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Experiment Instructions
PT 500.11 Crack Detection in
Rotating Shaft Kit
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i
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Experiment Instructions
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
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.
Version: 1.1 Subject to technical alternations
Authors: Dr.-Ing. Detlef Abraham
Dipl.-Ing. Jack Boxhammer
Dipl.-Ing. Peter Mittasch
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Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Health hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Hazards to the unit and its function . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 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
4 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214.2 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
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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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
iii
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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1 Introduction
The PT 500.11 Crack Detection in RotatingShaft Kit allows a shaft with a crack to be simu-
lated. Cracks caused by material fatigue are very
dangerousfor rotatingmachinesas they often lead
to the dreaded fatigue fracture, with fatal conse-
quences. As a result, early detection is vital.
A crack in the shaft influences the shaft’s vibration
behaviour by changing its rigidity. These changes
can be identified by measuring the vibrations on
theshaft andusingappropriateanalysissoftware.
Learning content/Exercises
– Change in characteristic vibration behaviour
(natural frequency, resonance speed, ampli-
tudeand phase ofvibrations) due toa 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 1
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
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1.1 Intended use
The PT 500.11 unit is to be used only for teachingpurposes.
1 Introduction 2
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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 Explanation
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, mayresult in minor or moderately serious injury.
NOTICE Indicates a situation which may result in damageto equipment, or provides instructions on opera-
tion of the equipment.
2 Safety 3
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Symbol Explanation
Rotating shafts
General hazard location
Notice
2 Safety 4
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2.1 Health hazards
WARNING
Rotating shafts
Risk of injuries.
• Make sure that long hair, long beards,
chains, ties and loose clothing does not
come into contact with the rotating parts.
• Only operate theunit with theprotective hood
closed.
• Switch off the motor before any modifica-
tions.
2 Safety 5
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2.2 Hazards to the unit and its function
NOTICE
At least two of the six hexagon headscrewsdistrib-
uted around the circumference must be securely
tightened with no clearance with spacer sleeves.
The remaining screws must be fitted as loose con-
nections 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 speedshould be avoided. The critical bending speed
depends on the individual experimental setup.
2 Safety 6
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3 Unit description
This unit simulates the characteristic behaviour ofa 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 depend-
ing on the installation direction of the spacer
sleeves.
When rotated with a bending load, this flange con-
nection results in intermittentseparation of thebutt
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).
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.
3 Unit description 7
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Fig. 3.1 Shaft with no crack -
Flange connection withsix supporting screwsA = Loose connectionB = Secure connection
Fig. 3.2 Shaft with small crack -Flange connection withfive supporting screws
Fig. 3.3 Shaft with maximumcrack - Flange connecti-on with two supportingscrews
B
B
A
A
B
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3.1 Layout
3 Unit description 8
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Fig. 3.4 Overall view of PT 500.11 - “Crack Detection in Rotating Shaft Kit”
1 Driving shaft (PT 500)
2 Clamping set
3 Centring pin
4 Pick up disc
5 Hexagon head screws
6 Spacer sleeve
7 Flange with long shaft (output for weight)
8 Flange with short shaft (output for belt drive)
8 7 6 5 4 3 2 1
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3.2 Assembly of the flange connection for simulation of a crack
– Align the flange with the shaft (Fig. 3.4, 7 or 8)and pick up disc (4) using the centring pin (3)
and securewiththe hexagon headscrews(5).
NOTICE
The discs cannot be centred using the screws
alone.
– Dependingon the function, insertandtighten
the spacer sleeves (6).
• The use of a spacer sleeve for a looseconnection 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.
NOTICE
At least two of the six hexagon headscrewsdistrib-
uted 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 9
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Fig. 3.5 Loose connectionwith spacer sleeve
Clearance
Fig. 3.6 Secure connectionwith spacer sleeve
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3.3 Securing the flange connection on the shaft with the clamping set
To secure the pickup disc on a shaft with theclamping 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 whiledoing 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.
