振動(dòng)分析的完整指南（中英文）
如果尋找一種方法來(lái)讓機(jī)器更長(zhǎng)時(shí)間地保持良好的運(yùn)行，振動(dòng)分析將大有幫助。振動(dòng)分析是任何工業(yè)可靠性計(jì)劃的重要組成部分。它可以幫助團(tuán)隊(duì)監(jiān)控機(jī)器的健康狀況，預(yù)測(cè)維護(hù)需求并快速診斷缺陷。
本文介紹了什么是振動(dòng)分析以及它可以做些什么。仔細(xì)研究用于振動(dòng)分析的工具、軟件和方法。
振動(dòng)分析是可靠性中心維護(hù) (RCM) 和預(yù)測(cè)性維護(hù) (PdM) 計(jì)劃的核心。它通常與其他無(wú)損檢測(cè)維護(hù)技術(shù)相結(jié)合，如油分析、熱成像、超聲波檢測(cè)和電機(jī)電流分析。
If you’re looking for a way to keep your machines running better for longer, vibration analysis can be a huge help. Vibration analysis is a crucial component of any industrial reliability program. It helps teams monitor machine health, predict maintenance needs, and diagnose defects quickly.
This article explains what vibration analysis is and what it can do for your organization. We’ll also closely examine the tools, software, and methodology used for vibration analysis.
Vibration analysis is at the core of reliability-centered maintenance (RCM) and predictive maintenance (PdM) programs. It’s often coupled with other non-destructive testing maintenance technologies like oil analysis, thermography, ultrasonic testing, and motor current analysis.
什么是振動(dòng)分析？
What is Vibration Analysis?
振動(dòng)分析是測(cè)量和分析資產(chǎn)振動(dòng)模式的過(guò)程。這是一種行之有效的延長(zhǎng)資產(chǎn)使用壽命和減少計(jì)劃外停機(jī)時(shí)間的方法。
現(xiàn)代振動(dòng)傳感器和分析工具可以在問(wèn)題仍然易于修復(fù)的早期階段識(shí)別故障。這可以避免代價(jià)高昂的連鎖故障，并為維護(hù)計(jì)劃、采購(gòu)和設(shè)備安全停機(jī)留出時(shí)間。
作為任何狀態(tài)監(jiān)測(cè)或預(yù)測(cè)性維護(hù)計(jì)劃的關(guān)鍵組成部分，振動(dòng)分析提供了維護(hù)領(lǐng)導(dǎo)者所需的見(jiàn)解。這樣，決策者就可以提前預(yù)防機(jī)器故障并推動(dòng)更高效的維護(hù)計(jì)劃。
Vibration analysis is the process of measuring and analyzing your asset vibration patterns. It’s a proven, highly effective way to extend asset lifespan and reduce unplanned downtime.
Modern vibration sensors and analytic tools can identify faults at an early stage when problems are still easy to repair. This avoids costly cascade failures and allows time for maintenance planning, procurement, and safe shutdown of equipment.
As a key component of any condition monitoring or predictive maintenance program, vibration analysis provides the insights maintenance leaders need. That way, decision-makers can stay ahead of machine failure and drive more efficient maintenance planning.
振動(dòng)分析如何工作？
How Does Vibration Analysis Work?
旋轉(zhuǎn)機(jī)械的每個(gè)部件在使用時(shí)都會(huì)以離散且可量化的速率振動(dòng)。一定程度的振動(dòng)是正常的。但是，當(dāng)資產(chǎn)開(kāi)始過(guò)度振動(dòng)或以異常頻率振動(dòng)時(shí)，可能表明資產(chǎn)出現(xiàn)故障或正在惡化。
振動(dòng)分析可以查明振動(dòng)源，對(duì)其進(jìn)行診斷，然后采取適當(dāng)?shù)拇胧┻M(jìn)行糾正。維護(hù)團(tuán)隊(duì)使用各種工具從關(guān)鍵資產(chǎn)和組件收集振動(dòng)數(shù)據(jù)。然后，可以分析這些數(shù)據(jù)以了解資產(chǎn)的健康狀況。
診斷軟件收集和處理資產(chǎn)的振動(dòng)數(shù)據(jù)，識(shí)別異常，并在資產(chǎn)需要維修時(shí)通知維護(hù)團(tuán)隊(duì)。必要時(shí)，振動(dòng)分析專家會(huì)進(jìn)行更深入的診斷并為工作人員提供后續(xù)步驟的建議。
一些振動(dòng)分析軟件直接與計(jì)算機(jī)化維護(hù)管理系統(tǒng) (CMMS) 通信。只要振動(dòng)水平超過(guò)預(yù)定閾值或警報(bào)，良好的 CMMS 就可以生成自動(dòng)工作指令。
Every component of rotating machinery vibrates at a discrete and quantifiable rate when it’s in use. Some degree of vibration is normal. But when an asset starts to vibrate excessively or at an abnormal frequency, it may indicate that your asset is malfunctioning or deteriorating.
