mechanical noise, electrical noise, aerodynamic, and
impulsive noise. Mechanical noise is associated with fan/motor unbalance, bearing
noise, structural vibration, reciprocating forces, etc. electrical noise is generally due to
unbalance magnetic forces associated with flux density variations and air geometry,
brush noise, electrical arcing, etc. Aerodynamic noise is related to vortex shedding,
turbulence, acoustic modes inside ducts, pressure pulsations, etc. Finally, impact noise
is generated by sharp, short, forceful contact between two or more bodies. Vibration
monitor and analysis aim to correlate the vibration response the system with specific
defects that occur in the machinery and its components, trains or even in its mechani-
cal structures. Some of the more common faults or defects that can be detected using
vibration or noise analysis are summarized in Table 1.
698 J. Dai et al.

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

3 An Important Vibration Signal Process FFT Analysis


Numerous analysis techniques are available for condition monitoring of machinery or
structural components with noise vibration signals. The commonly used signal analy-
sis techniques are magnitude analysis, time domain analysis and frequency analysis.
State of technology in vibration monitoring of rotating machines is related to the cal-
culation of standard deviation and/or maximum values, their comparison with thresh-
olds and their trend behavior to determine increased wear or changes in the operation
conditions. Time domain averaging is applied to separate speed related information
from superimposed resonances and stochastically excitations like mechanical or flow
friction [6]. Spectrum analysis with special phase constant averaging routines allows
determining machine specific signatures by magnitude and phasing relation.
The measured vibrations and voices are always in analog form (time domain),
however the time domain single is difficult to condition monitoring of machinery.
Firstly, individual contributions from components in a machine to the overall machine
vibration and noise radiation are generally very difficult to identify in the time do-
main, especially if there are many frequency components involved. This becomes
much easier in the frequency domain, since the frequencies of the major peaks can be
readily associated with parameters such as rotation frequencies. Secondly, a develop-
ing fault in a machine 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 fault in the time domain. 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. When using vibration and voice as a diagnostic tool, the
measured analog signal needs to be transformed to frequency domain. As shown in
Figure 1, the fast Fourier transform (FFT) is widely used both by commercially avail-
able spectrum analysis and by computer based signal analysis systems [1].
Machinery Vibration Signals Analysis and Monitoring for Fault Diagnosis 699

Fig. 1. Fourier Transform (Schematic illustration of time and frequency components)

A general Fourier Transform pair, X () and x (t), is


X ( )= x (t )e i t dt .
1

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].

4 The Complex Machinerys Vibration Monitoring System


Vibration or noise analysis in plant often is involved complex machinery, and a con-
siderable amount of deterioration or damage may occur in there. Therefore vibration
source identification and ranking in complex machinery is very important for the
implementation condition monitoring and fault detection. The normal techniques use
a lot of sensors, which consumes in life in every operation. The paper discusses a new
useful way of vibration analysis and source identification in complex machinery
based on advanced signal processing techniques. The vibration monitoring and diag-
nostic method uses three of measurement intensity measurement techniques to
700 J. Dai et al.

identify vibration source in complex machinery shown in Figure 2. The vibration


monitoring system only uses 6 sensors (3 microphones and 3 accelerometers). Among
them, 2 microphones are used to measure sound intensity, one microphone and one
accelerometer are used to measure surface intensity and 2 accelerometers are used to
measure vibration intensity. Figure 2 shows a vibration monitoring and fault diagnosis
system for complex machinery. In practice, care has got to be exercised with all inten-
sity techniques and several procedures have been developed to reduce any phase er-
rors between the two microphones. These include the usage of phase matched
microphones, microphone switching procedures, which, in principle, eliminate the
phase mismatch, and a frequency response function procedure which corrects the
intensity data with the measured phase mismatch.
With the surface intensity technique, an accelerometer is mounted on the surface
of the vibration structure and a pressure microphone is held in close proximity to it. It
is assumed that the velocity of the vibration surface is equal to the acoustic particle
velocity and that the magnitude of the pressure does not vary significantly from the
vibrating surface to the microphone [8]. The resultant surface intensity normal to the
surface (sound intensity at the surface of the structure) is given as

x
Microphones

Amplifiers Filters FFT


A/D
Windows
Accelerometer

Amplifiers Filters FFT


A/D
Windows
Microphon
Filters
Amplifiers FFT
A/D
Windows
Accelerometers

Fig. 2. Vibration monitoring and fault diagnosis for complex machinery

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.

5 Condition Monitoring and Fault Detection on Mill Machine


The vibration monitoring method designed in this paper, are applied on a mill ma-
chine. The mill machine and its vibration condition monitor system are shown in
Figure 2. In this system, 3 accelerometers and 3 microphones are mounted in close
critical areas. In the actual experiment, continuously monitors signals come from the
accelerometers and microphones. High pass filtering increases significantly the prob-
ability of fault detection, too. These piezoelectric sensors generate analog signals that
measure the component vibration. The analyses system uses National Instruments Lab
VIEW developing a PC-based monitoring system with accelerometers and micro-
phones to predict failure of the complex mill machine components. In this case, sound
intensity and vibration intensity calculate was applied to analysis where the signal
consists of the general descriptive values of the time information (variance, kurtosis)
in certain specific frequency ranges as well as peak analysis known from the evalua-
tion of signals. A reference normal operation of all values are normalized to one.
The actual signatures can then be calculated as differences for comparison purposes.
The difference to the reference frequency spectra then is detected with a developing
fault. Figure 3 shows the measurement result with sound intensity measurement with
vibration fault source. For comparison purposes, of different operation conditions,
the actual signals frequency, amplitude and the difference to the reference normal
running signals are calculated. The signal classes can be separated depending on the
702 J. Dai et al.

Fig. 3. Determination of failure source using intensity measurement analysis

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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