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High Performace Test & Measurement Solutions for Noise & Vibration Applications


Data Physics Corporation(408) 437 0100 | www.dataphysics.com



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W E lCo m E to t h E I N S I D E RThe Data Physics Internal Newsletter

July 2013 | Volume 7 - Number 6

Keen readers of the Insider would have noticed that this issue is late and has been combined with the July issue, in effect re-ducing the number of publications this year. This is the conse-quence of increased sales and marketing activity that always happens around this time of year. We apologize for the lateness and hope you would rather have useful, weighty content than a light issue that turns up on time.

Sales activity is in full swing and the results look good so far. At the end of the month we will mark the halfway point in the Fis-cal Year and we hope to report that we are well on our way to making a great year. We continue to expand the workforce with new hires in Engineering and Manufacturing in Corona and are still looking for Field Service Personnel.

The web seminars we have been doing over the past year have been quite popular and have served our users well. Occasionally we hear from someone who missed a seminar that they really wanted to attend. We want to remind you that recordings of all the seminars are available at the Event Recordings Archive.

Corporate News

Announcements, Openings and Up-coming Events

SignalCalc & SignalStar

Software Release: SignalStar Controller Version 2.4

Honeywell Sensing and Control Se-lects SignalStar Controllers

To Order Track or Not to Order Track

Cross-Application Coverage for Critical Rotating Machinery with SignalCalc Turbo

SignalForce & SignalSound

LE-Series 3 Inch (76.2mm) Shakers are Gaining Momentum

Celestica Upgrades to a New Genera-tion of Shaker

Rotational and Cross-Axial Stiffness

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https://dataphysicsevents.webex.com/ec0606l/eventcenter/recording/recordAction.do?siteurl=dataphysicsevents&theAction=archive

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Announcements

SignalForce and SignalSound New Product Development gets a Boost from New Hire

Brian Stevens has joined Data Physics as a Mechanical Engineer reporting to Tim Spaeth, Mechanical Engineering Group Leader in Corona. Brian recently completed his Bachelor of Science degree in Mechanical Engineering from California Polytechnic State University, Pomona. Brian developed his passion for dynamics of machines while working at the Engi-neering Department in Corona as an intern during his student years.

openings

Data Physics is seeking qualified applicants for a number of positions in various functions at its offices in San Jose, California, Corona, California and Hamden, Connecticut. Please see listings in the Careers section of the Data Physics website for details. You are invited to refer suitable candidates with the promise of a monetary reward for the successful hiring of your referred candidates. The size of the reward will vary between $250 and $1000 depending on the position.

Web Seminars

Understanding the Shock Response Spectrum (SRS) was on Thursday, July 11, 2013

Kalyan Vitta, Senior Applications Engineer, presented the origination of SRS and why it is important to understand and analyze the shock response of a structure. This seminar also covered the different SRS applications and how SRS test-ing provides the ability to synthesize a time waveform from a SRS profile that can be controlled on an electro dynamic or electro hydraulic shakers in a consistent manner. You can access the recording of this highly popular seminar in the Event Recordings Archive.

High Intensity Acoustic Test Systems on Thursday, August 8, 2013

Wes Mayne III, Product Manager, Acoustic Test Systems, will provide a quick overview of some important aspects of RAT-Fs and PWTs, including their general configuration, the specification of test spectra, chamber low-frequency response and uniformity, auxiliary systems such as cranes, and other topics.

Introduction to Turbomachinery Vibration Analysis on Tuesday, August 20, 2013

Robert Bloomquist, Product Manager, SignalCalc Turbo, will cover the basics of vibration analysis on large rotating ma-chinery. He will lead you through a tour of basic considerations and requirements for turbomachinery vibration analysis. You will learn the challenges of turbomachinery vibration analysis compared to smaller general purpose machinery, how to make effective measurements, and what to look for when analyzing behavior on these large, critical machines.

http://www.dataphysics.com/about-us/careers.html


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Shaker Selection Basics in September 2013

Kevin W. McIntosh, Director of Product Management for the SignalForce and SignalSound Product Lines, will cover basics on proper shaker selection. Kevin has more than 30 years of experience in the vibration test industry, both in ser-vohydraulic and electrodynamic shakers. Kevin is currently the Chairman of the IEST Shaker Selection Working Group, writing the best practices document for the Institute of Environmental Sciences and Technology.

Register for upcoming Data Physics Web Seminars.

View Recordings of past Data Physics Web Seminars.

