Equipment for engineering education

gunt

PT 500
Machinery diagnostic system
Training in machine condition monitoring:
generating, measuring and evaluating mechanical vibrations
The system for an easy introduction to a demanding topic
 PT 500 Machinery diagnostic system
gunt
What is machine diagnosis?

The purpose of modern-day machine condition monitor-

ing systems (CMS) is to carry out needs-based main-
tenance or repairs and thus to minimise the repair and
other servicing downtimes of a machine. This increases
the overall equipment effectiveness (OEE) and optimises
the cost structure.
The aim ist to detect damage as it occurs, allowing
scheduled repairs or maintenance to be carried out.
The mechanical condition of a machine or of machine
components can be accurately diagnosed from the
nature and extend of vibrations they generate. Accord-
ingly, vibrations are measured, recorded and evaluated
using sensors and recording equipment.
Convenient PC software makes it easy to display the
measured values clearly.
Industrial plant x Vibrational analyser Evaluation of vibrational signals

Parameter monitoring

A (t)
The internal forces and energies in the machine Parameter monitoring involves measurement of the vibration amplitude and
are of interest for fault identification and diagno- comparison with a predefined limit value. Parameter monitoring can be carried
sis. These variables cannot be measured directly, out continuously and automatically. It is easy to implement and requires only little
but their effects – vibrations – can. specialist knowledge. On simple standard equipment, parameter monitoring is
Vibration measurement and analysis is therefore often sufficient.
an attempt to obtain a picture of these forces.
This can be used to identify their structure, the
causes of them and their behaviour over time.
Vibrations are normally frequency mixtures that
result from super­imposition of several vibrations.
Some of these vibrations are part of the machine’s
t
normal operation, while others are intensified,
or actually generated by defects. With sufficient
experience, the condition of the machine can be
assessed and a defect on the machine identified.
When it comes to machine condition monitoring, Frequency analysis
it is important to differentiate between parame-
Typical vibration signals in the time domain ter monitoring and frequency analysis. gunt PT 500.04 PC BASED EVALUATION SOFTWARE & INSTRUMENTATION KIT

The use of analysis in the frequency domain is much more complex but also
acceleration more powerful. This analysis enables the nature of a defect to be identified, which
velocity
displacement allows targeted repair measures to be initiated. However, performing frequency
analysis requires a good understanding of the operating mechanisms and suffi-
cient experience. Frequency analysis is mainly used as a supplementary method
in conjunction with parameter monitoring.

2 3
 PT 500 Machinery diagnostic system
gunt
Teaching concept and learning content Vibration analyser PT 500.04

The PT 500 system provides you with a flexible and modular learning platform offering an introduction to the complex The core of our machine diagnosis
and demanding subject of machine diagnosis. The target group is students in mechanical engineering/machine dynam- system is the PT 500.04 vibration
ics, but it also includes other professional people as part of on-the-job training and development in maintenance and analyser, which consists of the
servicing. following components:
The close links between practical work on the experimental unit and theoretical/analytical aspects of diagnosis foster • measurement amplifier
integrated learning. • USB interface for data acquisition
• analysis software
• vibration sensor
Successful work with the PT 500 requires knowledge of the Training using the PT 500 thus supplies a basis for effective and
basic principles from the fields of mathematics, machine dynam- successful work in practical industrial situations. • reference sensor
ics, mechanical vibrations and measurement tech­nology.
When used in conjunction with on-the-job training and devel-
In contrast to the widespread practice of solely learning on-the- opment, the intensive practice that is possible with the PT 500
job, the effects to be investigated can be represented in isolation significantly speeds up learning in the area of machine diagnosis.
and are reproducible. This makes it easier to provide a step-
by-step introduction to the topic and targeted development of
relevant experience in diagnosis.

