Vibration analysis and interpretation is often considered to be a "black art". However, when combined with extensive practical experience and an intuitive understanding of the way machines and structures respond, it can be a very powerful tool for applications such as Condition Monitoring, Quality Control, Fault Diagnosis and Structural Vibration. This can even be the case where conventional wisdom might conclude that there is insufficient information available for an accurate diagnosis - therein lies both the art and the "thrill" for an engineer.
Turbo Compressor Fault
Vibration analysis indicated that the compressor was surging which would cause damage and probably require a strip-down. However, by identifying precisely what was happening mechanically within the compressor and discussing the results with an AC expert, the fault was diagnosed as a gas shortage causing liquid to flash across the expansion valve - cured by re-charging. This sample illustrates the power of non-invasive fault identification.
Engine Test Rig
Persistent propshaft failures were compromising engine test programmes. Vibration analysis was used to diagnose the problem as strong coupling between the response of the engine on its mounts and a structural mode of the engine pallet. The solution was designed and fitted within an hour (a simple steel channel welded across the pallet was all that was required).
Coating Machine Quality Control
A gravure coating line was producing striations on the thin aluminium web (due to film thickness variations). As the marking wavelength was independent of line speed, a resonance was diagnosed. This was traced (using a non-contacting probe) to web vibration at a specific point in the coating head. The solution designed was a simple, low cost web damper.
Mill Bearing Failures
Bearing failures on a food processing mill continually recurred despite careful overhauls. Vibration signature comparisons with a second mill indicated a loose rear bearing. This diagnosis was confirmed in strip-down - the rear bearing was found to be turning in its housing.
Gearbox Faults
The motor/gearbox on a large fermentation vessel suffered varying motor current and intermittent noise. Downtime would be costly due to the production schedule. Single point vibration analysis indicated excessive input shaft float - very unlikely (due to the construction) but confirmed later on partial strip-down (25 thou v 6 thou specification). Pinpoint accuracy.
Pipe Vibration Control - Dynamic Vibration Absorbers
We have developed an elegant dynamic vibration absorber that can simply be bolted to pipe work or other structures to reduce vibration by 90-99%. Technically, this is very satisfying as the absorber is small, efficient and "sexy" ... a recent installation on petrochem pipe work (illustrated right) generated a constant stream of curious staff wanting to see how such a small device could have such a big effect!
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