Crack Detection Kit

Experiment Instructions
PT 500.11
Crack Detection in
Rotating Shaft Kit
04/2011
CRACK DETECTION IN ROTATING SHAFT KIT
All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010
PT 500.11
Experiment Instructions
This manual must be kept by the unit.
Before operating the unit:
- Read this manual.
- All participants must be instructed on
handling of the unit and, where appropriate,
on the necessary safety precautions.
Authors:
Dr.-Ing. Detlef Abraham

Dipl.-Ing. Jack Boxhammer
Dipl.-Ing. Peter Mittasch
Version: 1.1
Subject to technical alternations
04/2011
PT 500.11
Table of Contents
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Health hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Hazards to the unit and its function . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Assembly of the flange connection for simulation of a crack . . . . . . . 9
3.3 Securing the flange connection on the shaft with the clamping set . 10
3.4 Maintenance / care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Experiments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Simulation of crack in shaft with protruding shaft end . . . . . . . . . . 12
4.1.1
Purpose of the experiment . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.2
Required accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.3
Preparation and setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1.4
Performing the experiment . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.5
Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Simulation of crack in shaft with elastic rotor . . . . . . . . . . . . . . . . 23

4.2.1
Purpose of the experiment . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.2
Required accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.3
Preparation and setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.4
Performing the experiment . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.5
Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ii
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5
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.2 Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 Setup suggestions / photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.4 Items supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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PT 500.11
1
Introduction
The PT 500.11 Crack Detection in Rotating
Shaft Kit allows a shaft with a crack to be simulated. Cracks caused by material fatigue are very
dangerous for rotating machines as they often lead
to the dreaded fatigue fracture, with fatal consequences. As a result, early detection is vital.
A crack in the shaft influences the shafts vibration

behaviour by changing its rigidity. These changes
can be identified by measuring the vibrations on
the shaft and using appropriate analysis software.
Learning content/Exercises
Change in characteristic vibration behaviour

(natural frequency, resonance speed, amplitude and phase of vibrations) due to a crack
Cracks identification from the change in

vibration spectrum
Detection of cracks in rotating shafts at the a

protruding shaft end
Understanding and interpreting frequency

spectra
Use of a computerised vibration analyser.
Crack in a shaft with an elastic rotor (with

retain bearing from PT 500.10)
Notice:
Performance of the experiment is described using
the PT 500.04 Computerised Vibration Analyser.
However, vibration measuring instruments from
other manufacturers can also be used. The quality
of the measured results depends on the individual
experimental setup but reproduces the basic
characteristics.
1 Introduction
04/2011
PT 500.11
1.1
Intended use
The PT 500.11 unit is to be used only for teaching

purposes.
1 Introduction
04/2011
PT 500.11
2
Safety
The experiment instructions, in particular the safety instructions, must be read

thoroughly prior to starting up the unit. Prior to starting the experiments, the
participants are to be briefed on the safety aspects and the correct handling of
the unit. The signal words DANGER, WARNING or CAUTION indicate the
probability and potential severity of injury. An additional symbol indicates the
nature of the hazard.
Signal word
DANGER
Indicates a situation which, if not avoided, will

result in death or serious injury.
WARNING
Indicates a situation which, if not avoided, may

result in death or serious injury.
CAUTION
Indicates a situation which, if not avoided, may

result in minor or moderately serious injury.
NOTICE
2 Safety
Explanation
Indicates a situation which may result in damage

to equipment, or provides instructions on operation of the equipment.
04/2011
PT 500.11

Symbol
Explanation
Rotating shafts
General hazard location
Notice
2 Safety
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PT 500.11
2.1
Health hazards
WARNING
Rotating shafts
Risk of injuries.
2 Safety
Make sure that long hair, long beards,

chains, ties and loose clothing does not
come into contact with the rotating parts.
Only operate the unit with the protective hood

closed.
Switch off the motor before any modifications.
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PT 500.11
2.2
Hazards to the unit and its function

