SIGNATURE ANALYSIS

Which

frequencies exist and what are the relationships

to the fundamental exciting frequencies.
What are the amplitudes of each peak
How do the peaks relate to each other
If there are significant peaks, what are their source

COUPLE UNBALANCE

1800 out

of phase on the same shaft

1X RPM always present and normally dominates
Amplitude varies with square of increasing speed
Can cause high axial as well as radial amplitudes
Balancing
g requires
q
Correction in two p
planes at 180o

OVERHUNG ROTOR UNBALANCE

1X

RPM present in radial and axial directions

Axial readings tend to be in-phase but radial readings
might
g be unsteadyy
Overhung rotors often have both force and couple
unbalance each of which may require correction

Diagnosing Unbalance
Vibration frequency
equals rotor speed.
Vibration
Vib ti predominantly
d i
tl
RADIAL in direction.
Stable vibration phase
measurement.
V
Vibration
b
o increases
c e ses ass
square of speed.
Vibration phase shifts in
direct proportion to
measurement direction.

900

900

ECCENTRIC ROTOR

Largest

vibration at 1X RPM in the direction of the

centerline
t li off the
th rotors
t
Comparative phase readings differ by 00 or 1800
Attempts
Att
t tto b
balance
l
will
ill cause a decrease
d
iin amplitude
lit d
in one direction but an increase may occur in the other
direction

ANGULAR MISALIGNMENT

Characterized

by high axial vibration

1800 phase change across the coupling
Typically high 1 and 2 times axial vibration
Not unusual for 1, 2 or 3X RPM to dominate
Symptoms
y p
could indicate coupling
p gp
problems

PARALLEL MISALIGNMENT
1x

2x
4x

Radial

radial vibration 1800 out of phase

Severe conditions give higher harmonics
2X RPM often larger than 1X RPM
Similar symptoms to angular misalignment
Coupling design can influence spectrum shape and
amplitude
High

BENT SHAFT

Bent

shaft problems cause high axial vibration

1X RPM dominant if bend is near shaft center
2X RPM dominant if bend is near shaft ends
Phase difference in the axial direction will tend
towards 1800 difference

MISALIGNED BEARING

Vibration

symptoms similar to angular misalignment

Attempts to realign coupling or balance the rotor will not
alleviate the problem.
Will cause a twisting motion with approximately 1800
phase shift side to side or top to bottom

OTHER SOURCES OF HIGH AXIAL

VIBRATION
a. Bent Shafts
b. Shafts in Resonant Whirl
c. Bearings Cocked on the Shaft
d. Resonance of Some Component
p
in the Axial
Direction
e. Worn Thrust Bearings
f. Worn Helical or Bevel Gears
g. A Sleeve Bearing Motor Hunting for its Magnetic
Center
h. Couple Component of a Dynamic Unbalance

MECHANICAL LOOSENESS ((A))

Caused

byy structural looseness of machine feet

Distortion of the base will cause soft foot problems
Phase analysis will reveal aprox 1800 phase shift in the
vertical direction between the baseplate components of
the machine

MECHANICAL LOOSENESS (B)

Caused

by loose pillowblock bolts

Can cause 0.5, 1, 2 and 3X RPM
Sometimes caused by cracked frame structure or
bearing block

SLEEVE BEARING
WEAR / CLEARANCE PROBLEMS

Later

stages of sleeve bearing wear will give a large

family of harmonics of running speed
A minor unbalance or misalignment will cause high
amplitudes when excessive bearing clearances are
presentt

COMPONENT FREQUENCIES OF A SQUARE

WAVE FORM
FORM.

COMPONENT FREQUENCIES OF A SQUARE

WAVE FORM
FORM.

MECHANICAL LOOSENESS (C)

Phase

is often unstable
Will have many harmonics
Can be caused by a loose bearing liner, excessive
bearing clearance or a loose impeller on a shaft

ROTOR RUB
Truncated waveform

Similar

spectrum to mechanical looseness

Usually generates a series of frequencies which may
excite natural frequencies
Subharmonic frequencies may be present
Rub may be partial or through a complete revolution.
revolution

RESONANCE

Resonance

occurs when the Forcing Frequency

coincides
i id with
ith a Natural
N t l Frequency
F
1800 phase change occurs when shaft speed passes
through resonance
High amplitudes of vibration will be present when
a system
y
is in resonance

BELT PROBLEMS (D)

BELT RESONANCE
RADIAL
1X RPM

BELT RESONANCE

High

amplitudes can be present if the belt natural

frequency coincides with driver or driven RPM
Belt natural frequency can be changed by altering the
belt tension

BELT PROBLEMS (A)

WORN,
WORN LOOSE OR MISMATCHED BELTS

BELT FREQUENCY
HARMONICS

Often

2X RPM is dominant
Amplitudes are normally unsteady, sometimes pulsing
with either driver or driven RPM
Wear or misalignment in timing belt drives will give high
amplitudes at the timing belt frequency
Belt frequencies are below the RPM of either the driver
or the driven

BELT PROBLEMS (C)

