Chapter- 8

MODAL ANALYSIS AND CONDITION MONITORING

Syllabus: Signal analysis, dynamic testing of machines and structures, Experimental modal
analysis, Machine condition monitoring and diagnosis.

Dynamic testing of machine structure II method: Using modal testing

involves the finding the deformation of Any dynamic response of a machine can
machines at a critical frequency. Dynamic be obtained as a combination of its
modes a knowledge of mode shapes,
testing is a valuable complement to dynamic
modal frequencies and modal damping
analysis. ratios constitute a complete dynamic
description of the machine.
It can be done using the following:
EXPERIMENTAL MODAL ANALYSIS:
I method: Forced dynamic deflection shape
Basic idea
measured under steady state frequency of
1. When a structure machine or any
system.
system is excited its response exhibits
It involves an accelerometer is mounted at
a sharp peak at resonance.
some point on the machine as a reference
2. The phase of the response changes
and another moving accelerometer is placed
by 180° as the forcing frequency
at several other points and in different
crosses the natural frequency of the
directions. The magnitude and phase
structure or machine.
differences between the moving and
stationary ( reference) accelerometer at all
The necessary equipment
points under steady state operation of the
1. An exciter or source of vibration to
system are measured. By plotting these
apply a known input force to
we can find the deflection of parts of
structure.
machine move relative to another. Using
operational deflection shape measurements.
The deflection shape measured is valid only
for the force/frequency associated with the
operating conditions.

2. A transducer to convert the physical

motion of the structure or machine into
electrical signal. It translates changes in
mechanical quantities (such as
displacement, velocity, acceleration or
force) into electrical signals (such as
voltage or current).

Mr. Venkatesh B K Dept. of Mechanical Engg. NCET, Bangalore Page 1

3. A signal conditioning amplifier to
make the transducer characteristic
compatible with the input electronics.
4. An analyzer to perform the tasks of
signal using suitable software.
Exciter
The exciter may be an electromagnetic
shaker or an impact hammer , the
electromagnetic shaker can provide large
impact forces so that the response can be
measured easily. The excitation signal is
usually of a swept sinusoidal or random
type signal. Usually shaker is attached to
the structure or machine through the short
thin rod called a stringer to isolate the
shaker ,reduce the added man and apply
the force to structure or machine.
frequencies damping ratio’s and mode
shapes either in numerical or graphical form.
Digital signal processing
The analyzer converts the analog time
domain signals X(t)in to digital frequency-
domain data using Fourier series relations to
facilate digital computation. Thus the
analyzer accepts the analog output signals of
accelometers or force transducers, X(t) and
computes the spectral co-efficient of signals
a0,an and bn in frequency domain. The
process of converting analog signals in to
digitals is indicated in the Figure.

Transducer
Among the transducer the piezo electric
transducer are most popular. A piezo electric
transducer can be designed to produce
signals proportional to either force or
acceleration. In acceleration, the piezo
electric material acts as a stiff spring that
causes the transducer to have a resonant or
natural frequency.
X(t) – analog signal, X(ti)- represents
corresponding digital record with ti indicates
Signal conditioner
Since the output impedance of transducer is its discrete value of time.
If N no of X(t) is collected as discrete value
not suitable for direct i/p to the signal
of time ti the data.
analysis equipment, signal conditioner in the
form of charge or voltage amplifiers are X1 (ti) X2 (ti) –XN (ti).
used to match and amplify.
Xj=X(tj) =
Analyzer )
The response signal, after conditioning is ao =
sent to analyzer for signal processing. A
commonly used analyzer is called a fast
Fourier transform analyzer. Such as analyzer bi=
receiver analog voltage signals form a signal
conditioning amplifier, filter and digitizer The equation can be expressed in matrix
for computations. It computes the discrete
form,
frequency spectra of individual signals as
well as cross-spectra between the input and
the different output signals. The analyzed
signals can be used to find the natural Computed using FFT by the analyzer.