NOTICE
At least two of the six hexagon head screws distributed around the circumference must be securely
tightened with no clearance with spacer sleeves.
The remaining screws must be fitted as loose connections with clearance. For safety, all screws
must always be fitted, see section 3, Fig. 3.3.
NOTICE
Do not exceed the maximum permitted values
(see technical data).
NOTICE
For the Shaft with crack with protruding shaft end
experiment, the maximum belt tension is 70 N.
NOTICE
Continuous operation at a critical bending speed
should be avoided. The critical bending speed
depends on the individual experimental setup.
2 Safety
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PT 500.11
3
Unit description
Fig. 3.1
Shaft with no crack Flange connection with

six supporting screws
A = Loose connection
B = Secure connection
This unit simulates the characteristic behaviour of

a shaft with a crack using an asymmetrical flange
connection.
The flange connection is provided by six screws
distributed around the circumference. Tightening
the flange connection with spacer sleeves gives a
connection that is either loose or secure depending on the installation direction of the spacer
sleeves.
When rotated with a bending load, this flange connection results in intermittent separation of the butt
joint. This very closely resembles the behaviour of
a crack in the shaft.
To create this behaviour, it is necessary to load the
flange connection with a bending torque (e.g.
using the PT 500.14 belt drive or an imbalance
from a weight).
B
Fig. 3.2
Shaft with small crack Flange connection with

five supporting screws
NOTICE
At least two screws in the flange connection must
be securely tightened to give a secure connection
with no clearance.
For safety and to prevent imbalances, all screws
must always be fitted.
B
Fig. 3.3
Shaft with maximum

crack - Flange connection with two supporting
screws
3 Unit description
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PT 500.11
3.1
Layout
1 Driving shaft (PT 500)
5 Hexagon head screws
2 Clamping set
6 Spacer sleeve
3 Centring pin
7 Flange with long shaft (output for weight)
4 Pick up disc
8 Flange with short shaft (output for belt drive)
Fig. 3.4
Overall view of PT 500.11 - Crack Detection in Rotating Shaft Kit
3 Unit description
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PT 500.11
3.2
Assembly of the flange connection for simulation of a crack
Clearance
Align the flange with the shaft (Fig. 3.4, 7 or 8)

and pick up disc (4) using the centring pin (3)
and secure with the hexagon head screws (5).
NOTICE
The discs cannot be centred using the screws

alone.
Fig. 3.5
Fig. 3.6
Loose connection
with spacer sleeve
Depending on the function, insert and tighten

the spacer sleeves (6).
The use of a spacer sleeve for a loose

connection can be seen in Fig. 3.5. In
this type of connection, the flange and
pick up disc are held together by the
screws with clearance. When using the
spacer sleeve for a secure connection,
turn the spacer sleeve.
The use of a spacer sleeve for a secure

connection can be seen in Fig. 3.6. In
this type of connection, the flange and
pick up disc are held together by the
screws force with no clearance.
Insert the shaft clamping set (2) in the pickup

disc (4).
Fit the shaft with crack in the experimental

setup on one end of the short shaft using the
shaft clamping set.
Secure connection
with spacer sleeve
NOTICE
At least two of the six hexagon head screws distributed around the circumference must be securely
tightened with no clearance with spacer sleeves.
For safety and to minimise imbalance, all screws
must always be fitted.
3 Unit description
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PT 500.11
3.3
Securing the flange connection on the shaft with the clamping set
To secure the pickup disc on a shaft with the
clamping set, switch off the drive and carry out the
following steps:
Slide the pickup disc with loosened clamping

set onto the shaft.
Check that the clamping set is inserted flush

in the pickup disc.
Tighten the inner hexagon (A), if necessary

holding the outer hexagon (B) steady while
doing so. The thread of the inner hexagon
creates a cone (C) in the socket of the outer
hexagon. The shaft then twists with the
pickup disc.
Pick up disc
Shaft
Fig. 3.7
Layout of a clamping set

(shaft clamping set)
Fig. 3.8
Clamping set
3.4
Maintenance / care
When loosening the clamping set, hold the inner

hexagon (B) steady and unscrew the outer hexagon. After overcoming the initial loosening torque,
continue turning until the resistance starts to
increase again. Turning further presses the clamping set out of the mount and it can then be
detached by hand.
The PT 500.11 accessory set is maintenance free.
3 Unit description
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PT 500.11
4
Experiments
The selection of experiments presented here is not

intended to be complete. Instead, they are
intended as a stimulus for own experiments. The
results shown are intended as a guide only.
Depending on the construction of the individual
components, experimental skills and environmental conditions, deviations may occur in the experiments. Nevertheless, the laws can be clearly
demonstrated.
Generally, it is important to note that the shaft with
crack experiments involve very sensitive effects.
Note the following:
4 Experiments
The shaft should run true and not knock.