ECCENTRIC PULLEYS

1X RPM OF
ECCENTRIC
PULLEY

Eccentric

or unbalanced pulleys will give a high 1X

RPM of the pulley
The amplitude will be highest in line with the belts
Beware of trying to balance eccentric pulleys

RADIAL

BELT PROBLEMS (B)

BELT / PULLEY MISALIGNMENT

1X DRIVER
OR DRIVEN

Pulley

misalignment will produce high axial vibration

at 1X RPM
Often the highest amplitude on the motor will be at the
fan RPM

HYDRAULIC AND
AERODYNAMIC FORCES
BPF = BLADE PASS
FREQUENCY

If

gap between vanes and casing is not equal, Blade

Pass Frequency may have high amplitude
High
Hi h BPF may be
b present if impeller
i
ll wear ring
i seizes
i
on shaft
Eccentric rotor can cause amplitude at BPF to be
excessive

HYDRAULIC AND
AERODYNAMIC FORCES

FLOW TURBULENCE

Flow

turbulence often occurs in blowers due to

variations in pressure or velocity of air in ducts
Random low frequency vibration will be generated,
possibly in the 50 - 2000 CPM range

HYDRAULIC AND AERODYNAMIC

FORCES

CAVITATION

Cavitation

will generate random, high frequency

broadband energy superimposed with BPF harmonics
Normally indicates inadequate suction pressure
Erosion of impeller vanes and pump casings may
occur if left
l ft unchecked
h k d
Sounds like gravel passing through pump

BEAT VIBRATION
WIDEBAND SPECTRUM

F1

F2
ZOOM
SPECTRUM

beat is the result of two closely spaced frequencies

going into and out of phase
The wideband spectrum will show one peak pulsating up
and down
The
Th diff
difference b
between
t
th
the peaks
k iis th
the b
beatt ffrequency
which itself will be present in the wideband spectrum

ELECTRICAL PROBLEMS
STATOR ECCENTRICITY
SHORTED LAMINATIONS
AND LOOSE IRON

Stator

problems generate high amplitudes at

2FL (2X line frequency )
Stator eccentricity produces uneven stationary air
gap, vibration is very directional
Soft
S ft ffoott can produce
d
an eccentric
t i stator
t t

FREQUENCIES PRODUCED BY ELECTRICAL

MOTORS.
Electrical line frequency.(FL
frequency.(FL)) = 50
50Hz
Hz = 3000 cpm.
60HZ
60
HZ = 3600 cpm
p

No of poles. (P)
Rotor Bar Pass Frequency (Fb
(Fb)) = No of rotor bars x
Rotor rpm.

Synchronous speed (Ns

N )
Ns)

2xFL
P

y ( FS ))= Synchronous speed - Rotor rpm.

Slip frequency
Pole pass frequency (F
(FP )= Slip Frequency x No of Poles.

ELECTRICAL PROBLEMS

SYNCHRONOUS MOTOR
(Loose Stator Coils)

Loose

stator coils in synchronous motors generate high

amplitude at Coil Pass Frequency
The
Th coil
il pass ffrequency will
ill be
b surrounded
d d by
b 1X
RPM sidebands

ELECTRICAL PROBLEMS

POWER SUPPLY
PHASE PROBLEMS
(Loose Connector)

Phasing

problems can cause excessive vibration at 2FL

with 1/3 FL sidebands
Levels at 2FL can exceed 25 mm/sec if left uncorrected
Particular problem if the defective connector is only
occasionally
i
ll making
ki contact
t t

ELECTRICAL PROBLEMS
ECCENTRIC ROTOR
(Variable Air Gap)

Eccentric

rotors produce a rotating variable air gap,

this induces pulsating vibration
Often requires zoom spectrum to separate 2FL and
running speed harmonic
Common values of FP range from 20 - 120 CPM

ELECTRICAL PROBLEMS

DC MOTOR PROBLEMS

DC

motor problems can be detected by the higher than

normal amplitudes at SCR firing rate
These
Th
problems
bl
iinclude
l d b
broken
k fi
field
ld windings
i di
Fuse and control card problems can cause high amplitude
peaks at frequencies of 1X to 5X Line Frequency

ELECTRICAL PROBLEMS
ROTOR PROBLEMS

1X,

2X, 3X, RPM with pole pass frequency sidebands

indicates rotor bar problems.
2X line frequency sidebands on rotor bar pass
frequency (RBPF) indicates loose rotor bars.
Often
Oft high
hi h levels
l l att 2X & 3X rotor
t b
bar pass ffrequency
and only low level at 1X rotor bar pass frequency.