Vibration analysis lets you pinpoint the source of vibration, diagnose it, and then take the appropriate action to correct it. Maintenance teams use a variety of tools to collect vibration data from critical assets and components. Then, they can analyze that data for insights into asset health.
Diagnostic software collects and processes your asset’s vibration data, identifies anomalies, and notifies maintenance teams when an asset needs repairs. When necessary, vibration analysis experts perform a more in-depth diagnosis and advise your crew on the next steps.
Some vibration analysis software communicates directly with a computerized maintenance management system (CMMS). A good CMMS can generate automatic work orders whenever vibration levels cross a predetermined threshold or alarm.
認(rèn)識(shí)振動(dòng)
Understanding Vibration
振動(dòng)是物體圍繞中心位置的振動(dòng)，是理解和測(cè)量工業(yè)機(jī)械健康狀況的關(guān)鍵概念。所有旋轉(zhuǎn)機(jī)器都會(huì)產(chǎn)生振動(dòng)，每項(xiàng)資產(chǎn)都有自己獨(dú)特的振動(dòng)特征。當(dāng)機(jī)器的振動(dòng)水平發(fā)生變化時(shí)，通常表明該資產(chǎn)需要維護(hù)。
由于振動(dòng)是一種非常重要的診斷工具，因此每家依賴工業(yè)機(jī)械的公司都將受益于使用振動(dòng)分析。事實(shí)上，振動(dòng)分析是任何基于條件的監(jiān)控或預(yù)測(cè)性維護(hù)計(jì)劃的關(guān)鍵要素。如果做得正確，振動(dòng)分析可以精確定位新出現(xiàn)的資產(chǎn)故障的確切位置和性質(zhì)，以便維護(hù)團(tuán)隊(duì)可以快速進(jìn)行維修。
振動(dòng)通常以頻率和振幅來(lái)衡量。振動(dòng)頻率以赫茲為單位，描述每秒的振動(dòng)次數(shù)。振動(dòng)振幅描述每次振動(dòng)的大小，或從中心靜止位置行進(jìn)的距離。
振動(dòng)分析師在時(shí)間域中研究振動(dòng)水平，以全面了解振動(dòng)峰值發(fā)生的時(shí)間。他們還使用快速傅里葉變換 (FFT) 來(lái)解構(gòu)振動(dòng)波形并繪制振動(dòng)發(fā)生的頻率。結(jié)合使用不同的分析（FFT 和波形）可以讓分析師對(duì)關(guān)鍵資產(chǎn)的健康狀況有有用的了解。
Vibration, the oscillation of an object around a central position, is a key concept for understanding and measuring the health of industrial machinery. All rotating machines generate vibrations, and every asset has its own, unique vibration signature. When a machine’s vibration levels change, it’s usually an indication that the asset needs maintenance.
Because vibration is such an important diagnostic tool, every company that relies on industrial machinery will benefit from using vibration analysis. In fact, vibration analysis is a crucial element of any condition-based monitoring or predictive maintenance program. Done right, vibration analysis can pinpoint the exact location and nature of emerging asset faults, so that maintenance teams can make repairs quickly.
Vibration is typically measured in frequency and amplitude. Vibration frequency, measured in Hertz, describes the number of oscillations per second. Vibration amplitude describes the size of each oscillation, or the distance travelled from the central, resting position.
Vibration analysts study vibration levels in the time domain, to get an overall picture of when vibration peaks are occurring. They also use the Fast Fourier Transform, or FFT, to deconstruct the vibration waveform and plot which frequencies vibration occurs in. Using a combination of different analyses (FFT and waveform) can give analysts useful insights into the health of critical assets.
