SpectraQuest Vibration Simulation Learning Lab
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Courses
Learning Lab Sessions
Please join SpectraQuest for Hands-on Workshops on Vibration Analysis
SpectraQuest is a leading developer and manufacturer of world class Machinery Fault Simulators. We will offer two inter-active workshops and five structured hands-on demonstrations at our Learning Lab. The emphasis of all workshops and labs will be a hands-on approach. We strongly believe that one learns best by “touch, feel, and sense” performing controlled experiments using devices that emulate real world machinery scenario.
SpectraQuest Learning Lab will provide attendees with a unique approach to learn vibration analysis using theory/lectures followed by real time demonstration of different types of faults. The approach involves a classroom with several workstations set up for carrying out controlled exercises. Each workstation will consist of a Machinery Fault Simulator, a multi-channel data acquisition system, simulation and analysis software, fully wired sensors, and necessary accessories such as tachometer, strobe, etc. All workstations will be networked enabling the instructor to project the results on a large screen for explanation/discussion to maximize your benefits. You will have an opportunity to conduct controlled experiments, acquire data, perform analysis, and ask our experts to clarify your questions/doubts.
Courses
Workshop-1
Monday, December 5 – 8:00AM to 4:00PM
WS8 – Fundamentals of Signal Processing for Optimizing Benefits of Vibration Analysis
A sound understanding of signal processing is essential to maximizing the benefits of a condition monitoring program using vibration analysis technology. This workshop will provide attendees with the fundamental principles of digital signal processing. The basics of vibration data analysis will be presented in a simplified manner without resorting to the underlying complex mathematical structure. Students will learn how to utilize their existing vibration analysis tools to extract the maximum information from the vibration signal. The benefits will include how to determine the sampling rate, resolution, max frequency, how to distinguish if you are missing a frequency component in your selected resolution, and much more.
The attendees will also be able to clarify the concepts using SpectraQuest’s Signal Processing and Simulation software. Several workstations will be available to try out the software. Attendees will be able to perform computer simulation exercises involving different waveforms, frequency spectra, resolution, frequency lines, aliasing, effects of leakage and ways to compensate, various window functions, data smoothing by averaging, modulations and zero padding.
The workshop will cover the following topics:
- Types of signals and their representation
- Fourier Analysis: series/transform
- Digitizing and data acquisition hardware issues
- FFT and step-by-step explanation of the calculation process
- Data sampling, resolution, max frequency
- Aliasing, leakage and windowing
- Signal noise and different types averaging
- Measurement uncertainties and how to minimize
- Pitfalls of the FFT process: digitization, truncation, discrete frequency sampling (or picket fence effect)
- Enveloping and demodulation
- Order analysis (or tracking)
- Preliminary discussion of advanced topics such as cepstrum, filtering, and signal separation
Workshop-2
Tuesday, December 6 – 1:00PM to 4:00PM
Signature Analysis of Cavitation in Centrifugal Pumps
Timely detection of the occurrence of cavitation in pumps is very important as it can cause pitting, erosion, and loss of pump performance. Attempts to determine a unique signature of cavitation using vibration, acoustic emission, audible-acoustics, and higher order non-linear modeling techniques have been elusive. This workshop will provide an overview of the cavitation process: how it develops, how to detect it using vibration analysis, and some prevention techniques. Live demonstration of cavitation will be presented using SpectraQuest test set-ups and data acquisition along with analysis software, VibraQuest.
Tests will be performed to measure vibration, dynamic pressure, audible sound, motor current and the force due to cavitation of a centrifugal pump. We have developed a special force transducer for measuring fluctuating forces exerted by cavitation. This will be used to better understand the dynamics of cavitation phenomenon and signatures of a centrifugal pump operating under different cavitation conditions. The pump will be fitted with a LEXAN cover to see a live demonstration of bubble formation leading to the development of severe cavitation.
SpectraQuest’s Vibration Analysis and Machine Fault Diagnosis Learning Lab – Learning Zone
Wednesday, December 7 Sessions
Session 1 &2 – 9:45AM – 11:45 AM
Belt Natural Frequencies and Vibration Analysis
In vibration analysis of machine with belt drives, it is essential to understand the dynamic behavior of belts. Because of its special physical characteristics, there are many unclear issues regarding belt vibration analysis in the system. This hands-on workshop will provide attendees an opportunity to learn the dynamic characteristics and vibration analysis of belt drives. We will show you procedures to perform hammer test to determine belt natural frequencies. Experiments will be performed to demonstrate the relationships between belt natural frequencies and tension. Results will be analyzed to determine if belts can be modeled as a string or a beam. Tests will also be conducted to show the effects of belt misalignment and eccentric sheave on vibration spectra. The SpectraQuest fully instrumented Machinery Fault Simulator, a multi-channel data acquisition, and analysis software will be used for this workshop.
Session 3 – 1:00 PM – 2:00 PM
Hands-on Demonstration of Misalignment Vibration Signatures
Misalignment is a common cause of machinery malfunction. Considering the importance of alignment, the vibration spectrum of misalignment is not well documented. This workshop will provide you with an opportunity to learn vibration signatures of misalignment under different operating conditions. The effects of speed, type and level of misalignment, and coupling types on the vibration signature for misalignment will be discussed and demonstrated. The SpectraQuest Machinery Fault Simulators will be used to create the varying mechanical conditions.
Session 4 – 2:00 PM – 3:00 PM
Vibration Signature of Unbalance Overhung Rotors
Rotating machinery with overhung rotors is very common in industry. Vibration analysis and balancing of overhung rotors is lot more challenging than the center hung rotor configurations. Two-plane balancing of overhung rotors is one of the most challenging problems that a maintenance engineer may encounter. The first step is to perform a successful diagnosis of unbalanced overhung rotor system. The vibration and force signatures of unbalanced overhung rotors are different from those of the systems with center hung rotors.