Seminars

Navcon Engineering Hands-On Modal Seminars in Fullerton, CA on Aug. 13-16 and Nov. 5-8, 2013

Navcon Engineering provides regular training for modal testing utilizing Data Physics SignalCalc products. Using Sig-nalCalc Dynamic Signal Analyzers during the class serves as a general training on the use of the analyzer along with the fundamentals of modal testing. Due to the popularity of these seminars, Navcon is holding an additional seminar in August that is not listed on the website.

The overall goal for attendees completing the class is to be able to conduct a modal test from start to finish on their own. This training is about methods and applications. Modal theory is presented from the experimentalist’s point of view. More information on the seminar content and registration can be found on the Navcon website.

http://www.dataphysics.com/news-and-events/seminars.html


http://www.navcon.com/HandsOnModal.htm

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tradeshows

Visit the Data Physics website for a complete list of 2013 tradeshows.

Noise-Con at Denver, Colorado on August 26-28, 2013

Noise-Con 2013 conference and exposition will be held in conjunction with the 2013 International Wind Turbine Noise Conference. The event focuses on the latest in technology and services in the areas of noise and vibration. Topics include building acoustics and noise control, product noise emissions, community and environmental noise, industrial noise, motor vehicle noise, and air and space system noise and vibration. Data Physics will be at booth 21.

Automotive Testing Expo China on September 10-12, 2013

Data Physics will be at booth 3060 again this year in Shanghai at the Automotive Testing Expo China. The rapid growth in new car sales and the need for higher quality and safer vehicles is bringing together the world’s leading test equip-ment manufacturers and test service providers in an intense three-day event. The Data Physics team in China will be in attendance.

Turbomachinery Symposium in Houston, TX, USA on Sept. 30 to Oct. 03, 2013

Data Physics will be present at booth 230 at the 42st Turbomachinery Symposium in the George R. Brown Convention Center in Houston, Texas. Data Physics Turbo expert Rob Bloomquist will be on hand to showcase the SignalCalc Turbo Rotor Dynamics Analyzer which is suitable for diagnosing rotating machinery problems. Thousands of engineers, manu-facturers and users will be in attendance.

http://www.dataphysics.com/news-and-events/tradeshows.html

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Software Release: SignalStar Controller Version 2.4

SignalStar Controller version 2.4 is being prepared for release as this volume is going to press. All users under software support will receive the new update of SignalStar software during July. The new software version has more than 50 software fixes and many new features and enhancements. Noteworthy software enhancements and features include:

• SRSincludes"True"dampedSinesinadditionto“ZERD”dampedSines• MultiFrequencySineincludesafeasibilitycheckafterpre-test• LimitchannelsensitivityinMultishakerSineisnowautomaticallyset• Profiletablesacceptpasteofcellcontentsfromaspreadsheet• ImprovementstoReplicatorandMultishakerReplicatorallowingsmoothertransitionofsequences• Sineprofilessupportvariabledisplacementsegments• ClassicalShocksupportsRCTADO160Especificationtolerancelimits• AsignificantnumberofGUIenhancementsinRandomAcousticControl• MultishakerRandomreferenceprofilesacceptimportofMatlabspectralmatrix• Header/Footerinformationisnowlinkedbetweenthereportgenerationandthepagesetupforprinting• BoxtolerancesareautomaticallyaddedtoreferenceprofilesinsingleshakerandmultishakerSinewhen there is a step change in reference profile amplitude• Newtoolbarbuttontoaddcursorstograph

Users who are not under software support can still get to renew their support contract at a reduced price until Au-gust 31, 2013. Please contact Applications Engineering for terms of the offer.

honeywell Sensing and Control Selects SignalStar Controllers

Honeywell Sensing and Control in Freeport, IL recently purchased three SignalStar Scalar controllers for their environ-mental test facility. These controllers were purchased to replace three Unholtz Dickie controllers used with Unholtz-Dickie shakers. This order also included a replacement amplifier for one of the Unholtz-Dickie shakers.

The order was placed after a lengthy evaluation that included the new Unholtz-Dickie and Vibration Research control-lers. After a demonstration, Honeywell did a month long evaluation of the Scalar controller. They found the Scalar to be much more capable than both the Unholtz-Dickie and Vibration Research controllers. This is typical of users that are concerned with capability and quality of their vibration controller.

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to order track or Not to order track

3D printers might change the future of manufacturing in years to come but for now we still rely on good old high speed cutting tools for manufacturing goods. As the name implies, high speed cutting tools run at top speeds to produce high precision work pieces in a consistent and accurate manner. In machining operations such as boring, drilling, tapping, turning, etcetera, the cutting tool is susceptible to high vibration because of the dynamic interaction between the cut-ting tool and the work piece. It is important for the machine tool manufacturer to understand the source of vibration that excites the mechanical modes of the system and hinders the performance of the machine. Excess vibration affects the accuracy and surface finish of the work piece not to mention shortening tool life.