When modifying the shaft with a crack,
ensure that the centring is retained.
The shaft should not be loaded with any additional imbalances.
The screws on the flange should be secured

finger tight, not with force. The gap that forms
at the flange for the shaft with crack should
be able to breathe.
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4.1
Simulation of crack in shaft with protruding shaft end
4.1.1
Purpose of the experiment
A shaft crack at the protruding end of the shaft is to

be simulated. The simulation will be carried out
using the short shaft with flange. The constant
radial load is created using the belt drive
(PT 500.14).
For the experiment with no shaft crack, all

six screws should be fitted with spacer
sleeves to give a secure connection with no
clearance (Fig. 3.1).
For the experiment with a shaft crack, three

consecutive screws are fitted as a loose connection.
The frequency spectra for the two experiments are

to be compared.
4.1.2
Required accessories
PT 500
Machinery Diagnostics System
PT 500.04 Computerised Vibration Analyser

PT 500.14 Belt Drive Kit
4 Experiments
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Preparation and setup
4.1.3
16
17
Belt running
direction upwards
15
14
13 11 12 11 10
1 Belt tensioner
10 Reference sensor
2 Belt
11 Setting ring
3 Small belt pulley
12 Bearing block
4 Short shaft with flange
13 Elastic claw coupling
5 Pick up disc
14 Drive unit
6 Shaft clamping set
15 Magnetic clamp with steel plate
7 Acceleration sensor
16 Reflective mark
8 Bearing block
17 Large belt pulley with bearing block
9 Short shaft
Fig. 4.1
Experimental setup for shaft with crack with protruding shaft end
4 Experiments
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Fig. 4.2
Pick up disc with clamping

set, short shaft with flange
and small belt pulley. Two
supporting screws (A)
Set up based on the diagram or the following

points:
Fit the drive unit (14) on the clamping plate.
Connect the drive unit to the control unit.

Connect the control unit to the power supply.
Fit the elastic claw coupling (13) to the drive

unit (see PT 500 section 3.6).
Set up the short shaft (9) with two bearing

blocks (12 & 8) and setting rings in such a
way that the short shaft can be connected to
the drive unit with the elastic claw coupling
(13). Also, so that it can subsequently be
secured axially to the first bearing block.
Align and secure the drive unit and bearing

blocks. To align on the clamping plate, slide
all components forward or back at right
angles to the grooves to minimise possible
lateral misalignment.
Axially secure the shaft with setting rings to

the first bearing block.
Secure the fully assembled unit made up of

the pickup disc (5) and short shaft with flange
(4) (Fig, 4.2) to the end of the shaft (9) with
the clamping set (6). For the crack in a
shaft experiment, the flange should be fitted
as described in section 3.
Shaft without crack
4 Experiments
Six hexagon head screws with spacer

sleeves as a secure connection (Fig.
3.6)
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PT 500.11
Shaft with crack
Belt tension
adjustment
Feeler 0.4 mm
Fig. 4.3
Belt tension adjusted using

feeler, or alternatively with
belt pretension measuring
unit (tension approx. 70 N)
4 Experiments
Four hexagon head screws with spacer

sleeves as a loose connection (Fig. 3.5)
Two hexagon head screws with spacer

sleeves as a secure connection (Fig.
3.6)
Secure the small belt pulley (3) to the end of

the short shaft with flange using the clamping
set.
Assemble the belt drive with the bearing

block and belt tensioner from the PT 500.14
(belt drive), align and slightly tension the belt.
The correct direction of rotation must be
ensured (Fig. 4.1). The belt tensioner must
be fitted on the unloaded side of the belt. The
belt tension (Fig. 4.3) can be adjusted using
the belt tensioner. For each belt drive, the
adjusting screw moves a tension roller into
the loose side of the belt from below until the
belt is slightly tensioned.
Adjust the belt tension for the shaft with

crack.
The belt tension should be increased until the
feeler fits 0.4 mm into the gap between the
flange on the side opposite the supporting
screws. A measurement should also be carried out on the side opposite the belt drive (on
the side where tensile stress is acting on the
shaft).
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PT 500.11

