By means of the vibration diagnosis it is possible to detect smallest irregularities at drive trains, especially at the gearbox at an early stage. These irregularities can be for instance damages at rolling bearings, gears and shafts, imbalance and alignment errors. That way the operator of a drive train gets information on the condition, which facilitates the maintenance and saves him from unplanned shutdowns.
You would neither expect the owner nor the operator of a production plant to have that deep technical knowledge of all system components. Therefore, it is absolutely normal to involve specialists. So it is also with mechanical power trains, especially with gearboxes. The detection and evaluation of damages on gears as well as the derivation of specific recommendations for further operation and maintenance is part of a major service in great demand.
The gearbox inspection consists of the evaluation of
•the external condition of a gearbox, the detection of leaks, problems related to the fundament and thermal anomalies,
•the function of the lubricant,
•the tooth mesh on the basis of the visible tooth flanks and
•the accessible bearings.
For the inspection, the drive must be switched off and secured against movement. Then the inspection covers are opened. Now our specialist has a close look on viewable parts directly or by means of a video endoscope. The gearbox inspection should be combined with the vibration diagnosis, because:
•Although the inspection offers advantages in the evaluation of damage type and damage size on tooth flanks, it is limited to the currently visible teeth. In contrast to this, the vibration diagnosis provides statements to all teeth, but with less resilient results according to the damage size.
•The inspection provides definitive statements about the type and the size of damages, if they can be viewed directly or with tools. With the vibration diagnosis all race ways and rolling elements are necessarily analysed.
During the vibration diagnosis , the vibrations are recorded at the surface of the housing generally using piezoelectric accelerometers. These are positioned by means of magnets at the housing in the area of the bearings.
The measured vibration signal is analyzed for its composition of individual signals. The individual signals are distinguished by their frequency and signal form. Practically this is done when generating a spectrum and an envelope curve spectrum of the signal. In the spectrum one finds all harmonious (sinusoidal) suggestions, however, in the envelope curve spectrum one finds periodical impact excitation.
We accomplish the complete diagnosis up to the informative diagnosis report for you.
Prerequisite for the vibration diagnosis of a drive is that the kinematic data are known. These are the numbers of teeth, bearing manufacturer as well as bearing type and reference speed.
The data collection is usually carried out with eight channels. This ensures that the detected effects can be assigned with regard to its cause as precisely as possible. With more than eight measuring points more data sets are recorded. The speed is recorded in a further channel. For the data acquisition the drive should operate under normal conditions.
The time signal is stored at first for every single measuring point. From each time signal is a spectrum and and an envelope curve spectra will be created. These are searched for any features according to the previously calculated kinematic frequencies.The results of our diagnosis are summarized in a diagnosis report. Our reports will give you as far as possible precise recommendations.
The speed will be collected for speed variable drives. The signal is subject to an order analysis and is treated analogous.
With the PeakStore410 GfM offers the solution for almost all machine diagnostic tasks. The system was developed by experienced practitioners in the field of machine diagnostic for the real application on the field. The PeakStore410 combines simple operation and high signal quality.
The device PeakStore410 uses the eight channel collection for the data at mechanical drives. Piezoelectric accelerometers, inductive displacement sensors, resistance strain gauges (via telemetry) or simple voltage or current signals (via an adapter) are possible as sensors. The speed can also be collected for speed variable drives.
The setting up of the measurement configuration (sensor type, sensor sensitivity and meas-urement time) must be carried out via a personal computer. These settings will be transferred to the PeakStore410 and obtained as long as the settings are overwritten. It is possible to load several measurement configuration onto the PeakStore410, one of them must be activated via the display of the PeakStore410.
The PeakStore410 is an autarkic measurement device. A personal computer is not necessary for measurements.
The vibration data are collected with 50 kHz per channel and are stored directly on a custom-ary intern changeable memory card. Additionally, the measured speed is stored which is re-quired for the order analysis.
The amount of the stored data depends on the size of the memory card. Later the data can be transferred to a PC via LAN or direct read-out.
The software PeakStoreCalc which is also delivered by GfM enables the calculation of spec-tra, order spectra, envelope curve spectra and envelope curve order spectra for normal vibra-tion measurements.
The PeakStore410 can be programmed in an extended mode for different measuring tasks with additional inputs and outputs. These may be long-term measurements with data transfer to a PC or triggered measurements with online calculation.
The Peakanalyzer is an Online Condition Monitoring System. It is designed for permanent monitoring of large drives and automatically detects irregularities on gears and bearings as well as anomalies of couplings and shafts. It can be provided with minimal two and maximal 32 channels for vibration diagnosis and just as much channels to collect process values. Configuration, request and visualization of diagnosis results are realized by means of the PeakanalyzerManager.
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