When loosening the clamping set, hold the inner
hexagon (B) steady and unscrew the outer hexa-
gon. After overcoming the initial loosening torque,
continue turning until the resistance starts to
increaseagain.Turning further presses the clamp-
ing set out of the mount and it can then be
detached by hand.
3.4 Maintenance / care
ThePT500.11accessory set is maintenancefree.
3 Unit description 10
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Fig. 3.7 Layout of a clamping set(shaft clamping set)
A B C
Pick up disc
Shaft
Fig. 3.8 Clamping set
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4 Experiments
Theselectionof experimentspresentedhere 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 environmen-
tal conditions, deviations may occur in the experi-
ments. Nevertheless, the laws can be clearly
demonstrated.
Generally, it is important tonote that the “shaft with
crack” experiments involve very sensitive effects.
Note the following:
– The shaft should run true and not knock.
When modifying the shaft with a crack,
ensure that the centring is retained.
– The shaft shouldnot be loadedwithany addi-
tional 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 noclearance (Fig. 3.1).
– For the experiment with a shaft crack , three
consecutive screws are fitted as a loose con-
nection.
The frequencyspectra for the twoexperimentsare
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
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4.1.3 Preparation and setup
4 Experiments 13
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Fig. 4.1 Experimental setup for “shaft with crack with protruding shaft end”
1 Belt tensioner
2 Belt
3 Small belt pulley
4 Short shaft with flange5 Pick up disc
6 Shaft clamping set
7 Acceleration sensor
8 Bearing block
9 Short shaft
10 Reference sensor
11 Setting ring
12 Bearing block
13 Elastic claw coupling14 Drive unit
15 Magnetic clamp with steel plate
16 Reflective mark
17 Large belt pulley with bearing block
14 13 11 12 11 10 9 8 7 6 5 4 3 2 1
15 16 17
B e l t r u n n i n g
d i r e c t i o n u p w a r d s
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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 thecontrol unit to thepowersupply.
– 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 flangeshouldbe fitted
as described in section 3.
Shaft without crack
• Six hexagon head screws with spacer
sleeves as a secure connection (Fig.
3.6)
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Fig. 4.2 Pick up disc with clamping
set, short shaft with flangeand small belt pulley. Twosupporting screws (A)
A
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Shaft with crack
• Four hexagon head screws with spacersleeves as a looseconnection (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 andslightly tension thebelt.
The correct direction of rotation must be
ensured (Fig. 4.1). The belt tensioner must
be fitted on the unloadedside 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.
Thebelt tension shouldbe increaseduntil the
feeler fits 0.4 mm into the gap between the
flange on the side opposite the supporting
screws. A measurement should also be car-riedout on the sideopposite the belt drive (on
the side where tensile stress is acting on the
shaft).
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Fig. 4.3 Belt tension adjusted usingfeeler, or alternatively withbelt pretension measuring
unit (tension approx. 70 N)
Belt tensionadjustment
Feeler 0.4 mm
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Alternatively, thetensile stressof thebelt can
be measured using the belt pretension mea-suring unit (Fig. 4.5).
Procedure:
• Switch off the belt drive.
• Push the red lever on the belt preten-
sion measuring unit downwards so that
it indicates zero.
• With your index finger in the clip, slowly
press the measuring unit onto the beltfrom above, until you feel it click.
• Read the measured value of the red
pointer pushed upwards until it clicks.
(For details, refer to the manufacturer’s
instructions.)
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Fig. 4.4 Belt drive with tensioner
Fig. 4.5 Belt pretension measuring unit
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– Screw the acceleration sensor (7) into the
horizontal tapped hole in the bearing blockclose to the shaft with crack, Fig. 4.1.
– Fit thereflective marker (16) for thereference
transducer (10) on the shaft or weight.
– Fit the referencesensorwith magneticclamp
(15) and steel plate on the clamping plate
and roughly align with the reflective mark.
– Connect the reference transducer and accel-
eration 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 reflectivemark.
– Check the switching behaviour of the refer-
ence 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: 100 mV/g
Offset: 0.0
Factor: 1.0
– Gain on measuring amplifier: 10x.