Alternatively, the tensile stress of the belt can
be measured using the belt pretension measuring unit (Fig. 4.5).
Procedure:
Fig. 4.4
Belt drive with tensioner
Switch off the belt drive.
Push the red lever on the belt pretension measuring unit downwards so that
it indicates zero.
With your index finger in the clip, slowly

press the measuring unit onto the belt
from above, until you feel it click.
Read the measured value of the red

pointer pushed upwards until it clicks.
(For details, refer to the manufacturers

instructions.)
Fig. 4.5
Belt pretension measuring unit
4 Experiments
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Screw the acceleration sensor (7) into the

horizontal tapped hole in the bearing block
close to the shaft with crack, Fig. 4.1.
Fit the reflective marker (16) for the reference

transducer (10) on the shaft or weight.
Fit the reference sensor with magnetic clamp

(15) and steel plate on the clamping plate
and roughly align with the reflective mark.
Connect the reference transducer and acceleration sensor to the measuring amplifier.
Connect the measuring amplifier to the PC

via the USB measurement box.
Switch on the PC and start the pre-installed

PT 500.04 software.
Connect the power supply for the measuring

amplifier. Switch on the measuring amplifier
on the front panel.
Align the reference sensor with the reflective

mark.
Check the switching behaviour of the reference sensor. The second LED directly on the
reference sensor may only trip once when
scanning the reflective mark.
In the software, open the Sensor window.

Select the sensor and check the settings in
the Calibration menu.
Sensor:
Acceleration
Scale:
Offset:
Factor:
4 Experiments
100 mV/g
0.0
1.0
Gain on measuring amplifier: 10x.
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PT 500.11
4 Experiments
Check the signal strength in the Oscilloscope

window. To obtain optimum resolution when
digitising, select the largest possible gain
factor without exceeding the measuring
range. See also PT 500.04. section 3.3.
In the software, open the Frequency Spectrum window and check the following settings.
Channel A:
Channel 1
Channel B:
Reference
Scan Rate:
8 k/s
Scan Time:
4 Seconds
Of Means:
Mode:
Velocity
Window Function:
Uniform
Log Or Linear:
Linear
Unit Of Magnitude:
rms
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PT 500.11
4.1.4
Performing the experiment

Recording the frequency spectrum
To show the difference in the comparison, the
shaft without crack is recorded first.
Prepare the shaft without crack for the

experimental process, i.e. fit all six screws
with spacer sleeves as a secure connection,
see section 3, Fig. 3.1.
Check that all parts are fitted securely.
Close the protective hood.
Switch on the control unit for the motor.
Set the direction of rotation (determined by the belt drive - the belt
tensioner should act on the loose side).
Set the speed to zero.
Switch on the motor.
Set the speed, e.g. to 2400 rpm.
Plot the frequency spectrum.
Switch off the motor.
Prepare the shaft with crack for the experimental process, i.e. fit three adjacent screws
with spacer sleeves as a secure connection
and the other three as a loose connection,
see section 3.
NOTICE
For modifications, ensure that the centring is
retained. In other words, at least two screws
4 Experiments
19
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PT 500.11

must always secure the pickup disc and the
short shaft with flange.
Process: As described above for the
shaft without crack.
4 Experiments
20
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PT 500.11
4.1.5
Evaluation
Second order vibrations in the frequency spectrum
are characteristic for the shaft with crack. These
are caused by the anisotropic rigidity of the shaft.
The shaft passes through the area of lower and
higher rigidity twice per revolution. This results in
vibrations with double the frequency of the speed.
Anisotropic:
Anisotropic rigidity is a direction-specific rigidity.
First of all, the frequency spectrum for the shaft