HAAS Automation located in Oxnard, CA has been using SignalCalc software for analyzing vibration related problems on high speed cutting tools since 2011. HAAS is one of the largest CNC machine tool builders in the world, designing and building a full range of metal-cutting machine tools including Computer Numerical Control (CNC) machining cen-ters, lathes and rotary tables.

Figure 1: hAAS automated CNC lathe

Honeywell Sensing Systems is part of Honeywell Automa-tion and Control Systems and manufactures sensors for In-dustrial, Aerospace and Defense, Transportation, Medical, and Test and Measurement applications. The Scalar systems will be used in testing pressure sensors used in the Interna-tional Space Station.

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Spectrum analysis is a useful tool in understanding the information content of the vibration signal during the machin-ing operation. When the machine is operating at a constant speed, a power spectrum can be used to analyze vibrations associated with the shaft running speed and its harmonics (orders). As the machine speed varies such as in a machine run-up or coast-down, the vibration frequency also varies and power spectrum analysis of data sampled in time shows smearing of vibration information. As the spectral content is spread across different frequencies it is difficult to correlate and identify the vibration peaks to the specific rotating elements causing the problem.

Vibration related to rotating elements occurs at frequencies linked to the order of rotation and separating such vibra-tion is therefore called Order Analysis. Order analysis may be performed by the use of tracking filters (filters that track the rotational rate) or by performing FFT analysis of samples taken at constant fractions of rotation (constant angle increments), instead of samples taken at constant intervals of time.

In SignalCalc analyzers, sampling at constant angle increments is done by re-sampling of time domain samples. The tachometer input of the system is used to measure machine speed concurrently with the normal time domain acquisi-tion of signals. A digital re-sampling process provides the angle domain samples. The FFT of this data provides Order domain results.

Figure 2: Cutting tool measurement setup

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Depending on the operating condition of the rotating machinery, one of the following three different RPM modes may be used for measurement.

RPm Sweep – provides automated rapid (unaveraged) measurement of run-ups and run-downs. Machine RPM is used to pace the interval between measurements and is used to trigger the start and stop of the measurement session.

RPm Stepped – provides for averaged measurements at a constant speed which may then be changed through a se-quence of equally spaced RPM steps.

RPm Steady – provides averaging within a nominally constant speed.

Order Spectra is typically viewed in waterfall or spectrogram (colormap) format. These displays are three dimensional graphs that combine rotation speed, amplitude and orders on the same graph. Some users may even prefer to view the three dimensional data in a Campbell diagram, which uses shapes (typically circles) and the shape’s size to indicate peak levels. Three dimensional displays enhance data clarity and aid the user to easily distinguish if the phenomenon is order related or is a structural resonance in the system.

User knowledge of the rotating machine helps in dissecting the information and associating the vibration to the respec-tive components of the machine. Figure 3 illustrates 32nd order (vibration at 32 times the operating speed) of a high speed cutting tool. The user must then understand what happens 32 times per revolution to cause the excessive vibra-tion.

Figure 3: Waterfall plot showing orders vs. magnitude vs. RPm

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If the noise or vibration occurs during machine run up, coast down or other speed change, Order Analysis must be ap-plied for meaningful data. Order tracking is not only a great tool for analysis during speed change but also for under-standing order related events in any rotating machinery.

Cross-Application Coverage for Critical Rotating machinery with SignalCalc turbo

SignalCalc Turbo delivers many features that meet and surpass the capabilities of competitive products when it comes to diagnostics on large, critical, rotating machinery. The efficient user-interface, expandable channel count, exceptional phase accuracy and dynamic range, and self-calibration are capabilities that appeal to many customers. The ability to conveniently employ a single hardware front-end with multiple software applications, however, is a key selling point to users who understand the value of having more than one tool in their turbomachinery vibration analysis toolbox. Cross-application coverage is a major deficiency in some competitive products, such as the Bently ADRE 408.

Rotatingmachinerydynamicscanbestbeunderstoodwhen theentire“system” is considered.Thismeansnotonlyanalyzing vibration of rotating shafts, but also vibration characteristics of the supporting structure and ultimately how the rotor and structure interact. Combining the analytical power of SignalCalc Turbo with general SignalCalc dynamic signal analysis software, 3rd party Modal analysis applications, and Data Physics SignalForce shaker solutions makes a comprehensive analysis toolkit.