This hands-on workshop will present vibration signature of one and two plane unbalanced overhung rotors. Experiments will be carried out on a Machinery Fault Simulator (MFS) for both balanced and unbalanced rotor systems. The data will be analyzed using the VibraQuest software. Attendees will have opportunities to analyze the results and learn.
Session 5 – 3:30 PM – 4:30 PM
Rolling Element Bearing Defect Vibration Analysis
Prompt diagnostics of rolling element bearing faults is critical not only for the safe operation of machines, but also for the reduction of down time and maintenance cost. This workshop will provide you an opportunity to collect vibration data on intentionally faulted bearings. Bearings with inner race, outer race, and ball defect will be provided. Attendees will be able to study the effects of speed and loading conditions on fault spectra.
Most commercial vibration data loggers and analyzers are using diagnostic technology developed twenty years ago. Many new developments have occurred since that time in applied signal processing. SpectraQuest has developed some of the most advanced bearing defect diagnosis algorithms. You will be able to use them to learn the analysis capabilities of the latest developments.
Session 6 – 4:30 PM – 5:30 PM
Whirl and Whip Phenomenon in Rotors
Oil whirl could be a serious problem for rotors operating with journal bearings. As the oil whirl frequency approaches the first critical speed of the shaft as the shaft exceeds more than two times its first critical speed, a dangerous resonant condition is created. The whirl turns into the oil whip. The oil whip frequency remains constant at the first critical speed of the shaft even at increasing shaft speeds. And it drops out only when shaft speed drops below two times its first critical speed. Both of these phenomena are serious and result in a breakdown of the lubrication film. When this happens, the shaft starts impacting against the bearing. This could cause serious damage to the system.
This interactive workshop will present a brief overview of oil whirl/whip phenomenon. Experiments will be conducted to demonstrate the rotor whirl/whip. The effects of load on the onset of oil whirl and whip will be presented. We will also describe the effects of bearing clearance on damping and whirl. Both time-frequency and obit plots will be used to describe the results. Attendees will have an opportunity to analyze the data to enhance learning.
Thursday, December 8 Sessions
Session 7& 8 – 9:45 PM – 11:45 AM
Resonance and Critical Speeds in Rotating Machinery: Basic Theory, how to measure and develop control strategies
All objects exhibit natural frequencies, whenever modal inertia forces are balanced with the associated elastic forces. Physically, energy is confined within the boundaries of the structure and cannot escape or dissipate quickly, creating standing wave deformations at the natural frequencies. Resonance is a condition of large amplitude oscillation when an object is excited at a natural frequency by a tiny force. Since resonance results in large amplitude vibration that can be both noisy and destructive, it is essential to avoid operation of a machine under such conditions.
This workshop will provide attendees the basic physics of the resonance phenomenon. Procedures will be provided on how to develop simple minded models to estimate natural frequency or critical speeds of a rotor. You will learn to perform run up and coast down experiments to determine critical speeds. We will show you methods to determine damping at different critical speeds and structural resonances. The workshop will also cover techniques to eliminate and/or minimize the effects of operation under critical speed conditions.
The emphasis will be hands-on demonstration. Real time experiments will be performed to illustrate most of the important principles. Attendees will have opportunities to participate in experiments and learn interactively. Several concepts will be clarified using SpectraQuest simulation software packages. These software packages are excellent tools for learning by performing virtual experiments. They also provide an inexpensive means for doing structural dynamics calculation to solve real life problems. We will set up a couple of work station for attendees to use the software and practice during breaks.
About Speaker:
Dr. Suri Ganeriwala is founder and president of SpectraQuest, Inc. He has over thirty years of industrial and academic experience and expertise in diagnostics, dynamics and vibration, signal processing, and viscoelasticity. He has been an invited speaker at several international conferences around the world. Suri has implemented successful condition monitoring and diagnostics programs in industrial settings and has developed unique products for education and research in wind energy, machine fault diagnosis, teaching fundamentals of vibration, controls, and dynamics and kinematics of machines. SpectraQuest’s flagship products Machinery Fault Simulators (MFS) and Drivetrain Diagnostics/Prognostics Simulators are his brainchild from conception to completion. These devices have been sold in over fifty countries around the world for research and teaching. He has authored over seventy papers, technical reports and articles in journals, magazines, and books. He obtained a Ph.D. in Mechanical Engineering from The University of Texas at Austin.
Dr. Roy Li is a Research and Development engineer at SpectraQuest. Dr. Li is an expert in analysis and modeling of machine fault diagnosis and prognosis of drive train – gears and bearings. Roy has published extensively in scholarly peer reviewed journals and conference proceedings. His expertise includes modeling machinery fault diagnosis/prognosis, signal processing, data mining techniques, automation & control, and advanced algorithm development. He obtained a Ph.D. in Mechanical Engineering from The University of Illinois at Chicago.
Jun Yang is a Senior Software Development engineer at SpectraQuest. He obtained a MS in Biomedical Engineering from The Virginia Commonwealth University in Richmond, VA and BS in Automation Engineering from the Tsinghua University in Beijing, China.
Nicholas Boyles is an Application engineer at SpectraQuest. Nick obtained a BS in Mechanical Engineering from The Virginia Commonwealth University in Richmond, VA
Christopher Drueke is an Application engineer at SpectraQuest. Chris obtained a BS in Mechanical Engineering from The Virginia Commonwealth University in Richmond, VA