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– Check thesignalstrength in theOscilloscope
window. To obtain optimum resolution whendigitising, 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 Spec-
trum” window and check the following set-
tings.
Channel A: Channel 1
Channel B: ReferenceScan Rate: 8 k/s
Scan Time: 4 Seconds
Of Means: 1
Mode: Velocity
Window Function: Uniform
Log Or Linear: Linear
Unit Of Magnitude: rms
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B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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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 allpartsarefittedsecurely.
• Close the protective hood.
• Switchonthe control unit for the motor.
• Set the direction of rotation (deter-
mined by the belt drive - the belt
tensionershouldacton thelooseside).
• Set the speed to zero.
• Switch on the motor.• Set the speed, e.g. to 2400 rpm.
• Plot the frequency spectrum.
• Set the speed to zero.
• Switch off the motor.
– Prepare the “shaft with crack ” for the exper-
imental 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
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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must always secure the pickup disc and the
short shaft with flange.• Process: As described above for the
“shaft without crack ”.
4 Experiments 20
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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4.1.5 Evaluation
Secondorder 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
vibrationswith doublethefrequency of thespeed.
First of all, the frequency spectrum for the “shaft
without crack” (six supporting screws) is dis-
played. Here, the fundamental vibration at 40 Hz
and the associated higher harmonics (f Dx
) can be
seen. Most of the other vibrations are caused by
thebelt drive,whichhas its fundamental frequency
at 8.8 Hz (measured). The shaft for the large belt
pulley rotates at half the speed f D/2
.
4 Experiments 21
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Anisotropic:
Anisotropic rigidity is a directi-on-specific rigidity.
Fig. 4.6 Frequency spectrum of protruding shaft end without crack (six supporting screws)
n = 2400 rpm
40 Hz, f D = drive, f R = belt drive
f D1
f D2 f D3
f D4
f D5 f R1
f R2
f R3
f R4
f R5
f D/2 f R6
f R7
40.0
8.8
17.6
26.5
35.2
20.0
44.0
52.8
61.6
80.0 120.0
160.0
200.0
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For the “shaft with crack”, the fundamental vibra-
tion (f D1
) with the higher order harmonics (f D2-D5
)
can also be seen. The amplitude of the fundamen-
tal vibration for the “shaft without crack” is greater
than in the “shaft with crack” setup.
The “shaft with crack” also clearly shows the char-
acteristic rise in the 2nd order vibration f D2
. This is
an indicator of the crack.
Calculated belt frequency:
f n U
LR
AR
R
60
2400
60
1979
9128 7
min mm
mmHz
1 ..
4 Experiments 22
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Fig. 4.7 Frequency spectrum of protruding shaft end with crack (three supporting screws)
n = 2400 rpm
40 Hz
f D1
f D2
f D3
f D4
f D5
f R1
f R2
f R3
f R4
f R5
f R6
f R7 f D/2
40.0
8.8
17.6
17.6
26.4
35.2
44.0
52.8
61.680.0
120.0
158.9
200.0
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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 ofthe 2nd order vibration speed rises sharply. Typi-
cal 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 23
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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4.2.3 Preparation and setup
Set up based on the diagram or the following
points:
– 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 thecontrol unit to thepowersupply.
4 Experiments 24
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Fig. 4.8 Experimental setup for “shaft with crack” simulation with elastic rotor
1 Acceleration sensor horizontal
2 Bearing block
3 Long shaft with flange
4 Pick up disc
5 Vertical displacement sensors6 Horizontal displacement sensors
7 Retain bearing
8 Short shaft with marking
9 Reference sensor
10 Bearing block
11 Elastic claw coupling
12 Drive unit
13 Magnetic clamp with steel plate
14 Setting ring
15 Reflective mark16 Weight with clamping set
17 Clamping set
18 Spacer sleeve
19 Hexagon head screws
12 11 10 9 8 7 6 5 4 3 2 1
13 14 14 15 16 17 18 19
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– Fit the elastic claw coupling (11) on the drive
unit.
– Loosely fit a bearing block (10) on the clamp-
ing plate flush in front of the elastic claw cou-
pling.