SignalCalc Turbo is an advanced, portable vibration data acquisition and analysis system for rotating machinery, with special consideration for fluid-film bearing ma-chines. Designed to handle input signals from orthogo-nally mounted proximity transducers, SignalCalc Turbo provides convenient graphical display of shaft centerline position and orbits relative to the structure on which the transducers are mounted. SignalCalc Turbo also easily measures signals from casing-mounted accelerometers and velocity transducers for analysis in the time and fre-quency domains.

Additional insight may be necessary, however, to obtain a more comprehensive understanding of vibration char-acteristics associated with the supporting structure. For example, while most large, rotating machinery are firmly anchored to a pedestal and supporting foundation, in-creased compliance in the structure due to compromised structural integrity and rotating forces may contribute to high machine casing vibration levels. Furthermore, some rotating machinery are mounted on fabricated I-beam “skids”,andinstallationissuesmaybringintoplaystruc-tural resonances in the same frequency range as rotor-related excitation forces.

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Perhaps the most commonly needed capability along with general turbomachinery vibration analysis is modal im-pact testing or bump testing. SignalCalc software supports impact hammer testing of structures for transfer function measurement. The impact hammer provides a wide-band excitation source for exciting natural frequencies in the structure. The transfer function provides normalized fre-quency response for accurate determination and compari-son of observed natural frequencies and corresponding modes. Whereas a hammer impact test provides wide-band excitation and flexibility, it is not always practical and is sometimes prone to human error. A more controlled and accurate approach to structural testing is to use a modal or inertial shaker to apply a known excitation force to the structure across a desired frequency range.

When these results are considered along with shaft vibration measurements, the user is now armed with a complete picture of potentially damaging structural resonances which may be excited by rotor-related excitation forces. Typi-cal rotor-related excitation forces include:

• Shaft unbalance (1X running speed and multiples)

• Misalignment (1X and 2X running speed)

• Rotortostationaryelementrubs(1/2Xrunningspeedandmultiples)

• Fluid-induced instability (0.38-0.48X running speed)

• Vane-pass frequency (number of vanes x running speed)

• Gear mesh frequency (number of gear teeth x running speed)

General FFT analysis can also be used with Modal software like ME’Scope to provide a 3-dimensional animated view of structural vibration, called the Operating Deflection Shape (ODS). This provides additional insight into deflection of the structure at various modes.

Other plant operations such as piping analysis, gearing issues, and acoustic noise emissions can also be addressed with SignalCalc. The default correlation capability combined with structural analysis using transfer functions is a very powerful tool for tracking and fixing pipe vibration issues. Demodulation provides analysts advanced capabilities for demodulating signals that more complex gear or rolling element bearing defects may produce. Machinery noise be-comes a problem on occasion and realtime octaves and acoustic intensity tools are available for users to address those types of problems.

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While it is not uncommon for SignalCalc Turbo to be used with the alarming option and installed on a temporary basis to diagnose vibration problems, the Event Capture feature of the general SignalCalc software provides another set of powerful monitoring and recording features. Event Capture is designed to record data triggered from any signal or statistic, across any frequency bandwidth and from any channel. This power capability allows users to perform cyclic recording with the Abacus and set long pre-triggers to aid with root cause analysis. Multiple recordings can be ob-tained along with a log file showing each recording trigger event and time.

In summary, Data Physics suite of SignalCalc Dynamic Signal Analyzers and SignalForce Electrodynamic Shakers de-liver powerful cross-application coverage for the advanced rotating machinery vibration analyst. The ability to obtain a comprehensive understanding of both shaft and structural vibrations - and how they interact - provides the user with the necessary tools to diagnose complex problems that might otherwise go unsolved, sometimes with catastrophic results. Data Physics solutions also make this convenient by leveraging a common hardware interface for all applica-tions that is compatible with popular vibration transducers used with rotating machinery such as proximity probes, velocity transducers, and accelerometers.

lE-Series 3 Inch (76.2mm) Shakers are Gaining momentum

As a positive sign of the momentum gathering behind the newly released series of 3 inch displacement shakers, Data Physicsisproudtoannouncetherecentordersforthesenewmodels.AlthoughtheLE-1316-3/DSA10-100Kshakerwasjustrecentlyformallyannounced,twonewcontractshaverecentlybeenawardedforLE-1316-3/DSA10-100Kshakers.

One of the shakers was purchased by Georgia Tech Research Institute. Originally opened in 1934, the Georgia Tech Re-search Institute employs nearly 1600 highly skilled people and conducts more than $200 million worth of government and industry sponsored research each year.