without crack (six supporting screws) is displayed. Here, the fundamental vibration at 40 Hz
and the associated higher harmonics (fDx) can be
seen. Most of the other vibrations are caused by
the belt drive, which has its fundamental frequency
at 8.8 Hz (measured). The shaft for the large belt
pulley rotates at half the speed fD/2.
fD1
40.0
fR2
fR5
17.6
fR4
44.0
fD/2 fR3
fR1
8.8
Fig. 4.6
20.0 26.5
fD4
fR7
35.2
fR6
52.8
160.0
61.6
fD2
80.0
fD3
120.0
fD5
200.0
Frequency spectrum of protruding shaft end without crack (six supporting screws)
n = 2400 rpm = 40 Hz, fD = drive, fR = belt drive
4 Experiments
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fD5
fR2
200.0
17.6
fR5
44.0
fD1
40.0
fD/2
17.6
fR3
26.4
fR7
61.6
fR4
158.9
35.2
fR6
52.8
fD3
fR1
fD4
fD2
80.0
120.0
8.8
Fig. 4.7
Frequency spectrum of protruding shaft end with crack (three supporting screws)
n = 2400 rpm = 40 Hz
For the shaft with crack, the fundamental vibration (fD1) with the higher order harmonics (fD2-D5)
can also be seen. The amplitude of the fundamental vibration for the shaft without crack is greater
than in the shaft with crack setup.
The shaft with crack also clearly shows the characteristic rise in the 2nd order vibration fD2. This is
an indicator of the crack.
Calculated belt frequency:
fR =
4 Experiments
n U AR 2400 min -1 197.9 mm
= 8.7 Hz
60 LR
60
912 mm
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4.2
Simulation of crack in shaft with elastic rotor
4.2.1
Purpose of the experiment

A shaft crack with an elastic rotor is simulated
using the long shaft with flange, the short shaft
(PT 500) and a weight (PT 500). For comparison,
the curves from the 1st and 2nd order response
analysis with and without a crack in the shaft are
plotted.
The shape of the response analysis curve shows
whether and in what speed range the amplitude of
the 2nd order vibration speed rises sharply. Typical orbit curves can only be expected if this
happens.
The displacement sensors will then be used to plot
the orbit curves.
4.2.2
Required accessories
PT 500
Machinery Diagnostics System
PT 500.04 Computerised Vibration Analyser

PT 500.10 Elastic Shaft Kit
4 Experiments
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4.2.3
Preparation and setup
13 14 14
12
11
10
15 16
17
18
19
1 Acceleration sensor horizontal
11 Elastic claw coupling
2 Bearing block
12 Drive unit
3 Long shaft with flange
13 Magnetic clamp with steel plate
4 Pick up disc
14 Setting ring
5 Vertical displacement sensors
15 Reflective mark
6 Horizontal displacement sensors
16 Weight with clamping set
7 Retain bearing
17 Clamping set
8 Short shaft with marking
18 Spacer sleeve
9 Reference sensor
19 Hexagon head screws
10 Bearing block
Fig. 4.8
Experimental setup for shaft with crack simulation with elastic rotor
Set up based on the diagram or the following

points:
4 Experiments
Fit the drive unit (12) on the clamping plate

(i.e. on the far left, so that there is space for
the remainder of the setup and the hood can
be closed).
Connect the drive unit to the control unit.

Connect the control unit to the power supply.
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Fig. 4.9
Fit the elastic claw coupling (11) on the drive

unit.
Loosely fit a bearing block (10) on the clamping plate flush in front of the elastic claw coupling.
Slide the short shaft (8) through the bearing

of the first bearing block (10) on the drive unit.
Slide the setting rings (3) onto the shaft in
such a way that the shaft can subsequently
be fixed in place at the first bearing block.
Slide the weight (16) with clamping set and

retain bearing (7) onto the short shaft and
loosely attach so that the fully assembled
shaft with / without crack unit can subsequently be fitted on the free end of the short
shaft.
Secure the fully assembled unit (shaft with

crack, Fig. 4.9), consisting of the pickup disc
(4) and long shaft with flange (3) (as
described in section 3.3) on the free end of
the short shaft (8) with the clamping set (17).
Fit the second bearing block (2) onto the free

end of the shaft with flange (3) (see Fig. 4.8).
Connect the short shaft (8) to the elastic claw