– 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 subse-
quently 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) (asdescribed in section 3.3) on the free end of
the short shaft (8) with the clampingset (17).
– Fit the second bearing block (2) onto the free
end of the shaft with flange(3) (seeFig.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, slideall 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.
4 Experiments 25
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Fig. 4.9 Fully assembled unit(shaft without crack)
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– Screw the displacement sensors (5 and 6)
into the horizontal and vertical tapped holesin the retain bearing (2) in sucha way that the
transducersarenot in contact with theshaft.
– Fit thereflective marker (15) for thereference
transducer (9) on the shaft or weight.
– Secure the accelerationsensor (1) in the hor-
izontal tapped hole in the bearing block (2).
– Fit the reference sensor onto the clamping
plate with the magnetic clamp (13) and steelplate.
– Connect the reference sensor and accelera-
tion 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 measuringamplifier. Switch on the measuring amplifier
on the front panel.
– Align the reference sensor with the reflective
mark.
– Check the switching behaviour of the refer-
ence 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 dis-
placement sensor, refer to PT 500.10, sec-
tion 3.2 and 3.3.
4 Experiments 26
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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– Open the “Sensor” and “Calibration” win-
dows 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: 100 mV/g
Offset: 0,0Factor: 1,0
– Check the signal strength in the “Oscillo-
scope” window. To obtain optimum resolu-
tion when digitising, select the largest possi-
ble gain factor without exceeding the mea-
suring 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: 1.25 V/mm
Offset: 0,0
Factor: 1,0
For assembly and calibration of the displace-
mentsensors, refer to PT500.10, section 3.2
and 3.3.
4 Experiments 27
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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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 “Sen-
sor” in the menu in the PT 500.04 soft-
ware (check the configuration if neces-
sary).
• Open the “Tracking Analysis” window
from the menu in the PT 500.04 soft-
ware. Make the following settings in the
window:
Channel: Channel 1
Mode: Velocity
Graph Order A: 1
Graph Order B: 1
Scale: Auto
• Check that allpartsarefittedsecurely.
• Close the protective hood.
• Switchonthe control unit for the motor.
• Set the desired direction of rotation.
• Set the speed to zero.
• Switch on the motor.
4 Experiments 28
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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Notice
The required printer must be set as thedefault printer before starting the pro-
gram.
• Either plot the response analysis chart
manuallyor continuouslyandautomati-
cally (selected here: Continuous).
• Start the measurement and slowly
increase the speed (from 0 rpm to3000 rpm), while observing the curve
plotted in the program window. The
measurement can be carried out con-
tinuously using the software or manu-
ally using individual values.
• To finish continuous measurement at
the end, click on the “Continuous” but-
ton.
• Print out the results on the default
printer.
• Switch off the motor.
– Prepare the “shaft with maximum crack” for
theexperimental process, i.e. fit twoadjacent
screws with spacer sleeves as a secure con-
nection and the other four as a loose connec-
tion. Refer to section 3 for details.
• Process: As described for the “shaft
without crack” in this section.
4 Experiments 29
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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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 win-
dow:
Mode: Displacement
Order ---
Scale 1-10-100-1000
For a scale greater than 1, the value
read in the diagram has tobedivided by
the selected scaling value.
• Check that allpartsarefittedsecurely.
• Close the protective hood.
• Switchonthe control unit for the motor.
• Set the desired direction of rotation.
• Set the speed to zero.
• Switch on the motor.• 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 maxi-
mum.
• Save or print the results.
• Set another speed and plot a new orbit
curve.
4 Experiments 30
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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– Prepare the “shaft with crack” for the experi-
mental process, i.e. fit two adjacent screwswith 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
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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4.2.5 Evaluation
For the elastic shaft, the occurrence of 2nd
order vibrations, such as those that occur on
the shaft witha crack for example,dependon
the load on the shaft. This changes with the
speed due to resonant vibrations. Therefore,
a measurement ata fixed speed may not pro-
vide any conclusions.
The response analysis over a wider fre-
quencyrange reliably identifies the2ndorder
vibrations sought.