Mr. Venkatesh B K Dept. of Mechanical Engg. NCET, Bangalore Page 2

Analysis of random signals:-
The out and input data measured by the
transducers usually contains some random
component or noise that make it difficult to
analyses. In a deterministic manner in some
case random excitation is used is vibration
testing. Thus random signal analysis
becomes necessarily in vibration testing.
If X(t) is a random signal. The average or
mean denoted as
Corresponding to any random signal y(t)and
a new variable x(t) as x(t)= y(t)- y(t) so that
mean value of x(t)is zero. Hence without
loss generating we can assume that X(t) to
have a zero mean and define the mean
X(t
)
t
square value or variance of X(t).
The root mean square velocity (rms)
Xrms=
The auto co relation function of random
signal X(t) denoted as R(t). It gives the
measure of the speed with which the
changes in the time domains
S
Mr. Venkatesh B K
S(w) is power spectral density of random
signal x(t) denoted as s(w), gives the
measure of speed with which the signal
change is frequency domains.
Co-herence function; A function known as B
is defined as a measure of noise presents in
signal.
Determination of modal data from
observed peaks:-
The frequency response function H(iw) can
be used to find the natural frequency,
damping ratio, and mode shapes,
corresponding to all resonant peaks. Let the
graph of frequency – function as shown in
below.
The response output from the system being
tested can be modeled as four degree of
freedom if the resonance frequency closely
spaced in graph H(iw).
Here frequencies ranges are proportioned
these are considered as the frequency
response function of a single degree of
freedom. This mode represents a resonance
point corresponding to a phase angle to be
900 at each of the peaks.
The damping ratio is given by.
and are known as half
power points
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1. Since the damping is small it can be
considered approximately equal to
undammed natural frequency of system.
2. Determination of model data from
nyquist plot.
3. Determination of modal data from bode
plot.
4. Measurement of mode shapes.
Machine condition monitoring and
diagnosis
Failur
e Machine condition Monitoring
time
Machine maintenance technique
The life of machine follow classical bath tub
curve shown in above figure of a machine is
usually characterized by increase in
vibration. The vibration level decreases
during initial condition. They remains
constant in normal condition and increase
rapidly due to serve wear out.
Three types of maintenance schemes can be
used
1) Break down maintenance.
2) Preventive maintenance.
3) Condition based maintenance.
1) Break down maintenance:
The machine is allowed to fail, at which
time the failed, machine is replaced by new
one. This strategy can be used if machine is
in expressive.
2) Preventive maintenance:
Maintenance is performed at fixed intervals
such as very 3000 operating hours or once
year. In intervals are determined statistically
from past experience. This method is found
to be uneconomical.
Mr. Venkatesh B K
3) Condition based maintenance:
The fixed- interval over hours are replaced
by fixed –interval measurements that permit
the observation of changes in the running
condition of the machine regularly. These
vibrations are measured regularly. If
vibration levels are unacceptable the
machine should be serviced. This is also
called predictive maintenance. In this
method the maintance casts are greedily
reduced due to fewer catastrophic failures.
Machine condition monitoring
techniques:
Variables
Operation
Temp
Debris
Wear
Auras
Visusa
Vibration
Several methods can be used to monitor the
condition of a machine.
Machine condition monitoring
Auras & visual: These are basics forms of
monitoring technique in which skilled
technician, having an intimate knowledge of
machine can identify the faults by listen its
sounds; visually observing large amplitude
by using stroboscope, microphone.
Ope ration variables: It’s a duty cycle
monitoring performance of m/c is observed
with regard to its intended duty any
deviation from intended duty denotes
malfunction of m/c.
Temp involves measuring of surface temp of
machine devices used are optical pyrometer,
thermo couple, thermo graphy.
Wear debris: Wear debris is generated as
relative moving surfaces of load-bearing m/c
elements. The wear particles can be found in
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lubricating oils or grease can be used to
arren the extent of damage.
Machine vibration mounting technique
1. Time domain technique
a) Wave form
b) Shaft orbits
c) Statistical analysis
2. Frequency domain technique
3. Quefrency domain
Time domain analysis:
Time wave form: time domain analysis
uses the time history signal. The signal is
stored in an oscilloscope or real time
analyses are any non steady impulses are
noted.
Discrete damage such as broken teeth is
gears and crack in inner or outer races are
shown by wave form of gear box.
This indication that acceleration wave form
pulses occur periodically with period of 20
millisecs. This origin of signals can be
attributed to broken gear tooth.
Shaft orbit : Certain patterns called orbit
can be obtained by displacing time
waveform obtained from two transducer
whose outputs are shifted by 90o. Any
change in pattern of these figure or orbit can
be used to identify faculty such as
misalignment in shaft, unbalance in shaft,
shaft rub, and wear in journal bearings.
Statistical methods:
Probability density curve: All vibration
signals will have a characteristic shape for
its probability density curve. The probability
Mr. Venkatesh B K
density of a signal can be defined on the
probality of finding its instantaneous
amplitude within a certain range. The good
conditioned components will have a bell
shaped probability density curve similar to
normal distribution.
Moments of probability density curve can be
used for the machine condition monitoring.
These are similar in mechanical moments
about the centroidal axis of area.
Frequency domain analysis:
Frequency spectrum: It is a plot of the
amplitude versus frequency. It can be
derived by using digital fast Fourier analysis
of time waveform. The vibration response of
machine is governed not only by its
assembly, mounting and installation. As
long as the excitation force remains constant
the measured vibration level of the machine
also remains constant. By comparing the
frequency spectrum of machine in good
condition and as in faulty condition, the
nature and location of the fault can be
detected.
Quefrency domain analysis: Quefrency
serve as the abscissa for a parameter known
as cepstrum similar to frequency that serves
as the abscissa for the parameter spectrum.
Cepsturn is useful in machine condition
monitoring and diagnosis since it can detect
any periodity to the spectrum caused by the
failure of components such as blade in
turbine and gear tools in a gear box.
***BEST OF LUCK***
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