Learning content gunt PT 500.04 PC BASED EVALUATION SOFTWARE & INSTRUMENTATION KIT

USB interface measurement

Mechanical vibrations Causes, formation mechanisms, imbalance, Laval shaft, amplifier
resonance, damping, impact

Vibration measuring
PT 500.04 PC BASED EVALUATION SOFTWARE & INSTRUMENTATION KIT

Measurement sensor, measuring amplifier, representation,

gunt

technology oscilloscope, speed measurement

Vibration analysis Acceleration, vibration speed, vibration displacement amplitude,

parameters, representation in time and frequency domains, power
spectrum, FFT, orders, tracking analysis, envelope analysis, supply
orbit, path curve
PC with evaluation software
vibration reference
sensor sensor
Machine diagnosis Bearing and shaft vibrations, permissible vibration amplitude,
roller bearing defects, electromagnetic vibrations, Measuring system set-up Evaluation software
imbalance vibrations and balancing, gear defects,
vibrations on belt drives, cavitation in pumps, blade vibrations,
vibrations and impacts in crank drives, The measurement amplifier supplies the acceleration and dis- ICP acceleration sensors are used as vibration sensors.
speed-dependent vibrations placement sensors with power and provides adjustable pre-am- The advantage of ICP sensors is that they have an integral
plification. Output sockets also allow the vibration signal to be amplifier and thus guarantee that processing of the measured
output as a voltage signal. This allows you to integrate your own signal is insensitive to interference. The industrial quality sen-
measuring instruments, e.g. an oscilloscope, into the measure- sors used are robust, have stable connecting cables and plugs
In addition, practical skills and experience in handling and assem- Questions provide value experience for subsequent practical ment set-up. and are therefore ideally suited for use in harsh training situa-
bling machine components such as bearings, shafts and cou- work in industry: tions.
plings are gained. The construction of mechanical machines can The measurement amplifier also provides the opportunity to
• which measurement sensor do I use? connect the displacement sensors PT 500.41, available as an The reference sensor is used for speed measurement and
also be studied.
• where can I expect a usable measuring signal? accessory. phase information. A laser sensor with a large scanning range
is used here, which delivers a reliable signal even in poor light-
• how do I effectively mask interference signals? The analysis software runs on any standard PC under Windows.
ing conditions and with difficult access to the rotating shaft.
The USB interface provides an easy connection to the PC or
A self-adhesive reflective strip acts as the reference mark.
laptop.

4 5
 PT 500 Machinery diagnostic system
gunt
Example: identification of bearing defects

Bearing defects Experimental set-up for the identification of bearing defects

Each rolling bearing has characteristic damage The bearing to be investigated

frequencies for the inner race, rolling bearing USB box measurement amplifier
(PT 500.04) (PT 500.04) (PT 500.12) is fitted in a vice.
and outer race. These frequencies depend on Because bearing defects are only
the speed Ω, the geometric dimensions and the apparent under load, the belt force of
number of rolling elements. Thus, with a known belt drive the tensioned belt drive (PT 500.14)
impact frequency the type of damage and the (PT 500.14)
presents a radial load to the bearing.
defective bearing can be identified. The shaft is powered by a variable
speed motor. An acceleration sensor
PC with evaluation software on the bearing block measures the
Impact force while running over (PT 500.04) impacts caused by the bearing defect.
bearing surface damage reference sensor A reference sensor is used to mea-
(PT 500.04) sure the speed. The measurement
drive motor, coupling and shaft
(PT 500 base unit) amplifier (PT 500.04) transfers the
measuring signals to the PC. The soft-
acceleration ware performs the envelope analysis.
sensor
(PT 500.04)

damaged bearing with

Bearing surface damage to the outer race, Bearing surface damage to the inner race, A damaged rolling ball element, bearing block (PT 500.12)
frequency 3,58 Ω frequency 5,42 Ω frequency 4,65 Ω

Envelope analysis process Typical experimental results

Envelope analysis is used to identify defects, for example on or even impossible to identify in the normal spectrum. Envelope
rolling bearings and gears. The defects generate impacts with analysis demodulates the high frequency impact signal, thus The illustration shows the envelope gunt PT 500.04 PC Based Evaluation Software & Instrumentation Kit
very high frequency vibration components. The low frequency ­allowing the impact frequency to be measured. spectrum for a typical bearing defect.
impact frequency relevant for diagnosis of the damage is difficult To obtain a representation indepen-
dent of the rotary frequency, the order
Measurement of the high frequency impact signal and has been selected as the X coordinate.
high pass filtration to suppress low frequency interference signals A rotary frequency signal has an order
(imbalance, alignment errors). of 1. Frequency lines with an order of
3,58 are read when multiplying.
This indicates an outer race defect in
the bearing. The lack of side band lines
Rectification of high frequency signal with the same spacing as an order
indicates a constant force direction –
the belt tension in this case – and no
rotating imbalance load.
Extracting the envelope of the rectified signal using a
low pass filter
Envelope analysis process

