10252016 Diagnosis of Shat Misaligrment adits Efects (Theory) : Relating Machinery Fault Simulation: Mechanical Engineering IT KHARAGPUR Viral La Diagnosis of Shaft Misalignment and its Effects 7 SAS BBO w % Introduction Objective Thory—«~Procedure ‘Simulator Reference Quiz_—=—=rofect Team ‘Feedback Misalignment Ccusling misslonment If 9 condition where the shat of the drver machine ans the erven machine are not on the same centerine. For dascusson purses, the noncoalcondton can be paralll msalgnment ar angular misalonment 25 depicted. The more commen canton Is combination f tne twa in bah the horzotal and vertical direction. Ts compounding & msafgnment, saat and angular in bth vrtial Sd Rorzantl sections, i what hat made the correction of misalignment so frustrating, Correcting for ane fects another andthe agament technician hunts he or her way to beter algnmient wi repeated measurement ané move, then anether measurement and move, ane 59 forth. The lustratons in Ngure suapest curling misalgnment fs the subject. Ths s the more commen stuation, but the arabs method s palcable vo gar and bearing misalignment ae ralh—f E TAA | gure 3 -() Vera atgnment. (6) Horzontalalgnment We are forced into this situation of coupling agnment because equipment from cierent suppliers must be mated together. Motor rmanufetuers do not make pumps, end fen manufocturers donot make mators. ome equipment, ike veneaxil fans and some centrifugal Chiles is bulk with an Integral motor andthe impeller Is mounted rectly on the motor shat, In ths eaee, thee is 0 shaft or couslng Iisaonment problem because tere Is only one shat. We are abo forced into this Stuaten because fd handing machines can poauce ferent Moms and pressures at aifeent speeds and horsepower ratings. tis desirable ta maintain tis Newilty of mang ferent meter to fans ond pumps to echeve the dese lw an pressure Forth ler reson, loks like nustry has prolem that aot s6h9 6 go aay oon, ane tree Job seat In leaming presican alent proceies See it's possible get the output shaft of ane machine perecy algne tothe input shat of the crvan machne, exible couplings are ralabe to take up the mealgnment, Flexible couplings alm the two machines to operate but not necessary smahly. Te further nay Irom perfect algnret the shafts are, the mor srain tere i on the couplings. This sain causes a higher level of aration. I aio causes bearing, seals more requenty than at 5 year intervals, kay that you have a misalnmen pater. Msignment svows up in the frequency somain as 9 series of harmonics of the ronning speed. The harmonics occur becuse ofthe san Induced in the shaft. The harmonies are act realy wibratons at those frequencies, but a falbut ofthe dgtal signal process when maton hp sitago.vlab co sub AObrch= 2198s ter 4510252016 Diagnosis of Shat Misaligrment adits Efects (Theory) : Relating Machinery Fault Simulation: Mechanical Engineering IT KHARAGPUR Viral La rested. two shafts are not allied and coupled, then ey can rotate rely on the own axis. When the two shas are couple together, they are now strained toward each other. When coupled and rotated together, the two stats are eylcaly strained at ring sped. Stee! shafts are very sf, but they stil eet a small amount. Ths defection cretes forces onthe nearby Gearngs ane sts the entre housing of botn machmes into eylkal melon, The housings ang besrings create reactionary fers that grevent the sna from moving as uch 2 st ‘mould tend to, Thete rations prevent the nermal sine wave motion frm achieving full excurson in amplude In athe word, the ine trove mtion of shaft deflection is torte atthe extremes, Iti this Gstrtion that generates the harmanic. The conservation of energy Principal quires te generation of armani er dtorton wen the sine wave clipped of. The missing part ofthe waveform = dled to 8 Geren part of the spectm, i, , fo higher Hequendes, The unwanted sna defeion also caures accelerated wear ofthe couPIng and 2cjcent bearing and seas. Figure 4 -Spacrum ofa 180-np motor coupled to 2 bol caf fn, Te running speed is 1096 rm (8.2 Ha). These machines ae wall atnceg bt he harmonics of running speed indicate Msalgnment A) gure §- Uncouled shat fre to rotate whout binding que 6 ~ Shas couples and strane. \ \ Figure 7 - Distorted sine wave generates harmanic This aves you a cue t the problem on machines that have reauent Inboard bearng changes. The misalgned shafts also cause a stain onthe oupng and cause the intemal parts of the xuplng to ocess against each ater every revolution. The prt touch, press together, cme 2a, then touch agai on the next rotation, and continue his cyl. Ths eda! touching causes areal viation a the eauency of te causing soments contacting. This requency is tne number of elements times the rtlional speed Ifyou sw the patter of varation ona rotating machine, with feble couplngs, you could strongly svspec misallnment. Notice in Fos. that the amaltude is n acceleration uns. Remember that acsleraton emgnaszes the hignerequences over velzcty and dplacement, The acceleration dsp ithe bast lace to see the harmodls ef misalenment. “This