振動(dòng)測(cè)量類型
Types of Vibration Measurement
振動(dòng)以頻率、速度、加速度、速度和位移來(lái)測(cè)量。
頻率測(cè)量振動(dòng)物體每秒進(jìn)行的振動(dòng)次數(shù)。頻率以赫茲為單位。
位移測(cè)量振動(dòng)物體從其中心移動(dòng)的距離。最大位移稱為振幅。位移以毫米為單位。
速度測(cè)量位移率的變化，以毫米/秒為單位。
加速度測(cè)量速度隨時(shí)間的變化，也以毫米/秒為單位。
大多數(shù)振動(dòng)測(cè)量都是通過(guò)加速度計(jì)進(jìn)行的，加速度計(jì)測(cè)量資產(chǎn)和組件發(fā)出的沖擊和振動(dòng)。許多加速度計(jì)（包括大多數(shù)無(wú)線傳感器）都依賴于壓電技術(shù)，該技術(shù)將物理振動(dòng)轉(zhuǎn)換為電信號(hào)。
技術(shù)人員使用各種振動(dòng)監(jiān)測(cè)工具來(lái)監(jiān)測(cè)資產(chǎn)的振動(dòng)水平。在基于路線的維護(hù)期間使用的手持式監(jiān)視器可以捕獲振動(dòng)水平的快照。無(wú)線振動(dòng)傳感器可以在機(jī)器運(yùn)行的整個(gè)過(guò)程中實(shí)時(shí)收集振動(dòng)數(shù)據(jù)，并將數(shù)據(jù)傳輸?shù)皆贫诉M(jìn)行分析。如今，大多數(shù)工廠在其關(guān)鍵資產(chǎn)上使用無(wú)線傳感器。這些傳感器可以捕捉到振動(dòng)水平的細(xì)微變化。它們也易于安裝在資產(chǎn)和零部件上，因此可以提供有針對(duì)性的數(shù)據(jù)。
Vibration is measured in frequency, velocity, acceleration, velocity, and displacement.
Frequency measures the number of oscillations a vibrating object performs per second. Frequency is measured in Hertz.
Displacement measures how far a vibrating object moves from its center. The maximum displacement is referred to as amplitude. Displacement is measured in milimeters.
Velocity measures changes in the rate of displacement and is measured in milimeters per second.
Acceleration measures changes in velocity over time and is also measured in milimeters per second.
Most vibration measurements are taken with a form of accelerometer, which measures the shocks and vibration emitted by assets and components. Many accelerometers – including most wireless sensors – rely on piezoelectric technology, which converts physical vibrations into electrical signals.
Technicians use a wide range of vibration monitoring tools to monitor an asset’s vibration levels. Hand-held monitors, used during route-based maintenance, can capture a snapshot of vibration levels. Wireless vibration sensors can collect vibration data in real-time, throughout a machine’s operation, and can stream that data to the cloud for analysis. Today, most plants use wireless sensors on their critical assets. These sensors can pick up on even subtle changes in vibration levels. They are also easy to mount on assets and component parts, so that they can provide targeted data.
進(jìn)行振動(dòng)分析：分步過(guò)程
Conducting Vibration Analysis: the Step by Step Process
每個(gè)操作都不同，但振動(dòng)分析應(yīng)始終包括以下過(guò)程：
第一步：規(guī)劃和實(shí)施
在此階段，團(tuán)隊(duì)制定資產(chǎn)層次結(jié)構(gòu)并確定哪些設(shè)備最為關(guān)鍵。這使團(tuán)隊(duì)可以決定要監(jiān)控哪些資產(chǎn)。
在實(shí)施階段，管理者應(yīng)該確定哪種傳感器最適合工廠，以及將它們安裝在何處。還應(yīng)該決定使用哪些工具來(lái)分析振動(dòng)數(shù)據(jù)。
第二步：分析和解釋數(shù)據(jù)
有許多不同的工具可用于分析振動(dòng)數(shù)據(jù)。CMMS 可以組織用戶的數(shù)據(jù)并在振動(dòng)水平超過(guò)預(yù)定閾值時(shí)發(fā)出警報(bào)。好的 CMMS 甚至可以根據(jù)振動(dòng)水平的變化自動(dòng)生成工作指令。
如今，人工智能可以根據(jù)振動(dòng)數(shù)據(jù)成功診斷機(jī)器故障。先進(jìn)工具可以在沒(méi)有任何人工輸入的情況下“讀取”機(jī)器測(cè)試，查明機(jī)器故障，甚至向維護(hù)人員發(fā)出詳細(xì)的維修建議。
第三步：修復(fù)故障
一旦振動(dòng)數(shù)據(jù)被收集和分析，維護(hù)人員就可以進(jìn)行必要的維修。振動(dòng)分析使團(tuán)隊(duì)能夠盡早發(fā)現(xiàn)新出現(xiàn)的故障，以便輕松進(jìn)行維修。
這意味著計(jì)劃外停機(jī)時(shí)間顯著減少，因?yàn)楣ぷ魅藛T可以提前發(fā)現(xiàn)資產(chǎn)故障。這也意味著運(yùn)營(yíng)效率更高，維護(hù)成本更低。
Every operation is different, but vibration analysis should always include these processes:
Step One: Planning and Implementation
At this stage, teams develop an asset hierarchy and determine which equipment is most critical. This allows the teams to decide which assets they will monitor.
During the implementation stage, you should determine what kind of sensors are most appropriate for your plant, and where you’ll install them. You should also decide which tools you’ll use to analyze your vibration data.
Step Two: Analyzing and Interpreting Data
There are a number of different tools available for analyzing vibration data. A CMMS can organize your data and issue alerts when vibration levels cross a pre-determined threshold. A good CMMS can even auto-generate work orders in response to changes in vibration levels.