Performance of FFT to obtain the spectrum of the envelope. 10 Hz

The speed (10 Hz) and the impact frequency (35,8 Hz) can be 35,8 Hz
clearly identified. The side bands at the same spacing as the
speed (35,8 -10, 35,8 +10) indicate an amplitude modulation. 35,8 -10 35,8 +10 71,6 Hz Orders: 3,58 7,16 10,74 14,32
This represents an outer race defect with a rotating load.

0 20 40 60 80 100 120 Hz

acceleration, velocity, Screenshot of an envelope analysis showing outer race damage

displacement

6 7
 PT 500 Machinery diagnostic system
gunt
Example: field balancing

If the centre of gravity of a rotating machine component does not correspond to

the axis of rotation, i.e. it is not centred, the rotating mass of the machine com- ω Experimental set-up for the balancing in two planes
ponent generates centrifugal or imbalance forces. These forces are transferred F = e m ω2
via the bearing to the entire machine and surroundings and stimulate vibrations, The experimental set-up requires only
whose frequency corresponds to the speed. Because centrifugal forces depend s USB box measurement amplifier
m the basic PT 500 unit and the PC-based
on the square of the speed, they become much stronger as the speed increases. (PT 500.04) (PT 500.04)
PT 500.04 vibration analysis unit. The
Imbalance vibrations can be prevented or at least reduced by balancing. We dif- experimental set-up illustrated shows a
e w rotor with two weights for carrying out
ferentiate between balancing on special balancing machines, which is carried
out during production, and so-called field balancing on a machine that is already two-plane balancing. The acceleration
in operation. The PT 500 can be used to practice field balancing. sensors measure the bearing vibrations
directly adjacent to the weights. A reflec-
PC with evaluation software tive mark on one of the weights acts as
Development of the imbalance force (PT 500.04) a reference for the angle information. As
balancing determines the transmission
drive motor, coupling and acceleration behaviour between the weight and the
Balancing involves an attempt to bring the centre of gravity of the rotor back into shaft (PT 500 base unit) sensor measuring point, the individual measure-
alignment with the axis of rotation. To do this, weights are added to or removed (PT 500.04) ments are carried out at exactly the same
from the rotor. To determine the position and mass of the required balancing E1 speed. To simulate an original imbalance,
reference sensor
weights, the unknown imbalance must first be determined. Unfortunately, the (PT 500.04) small additional weights are screwed onto
imbalance cannot be directly measured but has to be determined indirectly from E1 the disk. The same applies to the test and
the measurable bearing vibrations. To do this, we use the bearing vibration to compensating weights.
determine the amplitude and phasing (vector) of the component with a rotary
frequency. All other vibration components are filtered out. The balancing process
is carried out as follows: S mass disks with
balancing planes (PT 500)
• measurement of bearing vibrations on imbalanced machine
(original out of balance run U) S
One-plane balancing

• measurement of bearing vibrations after an additional, known imbalance E1 E2

has been applied to the machine (test imbalance T)
Typical experimental results
• comparison of the two measurements enables the original imbalance E1 E2
to be calculated
The illustration shows the software gunt PT 500.04 PC BASED EVALUATION SOFTWARE & INSTRUMENTATION KIT
• calculation of the mass and position of the balancing weights user interface after a complete balanc-
to be added or removed S ing process. In the upper window,
• control measurement (A) after weight correction the vibration signal is displayed directly
S for monitoring purposes. The two
Depending on the success of the balancing, this procedure is repeated until the ­diagrams on the left and right show
desired limits for the bearing vibration are achieved. Two-plane balancing the imbalance signals from the
individual measurements as vectors.
Between them, a dialog box indicates
the next step to be performed. The
Measurement of the bearing vibrations of the out-of-balance machine lower section of the screen shows the
(original imbalance U). results of the measurements, the posi-
U U tion and mass of the test weights and
the position and mass of the calculated
compensating weights.

