Lab.

Exercises on Machine Vibration

Exercise #1: Baseline Vibration Objective: Learn the main components of the Machine Fault Simulator (MFS), Learn how to run the MFS and how to use the VQpro software, Run the system at selected speed and record baseline data for latter analysis of the faulty signals.

Procedures: Remove the belt drive and arrange the rotor in such a way that only two discs are mounted on the shaft Arrange four accelerometers to record the vibration signal at the two bearings Run the system at five different speeds provided for the group. Record the data at different frequencies and resolutions. Export the recoded data to excel and take a copy for analysis Analyze the data using root mean square (RMS), Kurtosis, Skewness, Crest Factor and Peak to Peak.

Exercise #2: Resonance Test Objective: Study the effect of resonance

Procedures: Remove the belts and the small sheave from the shaft, Install the resonance kit, Mount the four accelerometers at the two bearings, Arrange the rotors at equal distance with each other. Make sure that the connections between the rotors and the shaft are tight enough. Start the MFS and gradually increase the Figure 1: Setup for resonance test speed until vibration starts to increase. Keep increasing the speed until the vibration reaches maximum. Further increasing the speed will be seen accompanied by a decrease in the vibration amplitude. Reduce the speed gradually and make note of the speed at which the vibration amplitude gets maximum, Record the speeds at which the vibration amplitude are maximum. Connect one screw to one rotor to induce unbalanced weight. Repeat the above steps and record the vibration signal, Change the location of the rotors and repeat the test. Questions: a) What are the magnitudes of the critical speeds for each test? b) Discuss the effect of change in the rotor location on the critical speed. c) What is the effect of the unbalanced mass on the resonance? Discuss. d) Discuss the damaging effect of resonance and suggest remedial actions. Exercise #3: Bearing Fault Experiment Objective: Study the effect of bearing fault on the vibration response at the bearings Learn how to use vibration analysis tools Study the effect of increase in resolution on the spectral peaks
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Procedures: Remove the belts and the small sheave from the shaft, Install the two rotors and bearing loaders according to the setup shown in Fig. 2. For the first exercise, consider the 5/8 shaft Install two faulty bearings, Mount the four accelerometers at the two bearings. Start the MFS and run it at . RPM, Set the DAQ parameters as: Number of lines - 800, number of averages - 4, and maximum frequency 2kHz Allow it to settle for few seconds and record the data, Change the DAQ parameters to: Number of lines - 1600, number of averages - 4, and maximum frequency 2kHz Run the system at RPM and record the vibration data. Change the DAQ parameters to: Number of lines - 1600, number of averages - 8, and maximum frequency 2kHz Record the corresponding data. Replace the 5/8 shaft and bearings with 1 shaft, bearings and loaders and repeat the above test. Add unbalanced mass and repeat the experiment for the 1 shaft. Export the recoded data to excel and take a copy for analysis. Analyze the data using root mean square (RMS), Kurtosis, Skewness, Crest Factor and Peak to Peak.

Figure 2: Setup for Bearing Fault Exercise

Exercise #4: Misalignment Experiment Objective: Study the effect of misalignment on the vibration response at the bearings, Study the effect of shaft speed on the vibration amplitude,

Procedures: Remove the belt drive and arrange the rotor in such a way that only two discs are mounted on the shaft. The discs should be center hung. Install one loader between the left bearing the flexible coupling, Install the second loader between the right bearing and the disc on the right side. Arrange four accelerometers to record the vibration signals in the vertical and horizontal directions. Install one accelerometer to record the axial vibration in the left bearing. Introduce a known angular misalignment. Refer to Fig. 3. Start the MFS and run it at RPM. Allow it to run for few seconds and record the vibration signal. Repeat the test for speeds: . RPM Introduce offset misalignment and repeat the test. Replace the flexible coupling by a rigid coupling and repeat the test.

Figure 3: Options to induce misalignment