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FALIURE MODE EFFECT ANALYSIS OF FLEXIBLE MECHANICAL COUPLINGS USING DAS SYSTEM FOR TORQUE AND VIBRATION MEASUREMENT ON A ROTOR-SHAFT ASSEMBLY
Abstract
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Vibration-Based Condition Monitoring (VBCM) provides essential data to perform Condition-Based Maintenance for efficient, optimal, reliable, and safe industrial machinery operation. However, equipment required to perform VBCM is often relatively expensive. In this paper, a low-cost vibration measurement system based on a microcontroller platform is presented. The FRDM K64F development board was selected as the most suitable for fulfilling the system requirements. The industrial environment is highly contaminated by noise (electromagnetic, combustion, airborne, sound borne, and mechanical noise). Developing a proper antialiasing filter to reduce industrial noise is a real challenge. In order to validate the developed system, evaluations of frequency response and phase noise were carried out. Additionally, vibration measurements were recorded in the industry under different running conditions and machine configurations. Data were collected simultaneously using a standard reference system and the low-cost vibration measurement system. Results were processed using Fast Fourier Transform and Welch’s method. Finally, a low-cost vibration measurement system was successfully created. The validation process demonstrates the robustness, reliability, and accuracy of this research approach. Results confirm a correlation between signal frequency spectrum obtained using both measurement systems. We also introduce new guidelines for practical data storage, communications, and validation process for vibration measurements.
Design of Experiments (DOE) is statistical tool deployed in various types of system, process and product design, development and optimization. It is multipurpose tool that can be used in various situations such as design for comparisons, variable screening, transfer function identification, optimization and robust design. This paper explores historical aspects of DOE and provides state of the art of its application, guides researchers how to conceptualize, plan and conduct experiments, and how to analyze and interpret data including examples. In addition, this paper reveals that in past 20 years application of DOE have been growing rapidly in manufacturing as well as non-manufacturing industries. It was most popular tool in scientific areas of medicine, engineering, biochemistry, physics, computer science and counts about 50% of its applications compared to all other scientific areas.
This paper deals with one of the most common malfunctions in rotative machines: misalignment. Several studies have shown that misalignment produces at least 30% of the faults caused by vibration. In this work, an analysis of energetic losses generated by misalignment in rotative machines has been carried out, with the main objective of finding a correlation between vibration levels, energy consumptions and different degrees of misalignment. A laboratory test rig has been implemented to carry out experimental tests under different degrees of misalignment. Two industrial cases, one from a mining company and another from a thermoelectric company have been included in this study and two different methodologies were used to analyse the results. A statistical model based in the Response Surface Methodology (RSM) was used for the data analysis of one of the industrial cases. A simplified economical study illustrates the advantages for a company, when a preventive and predictive methodology is implemented, with the objective of reducing the energy consumption and keeping low levels of vibration by means of alignment.
Vibration measurement and its real-time graphical representation is often required for analysis of physical conditions of machines, engines as well as in scientific researches, earth-quake amplitude measurement etc. This project work was intended to develop a system for measurement and real-time visualization of vibration. An electronic accelerometer sensor facilitates the vibration sensing procedure. The measured value is then transmitted to the visualization software installed in a personal computer which provides quantitative and qualitative information about the vibration phenomena in addition with a real-time graphical visualization feature. Two test cases were selected to verify the performance of the system. The first one was implemented to visualize and measure vibration parameters of a simple plastic stand, and the second one was intended to test the system performance on an induction motor for measurement and visualization of its horizontal vibration parameters. The performance analysis in the above mentioned cases confirms the stability and reliability of the system in vibration analysis for frequency range up to 5 kHz. This concludes to a low cost vibration analysis system for uses in medium range vibration analysis like earth quake monitoring, machine vibration level monitoring etc. Though there are many available vibrations analysis systems are available, this paper work is intended to derive the process of building a low cost PIC microcontroller and C# .NET based vibration analysis system for general purpose uses like laboratory equipment or study material from commercially available equipment
A major cause for the production of higher harmonic forces on the rotating system is the Misalignment between the shafts. This in-turn produces vibrations during the function of any turbine unit that can bring about untimely wear of bearings, loosening of disparate fasteners, and crash of the entire installation. Good efficiency can well be ensured by means of the proper alignment with the rotating elements’ motor axis. And it also makes sure that the motion and power transmission happens devoid of significant loss. The misalignment can well be found if there is a variation on the torque at the motor end. Along with it, the misalignment can well be detected by the torque variation. Here, utilizing the theoretical relationship betwixt the deflection factor and harmonic bending force generated on a formed test rig, the torque and power surge are simulated. Aimed at the data analysis, a statistical design centered upon the Responses Surface Methodology (RSM) is employed. The outcomes are plotted utilizing the Box-Behnken (BB) model to perform a simplified economical study that exhibits when a preventive in addition to predictive methodology can well be applied in the instance of misalignment.
Experimental studies were performed on a rotordynamic test apparatus to verify the theoretical model of shaft misalignment and rotor unbalance. A self-designed simplified flexible coupling and a commercial helical coupling were used in the experiments. The rotor shaft displacements were measured under the different misalignment and unbalance conditions. The measured and predicted frequency spectra were obtained. The theoretical predictions are in good agreement with the experimental measurements. Both the measured and predicted spectra show that unbalance and misalignment can be characterized primarily by one and two times shaft running speed, respectively. However, misalignment effects at times may not be apparent because the forcing frequency of misalignment (2 × shaft running speed) is not close enough to one of the system natural frequencies to excite the system appreciably. Therefore, in some cases the misalignment response is hidden and does not show up in the vibration spectrum. On the other hand, if 2 × shaft running speed is at or close to one of the system natural frequencies, the misalignment effect can be amplified and a high frequency density level at 2 × shaft running speed is pronounced in the frequency spectrum.
Design and Manufacturing of a Test Rig for Experimental Studies on Misalignment Effect Between Rotors
- Mili Hota
- V D Dhiman
Hota, Mili, and V. D. Dhiman. 2022. "Design and Manufacturing of a Test Rig for Experimental Studies
on Misalignment Effect Between Rotors." Lecture Notes in Mechanical Engineering: 265-79.
Vibration responses of parallel misalignment in Al shaft rotor bearing system with rigid coupling
- D P Hujare
- M Karnik
Hujare, D. P. & Karnik, M. (2018). Vibration responses of parallel misalignment in Al shaft rotor bearing
system with rigid coupling. Materials Today: Proceedings Journal. 5.0(11.0), 23863.0-23871.0.
Available from: 10.1016/j.matpr.2018.10.178