Measurement of bearing vibrations according to which known T

imbalance was added to the machine (test imbalance T).
It is possible to calculate the original imbalance by comparing of the U U+T
U+T
two measurements.

Screenshot: balancing in two planes

Calculation of the size and position of the balancing masses (C)
to be added or removed. Control measurement (A) after performing U
mass correction. Depending on the success of balancing, A
C
this procedure is repeated until the desired limit value of the
bearing vibration is met. A

8 9
 PT 500 Machinery diagnostic system
gunt
Example: identification of cracks in shafts

Cracks in shafts are amongst the most dangerous of defects. intervals and the rotor was subjected to an extensive crack
If a crack is not detected in good time, the shaft can break. As test. The costs of this kind of inspection are huge. Modern
Experimental set-up for the identification of cracks in shafts
this usually happens at high speeds and loads, the consequences machine condition monitoring methods enable cracks to be
are disastrous and often result in the total destruction of the identified while the machine is still in place. USB box measurement amplifier The PT 500.11 Crack detection in rotating
machine. In the past, machines were totally dismantled at fixed (PT 500.04) (PT 500.04) shaft accessory kit can be used to create
belt drive two different experimental set-ups:
(PT 500.14)
F
• crack in a projecting shaft
crack in a protruding F under external load
shaft end
• crack in a Laval shaft

acceleration sensor
PC with evaluation software under own weigh load
(PT 500.04) The experimental set-up with a projecting

(PT 500.04)
shaft is shown here. The external load is
drive motor, coupling and shaft simulated by the pretensioning of the V belt.
F (PT 500 base unit) To simulate a crack with a variable depth, a
F special flange coupling is inserted into the
remaining
cross-section shaft. Depending on the installation position
of the specially designed gaps, either fixed
belt drive for Opening and closing clamping or a loose connection with
bending load of the crack during clearance is created at the connecting
a rotation
screws. The number of loose screws can
reference sensor flange joint for crack thus be used to simulate a crack of
Cracks are caused by material faults, material fatigue and the The crack reduces the rigidity of the shaft. This reduction in (PT 500.04) simulation (PT 500.11) different depths.
concentration of stress at surface faults. The continuous flexural rigidity is modulated by the rotation of the shaft, which means
fatigue stress when the shaft is rotating then causes the crack that the rigidity is slightly higher if the crack runs parallel to the
screws fastended,
to develop constantly until the remaining healthy cross-section load direction than perpendicular to it. In addition, the crack can no crack
finally yields to a forced fracture. continuously open and close while rotating.

screws loose,
crack
no crack small crack large crack
Analysis methods
Simulation of a crack via a flange joint
The phenomena mentioned generate a characteristic vibra- Tracking analysis involves recording the vibration signal over a
tion signal, which can be used to identify the existence of the wider speed range and investigating it for the different orders
crack. In particular the second order harmonic rises sharply of rotary frequency using a special filter.
compared to that for an undamaged shaft. Frequency analysis, Typical experimental results
Orbit analysis involves investigating the path of the shaft mea-
tracking analysis and orbit analysis are all appropriate analysis
sured using two displacement sensors. Second order compo-
methods. The two figures show the result of a tracking analysis.
nents can be discerned here by the formation of loops in the
Frequency analysis involves looking at the frequency spectrum path. The measurements were carried out on the experimental
of the signal at a fixed speed. If there is a crack, additional fre- set-up shown, with the projecting shaft. Graph A shows 1Ω
quency lines occur in the spectrum. the first order bearing vibration component (1Ω),
graph B the second order component (2Ω).
2Ω
In the top figure, all screws at the flange connection
y were tight, corresponding to the condition with no crack.
without crack
1 The first order bearing vibrations increase quite normally
Amplitude

Amplitude

without crack without crack 1 as the speed rises due to the imbalance. The second order
2 bearing vibrations are minimal. Tracking analysis shaft without crack
x
In the lower figure, a deep crack is simulated. Here, only
Frequency Speed two of the six screws were fully tightened. While the first
y with a crack
order bearing vibrations demonstrate similar behaviour 1Ω
2Ω
with a crack with a crack to a shaft without a crack, there is a very sharp rise in the
Amplitude