ROTOR BAR FREQUENCIES

(SLOT NOISE)
POLE

POLE

MINIMUM

MAXIMUM

MAX

MIN

CALCULATION OF GEAR MESH

FREQUENCIES
1700 RPM
51 TEETH
31 TEETH
20 TEETH

8959 RPM -- HOW MANY TEETH ON THIS GEAR?

GEARS
NORMAL SPECTRUM

2625 rpm
8 teeth

GMF= 21k CPM

1500 rpm
14 teeth

Normal

spectrum shows 1X and 2X and gear mesh

frequency GMF
GMF commonly will have sidebands of running speed
All peaks are of low amplitude and no natural
f
frequencies
i are presentt

GEARS
TOOTH LOAD

Gear

Mesh Frequencies are often sensitive to load

High GMF amplitudes do not necessarily indicate a
problem
Each analysis should be performed with the system at
maximum load

GEARS
TOOTH WEAR

8 teeth
2625 rpm

GMF = 21k CPM

14 teeth
1500 rpm

Wear

is indicated by excitation of natural frequencies

along with sidebands of 1X RPM of the bad gear
Sidebands are a better wear indicator than the GMF
GMF may not change in amplitude when wear occurs

GEARS
GEAR ECCENTRICITY AND BACKLASH

Fairly

high amplitude sidebands around GMF suggest

eccentricity, backlash or non parallel shafts
The problem gear will modulate the sidebands
Incorrect backlash normally excites gear natural
q
y
frequency

GEARS
GEAR MISALIGNMENT

Gear

misalignment almost always excites second order

or higher harmonics with sidebands of running speed
Small amplitude at 1X GMF but higher levels at 2X
and 3X GMF
Important to set Fmax high enough to capture at least
2X GMF

GEARS
CRACKED / BROKEN TOOTH
TIME WAVEFORM

cracked or broken tooth will generate a high

amplitude at 1X RPM of the gear
It will excite the gear natural frequency which will be
sidebanded b
by the rrunning
nning speed ffundamental
ndamental
Best detected using the time waveform
Time
Ti
iinterval
t
l between
b t
iimpacts
t will
ill be
b the
th reciprocal
i
l off
the 1X RPM

Nb

Bd COS

Pd
BSF =

2Bd

FTF =

1
2

Note : shaft turning

outer
t race fi
fixed
d
F = frequency
eque cy in cp
cpm
N = number of balls

1 - Pd

Bd

XRPM

X RPM

(1 - ( P COS XRPM
B
(1-P COS X RPM
d

BPFO =

1 + Pd COS

((

D1

Bd

DB

BPFI =

Nb

D0

ROLLING ELEMENT BEARINGS

STAGE 1 FAILURE MODE
ZONE A

ZONE B

ZONE C

ZONE D

gSE

Earliest

indications in the ultrasonic range

These frequencies
q
evaluated by
y Spike
p
Energy
gyTM ggSE,,
HFD(g) and Shock Pulse
Spike Energy may first appear at about 0.25 gSE for this
first stage

ROLLING ELEMENT BEARINGS

STAGE 2 FAILURE MODE
ZONE A
ZONE B

ZONE C ZONE D
gSE

Slight

defects begin to ring bearing component natural

frequencies
q
These frequencies occur in the range of 30k-120k CPM
At the end of Stage 2,
2 sideband frequencies appear above
and below natural frequency
Spike Energy grows e
e.g.
g 0.25-0.50gSE
0 25 0 50gSE

ROLLING ELEMENT BEARINGS

STAGE 3 FAILURE MODE
ZONE A

ZONE B

ZONE C

ZONE D
gSE

Bearing

defect frequencies and harmonics appear

Many defect frequency harmonics appear with wear the number of
sidebands grow
Wear
W
is
i now visible
i ibl and
d may extend
t d around
d the
th periphery
i h
off th
the
bearing
Spike Energy increases to between 0.5
0 5 -1.0
1 0 gSE

ROLLING ELEMENT BEARINGS

STAGE 4 FAILURE MODE
ZONE A

ZONE B

ZONE C
gSE

High just prior

to failure

Discreet

bearingg defect frequencies

q
disappear
pp
and are replaced
p
by
y
random broad band vibration in the form of a noise floor
Towards the end, even the amplitude at 1 X RPM is effected
High
Hi h frequency
f
noise
i floor
fl
amplitudes
lit d and
d Spike
S ik Energy
E
may in
i
fact decrease
Just prior to failure gSE may rise to high levels

GEARS
HUNTING TOOTH
fHt = (GMF)Na
(TGEAR)(TPINION)

Vibration

is at low frequency and due to this can often

be missed
b
i d
Synonymous with a growling sound
The
Th effect
ff t occurs when
h th
the ffaulty
lt pinion
i i and
d gear
teeth both enter mesh at the same time
Faults may be due to faulty manufacture or
mishandling

OIL WHIP INSTABILITY

oil whip

oil whirl

Oil

whip may occur if a machine is operated at 2X

the rotor critical frequency.
When the rotor drives up to 2X critical, whirl is
close to critical and excessive vibration will stop
the oil film from supporting the shaft.
shaft
Whirl speed will lock onto rotor critical. If the
speed is increased the whipfrequency will not
increase.

OIL WHIRL INSTABILITY

Usually

occurs at 42 - 48 % of running speed

Vibration amplitudes are sometimes severe
Whirl is inherently unstable, since it increases
centrifugal forces therefore increasing whirl forces