ThesecondandmostrecentsaleoftheLE-1316-3/DSA10-100KshakeristoSIRIMinMalaysia.SIRIMBerhadisawholly-owned company of the Malaysian Government under the Ministry of Finance. With over forty years of experience and expertise, SIRIM is the national organization for standards and quality in Malaysia. The organization also acts to promote industrial research and development. Other internationally recognized standards organizations that are currently Data Physics customers include NIST and PTB.

DataPhysicshasalsobeenawardedapurchaseorderforanewLE-4022-3”shakerandcoolingunitbyLockheedMartinin Ocala, Florida. This system will be a replacement for a very old Ling Electronics LE-4022 shaker system, using their existing amplifier system that was replaced approximately five years ago.

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Celestica Upgrades to a New Generation of Shaker

Located in Austin, Texas, the Celestica Aerospace and Defense Center for Electronic Manufacturing Services (EMS) spe-cializes in design and manufacture of electronic assemblies for aerospace and defense applications. In early June, this sitecommissionedaSignalStarScalarandaSignalForceLE-308/DSA10-20Kshakerintegratedinamonobasewitha36inch (914 mm) slip table for testing to MIL-STD-810 profiles up to 7 grms on electronic assemblies.

The LE-308 replaced an old MB Dynamics C150 shaker with a Spectral Dynamics Puma controller. As one of the only available resources for parts and service on aging MB Dynamics shakers, the Data Physics SignalForce service team had previously been providing service and support for the old C150. Their positive experience with Data Physics repair ser-vices for their shaker and amplifier, combined with guidance on new system selection from local field sales personnel, were both strong influences in their decision to purchase a Data Physics system.

The low mass armature of the LE-308 also allowed engineers at Celestica to scale down the size of their shaker. The MB C150 was able to generate 15,000 lbf (66 kN). The replacement LE-308 at 3,000 lbf (13.4 kN) is capable of running their most demanding profiles on their 80 lb mass test articles.

Having in-house vibration test capability is a competitive advantage for Celestica. Many EMS companies do not offer qualification or production vibration testing without their end customer funding a capital investment for equipment.

Celestica is a $6.5 billion global company that offers services for electronic manufacturing, product design and supply chain collaboration and management.

Rotational and Cross-Axial Stiffness It seems fitting to follow up last month’s discussion on Overturning Moments in Vibration Testing with a discussion on the rotational and cross-axial restraint capabilities of the LE-series shaker systems. Rotation and cross-axis motion are undesirable when testing sensitive devices and should be minimized whenever possible.

In many cases, the customer's test article is the culprit generating the off-axis energy through moments generated by either physical constraints or lack of attention being paid to the product’s center of gravity. If the test article is critical and cannot survive a test that has off-axis vibration, the off-axis motion should be constrained through the design of the shaker or an external guidance system. The external guidance system is a guided head expander for vertical testing or a guided slip table for horizontal testing. When designing extended displacement shakers of existing models, the engineering challenge was how to allow for more mechanical displacement without the loss of rotational and cross-axial restraint. For instance, with the LE-1216 and LE-1316 shakers, cross-axial restraint was achieved by the addition of a top guide bearing and the rotational re-straint was increased by addition of extra layers of flexure material.

With the LE-4022 and LE-5022 water cooled shakers, the task was made more complex due to the fact that the shakers already included dual hydrostatic bearings for guidance and cross-axial restraint. In order to achieve the desired results with the water cooled shakers the quantity of flexures was increased from four to eight. This was no small task consid-ering the limited space around the top plate and the machining modifications required to fit double the quantity of flexures onto the armature.

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Figure 1: Eight flexures around the lE-4022 armature

Judging from measured results, the engineering team can be quite proud of their accomplishment. Here are the mea-surements for the new shakers:

LE-4022: CrossAxialStiffness-45,873lbf/inchRotationalStiffness-3,137ft-lbf/degree LE-1216 and LE-1316:CrossAxialStiffness-35,158lbf/inchRotationalStiffness-893ft-lbf/degree

External guidance will be required if the off-axis forces will exceed the restraint as specified. Please consult SignalForce Applications Engineers for assistance with proper guidance for sensitive applications.

Contributors

Robert Bloomquist, Product Manager, SignalCalc TurboBourke MacDonald, Marketing Communications SpecialistKevin McIntosh, Director, Product Management, SignalForce and SignalSoundThomas Reilly, Director, Product Management for SignalCalc and SignalStarTim Settle, Business Manager, US Southern RegionKalyan Vitta, Senior Applications EngineerRussellZuppo,Director,MarketingManaging Editor: Sri Welaratna, PhD, President and Chief Executive Officer

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