Amplitude

1
1 second order in the middle speed range, clearly indicating
2 2 the presence of a crack.
3 x

Frequency Speed
Frequency analysis Tracking analysis Orbit analysis Tracking analysis shaft with crack

10 11
 PT 500 Machinery diagnostic system
gunt
Modular system

Base unit Basic accessories are required for numerous applications

The overview below shows how you
can flexibly combine the accessories
A range of training exercises relating to machinery diagno- The computerised
outlined for different experiments.
sis and monitoring can be carried out using just the PT 500 vibration analyser PTPT
500.04
500.04
PT 500.04
base unit together with the computerized vibration analyser • basic accessories are used PT 500.04 is required
PT 500.04. ­repeatedly. for every application.
As well as the exercises in the measurement of the vibra- • the modular system enables you to
tion (vibration displacement, velocity and acceleration in the easily create your own experiment
time or frequency domains), field balancing of rigid rotors configurations. Because many defects only become
and shaft alignment exercises can also be carried out. apparent under load, the brake and
• if a special measuring technique load unit PT 500.05 is useful in many
The base unit includes a vibration-damped workholder plate, is already in use, this can be of the experiments.
a speed-controlled drive motor with a tachometer, a shaft integrated into the system with
with two mass discs and two bearing units, a coupling and no problems.
balancing weights.
The belt drive PT 500.14 is also used to
A wide range of accessories enables almost any subject area generate static loads
relating to machinery diagnosis to be covered. or to allow the speed
to be reduced in
many experiments.

Accessory kits
PT 500.14
PT 500.04 PT 500.04 PT 500.14 PT 500.04 PT 500.04
PT 500.10 Elastic shaft PT 500.15 Damage to gears
Unbalanced mass vibration of a Identification of gear damage
flexurally elastic shaft; resonance, from the vibration signal, influence PT 500
PT 500.11 PT 500 PT 500 PT 500.41
PT 500
critical rotation speed, balancing of toothing type and lubrication

PT 500.10
PT 500.12

PT 500.11 Crack detection in rotating shaft PT 500.16 Crank mechanism

Experimental set-up bearing Experimental set-up Experimental set-up Experimental set-up
Vibration behaviour of a cracked Vibration in crank drives, vibrations and balancing shaft with crack bearing damages elastic shaft
shaft, identification of the crack free inertia forces, bumps and
from the vibration signal jolts resulting from bearing play
and wear PT 500.04

PT 500.05
PT 500.04 PT 500.14 PT 500.15 PT 500.04
PT 500.17

PT 500.05
PT 500.12 Roller bearing faults PT 500.17 Cavitation in pumps

PT 500.05
PT 500
PT 500
Identification of bearing damage Noise and damage resulting PT 500
from running noise. from cavitation, conditions for PT 500.04 PT 500
Various pre-damaged roller cavitation inception PT 500.13
bearings

Experimental set-up Experimental set-up Experimental set-up Experimental set-up

PT 500.13 Couplings PT 500.18 Vibrations in fans belt drive gears coupling cavitation

Properties of different coupling Vibration in fans, demonstration

types, influence of eccentricity, of vibration excitation by blade
wobble and pitch fault on passage, influence of centrifugal PT 500.04 PT 500.04 PT 500.04
vibration behaviour force

PT 500.05
PT 500.14

PT 500.18 PT 500
PT 500
PT 500.14 Belt drive PT 500.19 Electromechanical vibrations
Vibration in belt drives, resonance Interaction of electromagnetic/ PT 500.19
and critical rotation speeds, mechanical elements of system,
PT 500.16
influence of belt tension, influence of load, gap geometry
eccentricity and misalignment and electrical asymmetry Experimental set-up Experimental set-up Experimental set-up
vibrations in fans crank mechanism electromechanic vibrations

12 13
 PT 500 Machinery diagnostic system
gunt
Analysis software Instructional material