The orbit curves are a further characteristic
indicator of a shaft with a crack. These
should meet where 2nd order vibrations
occur.
4 Experiments 32
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Fig. 4.10 Response analysis for elastic rotor without crack, 1st and 2nd order. The 2nd order ampli-tudes (B) are smaller than and below the 1st order amplitudes (A) over the entire speedrange. (channel: 1; mode: Velocity)
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This kind of response analysis can also be
carried out with a real rotor (e.g. power sta-
tion turbine) when a stoppage is due. It is
essential that comparative data for the
undamaged rotor is available.
4 Experiments 33
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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 range1500 rpm to 2900 rpm.The 2nd order amplitude rises above the 1st order amplitude (A).
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To indicate the increase in 2nd order vibra-
tions depending on the formation of a crack,several response analyses are superim-
posed in a single chart. Here, even small
cracks (five screws tight) show significant
variations from the shaft with no crack.
The progress of the crack formation can be
clearly discerned.
4 Experiments 34
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Speed rpm
Fig. 4.12Fig. Plots for 1st order response analysis with different levels of cracks
A m p l i t u d e m m / s
Three supporting screws (1)
Four supporting screws (2)
Five supporting screws (3)
Six supporting screws (4)
1
2
4 3
1st order response analysis
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Characteristics of the shaft with crack:
• Second order amplitude is greater than firstorder in certain ranges.
• The crack causes the 2nd order amplitude to
increase.
The progress of the crack formation can again be
clearly discerned here.
4 Experiments 35
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Fig. 4.13 Plots for 2nd order response analysis with different levels ofcracks
A m p l i t u d e m m / s
2nd order response analysis
Speed rpm
1
23 4
Three supporting screws (1)
Four supporting screws (2)
Five supporting screws (3)
Six supporting screws (4)
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Orbit curves enable the 2nd order vibration com-
ponents to be effectively identified. This method isideal 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 identi-
fied here.Allchartswere plotted using thesettings:
Mode: Travel
Scale: 10
4 Experiments 36
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Fig. 4.14 Shaft without crack, n = 2040 rpm
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If there isa 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 37
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Fig. 4.15 Shaft with crack, three supporting screws;
n = 728 rpm; hardly any 2nd order vibrations.
Fig. 4.16 Shaftwith crack, threesupporting screws;
n =1463rpm;small 2ndorder vibration component.
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4 Experiments 38
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Fig. 4.17 Shaft with crack, three supporting screws;
n = 1785 rpm; large 2nd order vibrationcomponent.
Fig. 4.18 Shaft with crack, three supporting screws;
n = 2226 rpm; large 2nd order vibrationcomponent.
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4 Experiments 39
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Fig. 4.19 Shaft with crack, three supporting screws;
n = 2470 rpm; with 2nd order vibrationcomponent.
Fig. 4.20 Shaft with crack, three supporting screws;
n = 2842 rpm; with no 2nd order vibrationcomponent.
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5 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
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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5.2 Symbols
Belt frequency (calculated):
f n U
LR
AR
R
60
2400
60
1979
9128 7
min mm
mmHz
1 ..
where
n : Drive shaft speed in rpm
LR
: Belt length (912 mm)
U AR
: Circumference of drive roller (197.9 mm)
60 : Min to s conversion factor
f R
: Belt frequency in Hz
5 Appendix 41
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
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5.3 Setup suggestions / photos
5 Appendix 42
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0
Fig. 5.1 “Shaft with crack” experiment with protruding shaft end
Fig. 5.2 “Shaft with crack” experiment with elastic rotor and retain bearing
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5.4 Items supplied
1x PT 500.11Crack Detection in Rotating
Shaft Kit
1x PT 500.11Experiment instructions
PT 500.11 CRACK DETECTION IN ROTATING SHAFT KIT
04/2011
A l l R i g h t s R e s e r v e d
G . U . N
. T .
G e r ä t e b a u G m b H ,
B a r s b ü t t e l , G e r m a n y 0 1 / 2 0 1 0