same pattem af harmonics appears for being misalgnment aka. Some further analss needs to be done to separte the twe. Fer Instance, harmonics in the spectrum of 3 machine wrhout 2 flee couplog means tat coupling misalgnment& out ofthe question. The harmonies could be caused by bearing msalonment or ome ater dstrton. Likewise, tre dsgpearance of Memmanics an 9 motor run sol ie 9204 mdcation of eouping msalqnment. if hey remain, then the problem isi the motor an notin the algnment ef tre two maches. hp sitago.vlab co sub AObrch= 2198s10252016 Diagnosis of Shat Misaligrment adits Efects (Theory) : Relating Machinery Fault Simulation: Mechanical Engineering IT KHARAGPUR Viral La isegnment is temperature dependent. All mata grow with inceasing temperature, and metal exception. Motors warm up Several fegres, an the drven machine may worm up or col dawn from ambient depencing an the Mid I iz handling. Tis temperture cmange causes very slow movement asthe machses reach operating temperature. This movement changes the alenment conan. Therefore, 3 change in vibration, and spec in tha armencs, during temperature changes isa strong inacatio of misalignment. “etal narmarie datrtion i an effective measure of misalgnment. Some analyzers ave this feature and R can be used asa trending too Some snalyers also have a histogram espay. This so probability dsgrem ofthe chances of measuring the vokape around 9 ean of tran the time comain for 8 pure sine wave, the vakage aroun ie most ily to be a rr, tn dacreazng probably farther from zero in alter the postive or negative rection. By contrast, 9 square wave fom has a greater srabity atthe extremes and a lesser probably of beng at aro, When some harmenle dstorson is "aking place, as with misalgnment of looseness when the wavetorm is being clipped, then the Nstogam spay shows a decrease in probability and a brozening at the base in Fe. Fpute 8 - Spectrum from 400-hp mator-pump cambination tht ws misigne. The retatlonal speed was 1600 ep (30 M2) ane Ue ‘machine emitted the aude “gro” of misalignment: Fgure 9 - Hstogram dsplys of te vltage from an accoerometer en: {9} machine well aired and (5) the same machine msalgne. ‘As the two shafts ol aound wih each ether oth shafts rock an angular motion. Some bending takes plac nthe shaft, aut the angular ‘motion causes the machine housing to ae trace out this same motion. The res hat the machine varates up and down verte, and tack and forth horzontaly, but ako in and aut axial. Ifyou Rave an analyzer that can measure he, then this racking motion (actualy the shat traces cut a cone ) can be eeteced by 180". Out of phase readings. The machine casng wil rock 180° cut of pha readngs. The machine casing wl rock 180" out of phase up anc down vera, or and out hetzetaly from Want to back. You can also etext 180°prase tatference excl Tis measurement is belt taken adjacant tothe coupling. ne reading onthe motor and te other reaing en the pump (oe Carell of the pickup eientation. The dference will rely be exact £80°. TE may be 160°, 140%, or maybe even anly 120°. But the pon = th there willbe 9 snifeant derence inte phaes ‘sa fral example of dlagnesing misalgnment, s the time domain view of 3 misaligned machine. This machine Isa tabletop omensraton machine picture in Fig. wi 9 flecalecouping betwesn 3 1790~pm motor anda rter Te motor was intentionally maligne by moving wrt jackacrens, The tne domain view fe not very hepfl for diagnosing misalignment. Nothing in this vw stands out ae characartie of hp sitago.vlab co sub AObrch= 2198s10252016 Diagnosis of Shat Misaligrment adits Efects (Theory) : Relating Machinery Fault Simulation: Mechanical Engineering IT KHARAGPUR Viral La Laps LL Ht Mel Ik ity me Figure 10 gure 12 -Phatgraph of misafgnment demonstrator By contrast sa frequency domain view ofthe same msalaned tabletop derenstaton machine. The harmonics ef running spees Indcace Iisatonment, lu and clear. The conduson Is that the frequency domain view, espedaly withthe acceleration dsoby,' the bast Way detect misalignment. You now know tne two main causes of vibration “imbalance ang mabgnment. How can you tel the differance fom ation reoaings? “he queston sceasonsly comes up on which corrective technique shoul be ape ft balancing ar atgnment. Attn it may not be clear whit isthe cominant cause ef vbration, The answers to perform algnment fst because tare maybe erroneous 2X-rom vation readings f 2 large msalgnmet s present. This 1Xrpm vibration due to misalgnment must be remived fst for balancing tobe success. Ao, along Isa procedure that usually can be completed ina sherter tine than Balancing fa high cep vibration remans ater aging, hen li Gime to bolonce. Cite this Simulator: 1stegp.vlab.co.in,. (2012). Diagnosis of Shaft Misalignment and its Effects. Retrieved 25 October 2616, from {itegp.vlab.co.in/?sub=d0Bbrche213ksine734kent Fepditagovlab cones 408brh=2138sim=73éenk=1 ;m10252016 Diagnosis of Shat Misaligrment adits Efects (Theory) : Relating Machinery Fault Simulation: Mechanical Engineering IT KHARAGPUR Viral La hp sitago.vlab co sub AObrch= 2198s