Monitoring Gear Reducer Health With Vibration Analysis
When you're dealing with complex mechanized objects such as a Falk gear reducer
, vibration is undesirable because its presence indicates inefficiency. To be specific, imbalanced rotating parts cause mechanical vibrations. As an example, when the teeth in a surplus gear reducer meet and rub against each other, they will unavoidably create vibration.
A shift in vibration patterns usually heralds a mechanical failure. Since mechanized systems often vibrate more, or in unusual patterns, as they near the end of their lives, a change in vibration patterns may signify that gearbox repairs may be on the horizon. Indeed, by monitoring vibration propensities, technicians can restore deteriorating parts before they cause complete mechanical failure.
Defining Vibration Analysis
Vibration analysis is the name given to the analysis of mechanical components' vibration patterns. From a simple two-gear system to a complex surplus gear reducer, every mechanical system creates vibration patterns as it runs. Vibration analysis is one variety of condition monitoring. One basic rule of this field is that a Falk gear reducer or other gearbox should be running at its full capacity when vibration patterns are sampled. Gear type, equipment load, criticality and operation speed all impact vibration patterns.
Vibration Analysis 101
As you can imagine, the vibration sensor is the most important ingredient in vibration analysis. Each Falk gear reducer or other machine must be hooked up to a sensor. Once you've chosen a sensor, the method of attaching it to the body of the machine is the next challenge. Sensors may be attached via a stringer, magnets, screws, or they may be permanent fixtures. Other sensors are designed to take their measurements with lasers or microphones. Whatever fastening system is at play, each mounting solution slightly alters frequency measurements. To create universal measurements, sensor manufacturers provide calibration directions with their products. Each sensor's basic job is to convert vibration data into electronic impulses. A data collector translates those impulses into usable data.
The Importance of Vibration Analysis
Predictive maintenance is the ultimate goal of all types of condition monitoring, including vibration analysis. The sooner engineers and mechanics can detect shifts in vibration patterns, the earlier they can change out lagging parts, and the more expensive gearbox repairs that can be avoided. Ongoing vibration analysis empowers management to configure alarms to flag when each machine demands attention for preventative care.
Vibration Analysis Methodology
How long should I hold onto vibration data? If you aren't currently storing vibration data, it's a wonderful time to start. Engineers, designers and technicians appreciate this information, which helps them maintain machines. However, if you're hoarding vibration records that are more than a couple of years old, it may be time to clean house. Chances are you've changed out machines and components since older data was gathered. The older the data is, the better the chances are that it's completely irrelevant to your current setup. The bottom line is that each firm must designate its own requirements for data maintenance.
Is it okay to set generic amplitude levels? Don't take shortcuts in vibration analysis. It's tempting to set generic amplitude levels to show when a gearbox may ready to bust. However, because every machine has its own unique components determining vibration, this "shortcut" may actually cost you extra time and money in the long run.
by: Wayne Johnson
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