coupling (11).
Align and secure the drive unit and bearing

blocks. To align on the clamping plate, slide
all components forward or back at right
angles to the grooves to minimise possible
lateral misalignment.
Axially secure the shaft with setting rings to

the first bearing block.
Secure the weight (16) on the shaft with the

clamping set.
Fully assembled unit

(shaft without crack)
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PT 500.11
4 Experiments
Screw the displacement sensors (5 and 6)

into the horizontal and vertical tapped holes
in the retain bearing (2) in such a way that the
transducers are not in contact with the shaft.
Fit the reflective marker (15) for the reference

transducer (9) on the shaft or weight.
Secure the acceleration sensor (1) in the horizontal tapped hole in the bearing block (2).
Fit the reference sensor onto the clamping

plate with the magnetic clamp (13) and steel
plate.
Connect the reference sensor and acceleration sensor to the measuring amplifier.
Connect the measuring amplifier to the PC

via the USB measurement box.
Switch on the PC and start the pre-installed

PT 500.04 software.
Connect the power supply for the measuring

amplifier. Switch on the measuring amplifier
on the front panel.
Align the reference sensor with the reflective

mark.
Check the switching behaviour of the reference sensor. The second LED directly on the
reference sensor may only trip once when
scanning the reflective mark.
Connect the displacements sensor on the

rear of the measuring amplifier.
Channel 1 - Horizontal
= 0-180
Channel 2 - Vertical
= 90-270
For assembly and adjustment of the displacement sensor, refer to PT 500.10, section 3.2 and 3.3.
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Open the Sensor and Calibration windows in turn in the PT 500.04 software.
Select the sensor and check the settings in
the Calibration menu.
For the experiments with acceleration

sensors:
Sensor:
Acceleration
Scale:
Offset:
Factor:
100 mV/g
0,0
1,0
Check the signal strength in the Oscilloscope window. To obtain optimum resolution when digitising, select the largest possible gain factor without exceeding the measuring range (see also PT 500.04, section
3.3). Selected gain on measuring amplifier
here: 10x
For the experiments with displacement
sensors:
Sensor:
Displacement
Scale:
Offset:
Factor:
1.25 V/mm
0,0
1,0
For assembly and calibration of the displacement sensors, refer to PT 500.10, section 3.2
and 3.3.
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PT 500.11
4.2.4
Performing the experiment
4.2.4.1
Plotting the 1st and 2nd order response analysis
For example, prepare the shaft without

crack for the experimental process, i.e. fit all
six screws with spacer sleeves as a secure
connection. Refer to section 3 for details.
Select the Acceleration under Sensor in the menu in the PT 500.04 software (check the configuration if necessary).
Open the Tracking Analysis window

from the menu in the PT 500.04 software. Make the following settings in the
window:
Channel:
Channel 1
Mode:
Velocity
Graph Order A: 1
Graph Order B: 1
Scale:
4 Experiments
Auto
Set the desired direction of rotation.
28
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PT 500.11

Notice
The required printer must be set as the

default printer before starting the program.
Either plot the response analysis chart

manually or continuously and automatically (selected here: Continuous).
Start the measurement and slowly

increase the speed (from 0 rpm to
3000 rpm), while observing the curve
plotted in the program window. The
measurement can be carried out continuously using the software or manually using individual values.
To finish continuous measurement at

the end, click on the Continuous button.
Print out the results on the default

printer.
Switch off the motor.
Prepare the shaft with maximum crack for

the experimental process, i.e. fit two adjacent
screws with spacer sleeves as a secure connection and the other four as a loose connection. Refer to section 3 for details.
4 Experiments
Process: As described for the shaft

without crack in this section.
29
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PT 500.11
4.2.4.2
Plotting the orbit curves
Prepare the shaft without crack for the

experimental process, i.e. fit all six screws
with spacer sleeves as a secure connection.
Refer to section 3 for details.
Select Displacement under Sensor

in the menu in the PT 500.04 software
(check the configuration if necessary).
Open the Orbit Analysis window from

the menu in the PT 500.04 software.
Make the following settings in the window:
Mode:
Displacement
Order
--Scale
1-10-100-1000
For a scale greater than 1, the value
read in the diagram has to be divided by
the selected scaling value.
4 Experiments
Set the desired direction of rotation.
Set the required speed and plot the