An analysis software has been specially developed for the For example, a signal can be represented using different We have developed extensive instructional material for the • A comprehensive presentation (slides, CD) outlining the
machine diagnostic system to fully include the required teaching ­methods (time lapse, spectrum, orbit, order analysis). Likewise, PT 500 series. This provides you with an easy introduction to basic principles of machine diagnosis provides an
demands of a training system. the characteristics of acceleration, speed and displacement the demanding area of machine diagnosis. excellent teaching resource.
signals can be clearly repre­sented. The influence of the scan-
Standard systems for industrial use focus on the collection of • A representation of the vibration measurement method The instructional material is professionally designed using clear
ning rate, recording time, sensitivity and time base can also be
data, statistical functions and comprehensive adaptation to a shows the different vibration signals and gives an intro- graphics, and easily understandable text. The principles of vibra-
demonstrated. This enables the trainee to develop a feel for the
variety of tasks. In contrast to these industrial systems, our duction to the measuring technique. The capabilities of the tion measurement can be printed for student handouts.
processes involved in vibration analysis.
software features clearly laid out and easy operation and quick different analysis methods are explained in detail, with their
However, for sustained learning success in this complex and
changes between different analysis methods. This enables the Complicated adjustments and configurations, such as those on advantages and disadvantages.
demanding area, we recommend a solid engineering grounding
advantages and disadvantages of the various methods to be industrial systems, are not required.
• Detailed, illustrated recommended set-ups for practical in machine dynamics, vibration and math­ematics.
highlighted during a measurement process.
experiments in each of the areas of the topic are
included. Example measured results make it easier to
­correctly evaluate independent experiments
gunt PT 500.04 PC BASED EVALUATION SOFTWARE & INSTRUMENTATION KIT
and to identify mistakes.

Manuals with
gunt PT 500.04 PC BASED EVALUATION SOFTWARE & INSTRUMENTATION KIT example results

gunt PT 500.04 PC BASED EVALUATION SOFTWARE & INSTRUMENTATION KIT

gunt PT 500.04 PC BASED EVALUATION SOFTWARE & INSTRUMENTATION KIT

Fundamentals vibration
measurement methods

The following analysis methods PT500-praesentation.html

are available:
PT500-praesentation.html

gunt PT 500.04 PC BASED EVALUATION SOFTWARE & INSTRUMENTATION KIT • oscilloscope

• spectrum analysis
• vibration amplitude measurement
• tracking analysis PT500-praesentation.html

• orbit representation
• envelope analysis
• field balancing in one plane
• field balancing in two planes
Of course, the software is in four
The basic hardware is a measurement languages and has an integrated
amplifier for connection of two ICP acceler- help function.
Easily understandable
ation sensors, two inductive displacement presentation
sensors and an optical reference sensor. When you buy the PT 500
A USB data acquisition system allows a PC training system, you will receive
to be connected directly without making first rate documentation and
any adjustments on the computer. teaching materials.

14 15
Equipment for engineering education

The complete GUNT programme

Engineering mechanics and Mechatronics Thermal engineering

engineering design

• statics • engineering drawing • fundamentals of thermodynamics

• strength of materials • cutaway models • heat exchangers
• dynamics • dimensional metrology • thermal fluid energy machines
• machine dynamics • fasteners and machine parts • internal combustion engines
• engineering design • manufacturing engineering • refrigeration
• materials testing • assembly projects • HVAC
• maintenance
• machinery diagnosis
• automation and process control
engineering

Fluid mechanics Process engineering 2E345

Energy & Environment
• steady flow • mechanical process engineering Energy Environment
• transient flow • thermal process engineering • solar energy • water
• flow around bodies • chemical process engineering • hydropower and • air
• components in piping systems and • biological process engineering ocean energy • soil
plant design • water treatment • wind power • waste
• turbomachines • biomass
• positive displacement machines • geothermal energy
• hydraulic engineering • energy systems
• energy efficiency in buildings

Contact
G.U.N.T. Gerätebau GmbH
Hanskampring 15 -17
22885 Barsbuettel
Germany
+49 40 67 08 54 - 0
Visit our website
sales@gunt.de www.gunt.de
www.gunt.de

Planning and consulting · Technical service · Commissioning and training