orbit curve. The speeds selected
should be from the ranges in which the
2nd order amplitudes are at their maximum.
Save or print the results.
Set another speed and plot a new orbit

curve.
30
04/2011
PT 500.11
Prepare the shaft with crack for the experimental process, i.e. fit two adjacent screws
with spacer sleeves as a secure connection
and the other four as a loose connection.
Refer to section 3 for details.
Process: As described for the shaft
without crack on the previous page.
4 Experiments
31
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PT 500.11
4.2.5
Evaluation
For the elastic shaft, the occurrence of 2nd

order vibrations, such as those that occur on
the shaft with a crack for example, depend on
the load on the shaft. This changes with the
speed due to resonant vibrations. Therefore,
a measurement at a fixed speed may not provide any conclusions.
The response analysis over a wider frequency range reliably identifies the 2nd order
vibrations sought.
The orbit curves are a further characteristic
indicator of a shaft with a crack. These
should meet where 2nd order vibrations
occur.
Fig. 4.10
Response analysis for elastic rotor without crack, 1st and 2nd order. The 2nd order amplitudes (B) are smaller than and below the 1st order amplitudes (A) over the entire speed
range. (channel: 1; mode: Velocity)
4 Experiments
32
04/2011
PT 500.11
Fig. 4.11
Response analysis for elastic rotor with crack (three supporting screws), 1st and 2nd order.
For the 2nd order (B), the increase in the amplitude can be clearly seen in the range
1500 rpm to 2900 rpm.
The 2nd order amplitude rises above the 1st order amplitude (A).
This kind of response analysis can also be

carried out with a real rotor (e.g. power station turbine) when a stoppage is due. It is
essential that comparative data for the
undamaged rotor is available.
4 Experiments
33
04/2011
PT 500.11
To indicate the increase in 2nd order vibrations depending on the formation of a crack,
several response analyses are superimposed in a single chart. Here, even small
cracks (five screws tight) show significant
variations from the shaft with no crack.
1st order response analysis
Amplitude mm/s
Three supporting screws (1)
Four supporting screws (2)

Five supporting screws (3)
2
Six supporting screws (4)
Speed rpm
Fig. 4.12 Plots for 1st order response analysis with different levels of cracks
The progress of the crack formation can be

clearly discerned.
4 Experiments
34
04/2011
PT 500.11

Characteristics of the shaft with crack:
Second order amplitude is greater than first

order in certain ranges.
The crack causes the 2nd order amplitude to

increase.
2nd order response analysis
Amplitude mm/s
Three supporting screws (1)

1
Four supporting screws (2)

Five supporting screws (3)
Six supporting screws (4)
2
3
Speed rpm
Fig. 4.13
Plots for 2nd order response analysis with different levels of

cracks
The progress of the crack formation can again be

clearly discerned here.
4 Experiments
35
04/2011
PT 500.11

Orbit curves enable the 2nd order vibration components to be effectively identified. This method is
ideal in practice for rotors with floating bearings,
which are fitted with stationary orbit detection.
First, we plot the orbit curve for a shaft with no

crack. A more or less circular shape can be identified here. All charts were plotted using the settings:
Mode:
Travel
Scale:
10
Fig. 4.14
4 Experiments
Shaft without crack, n = 2040 rpm
36
04/2011
PT 500.11

If there is a crack, the 2nd order vibrations result in
loops in the orbit curve. Depending on the phasing,
different shapes can be formed.
Characteristic orbit curves with distinctive 2nd

order vibration of a shaft with crack at different
speeds.
4 Experiments
Fig. 4.15
Shaft with crack, three supporting screws;

n = 728 rpm; hardly any 2nd order vibrations.
Fig. 4.16

n = 1463 rpm; small 2nd order vibration component.
37
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PT 500.11
4 Experiments
Fig. 4.17

n = 1785 rpm; large 2nd order vibration
component.
Fig. 4.18

n = 2226 rpm; large 2nd order vibration
component.
38
04/2011
PT 500.11
4 Experiments
Fig. 4.19

n = 2470 rpm; with 2nd order vibration
component.
Fig. 4.20

n = 2842 rpm; with no 2nd order vibration
component.
39
04/2011
PT 500.11
Appendix
5.1
Technical data
Max. length:
250 mm
Flange diameter:
90 mm
Weight approx.:
5 kg
Flange hexagon head screws:

DIN 933-8.8
M8 x 20 mm
Maximum permitted bending torques:

Short shaft for the belt pulley
Max. permitted bending torque on the shaft:
15,9 Nm
i.e. max force vertical to the shaft with a lever
arm of l = 106 mm:
150 N
Long shaft for the weight
Max. permitted bending torque on the shaft:
3,9 Nm
With a lever arm of l = 220 mm, the maximum
force vertical to the shaft is:
15,5 N
Continuous operation at a critical bending speed
should be avoided. The critical bending speed
depends on the individual experimental setup.
5 Appendix
40
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PT 500.11
5.2
Symbols
Belt frequency (calculated):
fR =
n U AR 2400 min -1 197.9 mm
= 8.7 Hz
60 LR
60
912 mm
where
: Drive shaft speed in rpm
LR
: Belt length (912 mm)
UAR : Circumference of drive roller (197.9 mm)
5 Appendix
60
: Min to s conversion factor
fR
: Belt frequency in Hz
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PT 500.11
5.3
5 Appendix
Setup suggestions / photos
Fig. 5.1
Shaft with crack experiment with protruding shaft end
Fig. 5.2
Shaft with crack experiment with elastic rotor and retain bearing
42
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PT 500.11
Items supplied
1x
PT 500.11 Crack Detection in Rotating

Shaft Kit
1x
PT 500.11 Experiment instructions
5.4
5 Appendix
43

Crack Detection Kit

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Experiment Instructions

CRACK DETECTION IN ROTATING SHAFT KIT

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

Dr.-Ing. Detlef Abraham

Subject to technical alternations

CRACK DETECTION IN ROTATING SHAFT KIT

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Purpose of the experiment . . . . . . . . . . . . . . . . . . . . . . . . . 12

Preparation and setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Performing the experiment . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2 Simulation of crack in shaft with elastic rotor . . . . . . . . . . . . . . . . 23

Purpose of the experiment . . . . . . . . . . . . . . . . . . . . . . . . . 23

Preparation and setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Performing the experiment . . . . . . . . . . . . . . . . . . . . . . . . . 28

CRACK DETECTION IN ROTATING SHAFT KIT

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

5.4 Items supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

CRACK DETECTION IN ROTATING SHAFT KIT

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

A crack in the shaft influences the shafts vibration

Change in characteristic vibration behaviour

Cracks identification from the change in

Detection of cracks in rotating shafts at the a

Understanding and interpreting frequency

Use of a computerised vibration analyser.

Crack in a shaft with an elastic rotor (with

CRACK DETECTION IN ROTATING SHAFT KIT

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

The PT 500.11 unit is to be used only for teaching

CRACK DETECTION IN ROTATING SHAFT KIT

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

The experiment instructions, in particular the safety instructions, must be read

Indicates a situation which, if not avoided, will

Indicates a situation which, if not avoided, may

Indicates a situation which, if not avoided, may

Indicates a situation which may result in damage

CRACK DETECTION IN ROTATING SHAFT KIT

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

General hazard location

CRACK DETECTION IN ROTATING SHAFT KIT

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

Make sure that long hair, long beards,

Only operate the unit with the protective hood

Switch off the motor before any modifications.

CRACK DETECTION IN ROTATING SHAFT KIT

Hazards to the unit and its function

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

CRACK DETECTION IN ROTATING SHAFT KIT

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

Shaft with no crack Flange connection with

This unit simulates the characteristic behaviour of

Shaft with small crack Flange connection with

Shaft with maximum

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 01/2010

CRACK DETECTION IN ROTATING SHAFT KIT

1 Driving shaft (PT 500)

5 Hexagon head screws

7 Flange with long shaft (output for weight)

8 Flange with short shaft (output for belt drive)

Overall view of PT 500.11 - Crack Detection in Rotating Shaft Kit

CRACK DETECTION IN ROTATING SHAFT KIT

Assembly of the flange connection for simulation of a crack

Align the flange with the shaft (Fig. 3.4, 7 or 8)