Today, artificial intelligence can successfully diagnose machine faults based on vibration data. State-of-the-art tools can “read” machine tests without any human input, pinpoint machine faults, and even issue detailed recommendations for maintenance crews to make repairs.
Step Three: Repairing Faults
Once your vibration data has been collected and analyzed, maintenance crews can make the necessary repairs. Vibration analysis allows teams to catch new and emerging faults at the earliest possible stages, so that repairs are easy to carry out.
This means that there is a significant decrease in unplanned downtime, since crews can stay ahead of asset failure. It also means that there is greater operational efficiency and a reduction in maintenance costs.
振動(dòng)分析應(yīng)用
Vibration Analysis Applications
振動(dòng)分析是任何主動(dòng)維護(hù)計(jì)劃中不可或缺的要素。通過(guò)允許技術(shù)人員盡早發(fā)現(xiàn)機(jī)器故障，振動(dòng)分析可以最大限度地利用可用資源、提高生產(chǎn)率和效率。
振動(dòng)分析是任何旋轉(zhuǎn)資產(chǎn)或任何包含旋轉(zhuǎn)部件的工業(yè)機(jī)器的絕佳方法。它通常用于：
? 糾正壓縮機(jī)和渦輪機(jī)等旋轉(zhuǎn)設(shè)備的不平衡
? 診斷軸錯(cuò)位
? 確定軸承故障
? 診斷旋轉(zhuǎn)設(shè)備的松動(dòng)情況
振動(dòng)分析還可以診斷其他資產(chǎn)故障，例如泵葉輪、電機(jī)定子和電機(jī)繞組的缺陷等。
Vibration analysis is a vital ingredient in any proactive maintenance program. By allowing technicians to identify machine faults early, vibration analysis maximizes available resources, increases productivity, and boosts efficiency.
Vibration analysis is a great approach for any rotating asset, or for any industrial machine that includes a rotating component. It is often used to:
? Correct unbalance in rotating assets like compressors and turbines
? Diagnose shaft misalignment
? Identify bearing faults
? Diagnose looseness in rotating equipment
Vibration analysis can also diagnose other asset faults, like defects in pump impellers, motor stators, and electric motor winding, to name just a few examples.
振動(dòng)分析如何與狀態(tài)監(jiān)測(cè)配合使用？
How Does Vibration Analysis Work with Condition Monitoring?
狀態(tài)監(jiān)測(cè)和以可靠性為中心的維護(hù)是主動(dòng)維護(hù)方法，通過(guò)監(jiān)測(cè)振動(dòng)、潤(rùn)滑質(zhì)量、溫度和能耗等參數(shù)來(lái)跟蹤資產(chǎn)健康狀況。一些狀態(tài)監(jiān)測(cè)程序會(huì)持續(xù)收集數(shù)據(jù)并將其傳輸?shù)交谠频能浖M(jìn)行實(shí)時(shí)振動(dòng)分析。
由于振動(dòng)分析有助于及早發(fā)現(xiàn)故障，因此它是許多成功的狀態(tài)監(jiān)測(cè)程序的核心。它利用振動(dòng)傳感器、振動(dòng)分析軟件和專家人工分析，向維護(hù)團(tuán)隊(duì)發(fā)出設(shè)備性能下降的早期跡象警報(bào)。也許這很明顯，但這就是它被視為預(yù)測(cè)性維護(hù)的原因。
然而，振動(dòng)分析不僅適用于預(yù)測(cè)性維護(hù)。還可以使用振動(dòng)數(shù)據(jù)來(lái)診斷現(xiàn)有的機(jī)器故障或查明持續(xù)問(wèn)題的根源。這個(gè)過(guò)程稱為根本原因故障分析或 RCFA。例如，糾正旋轉(zhuǎn)不平衡的工具依靠振動(dòng)分析來(lái)定位和補(bǔ)救不平衡的根源。
Condition monitoring and reliability-centered maintenance are proactive maintenance approaches that track asset health by monitoring parameters like vibration, lubrication quality, temperature, and energy consumption. Some condition monitoring programs collect data continuously and stream it to cloud-based software for real-time vibration analysis.
Since vibration analysis helps identify faults early on, it’s at the heart of many successful condition monitoring programs. It alerts maintenance teams to very early signs of equipment degradation by utilizing vibration sensors, vibration analysis software, and expert human analysis. Perhaps it’s obvious, but is this is why it’s considered predictive maintenance.
However, vibration analysis isn’t only for predictive maintenance. You can also use vibration data to diagnose existing machine faults or pinpoint the source of a persistent problem. This process is called root cause failure analysis, or RCFA. Tools that correct rotational unbalance, for example, rely on vibration analysis to locate and remedy the source of unbalance.
振動(dòng)分析有哪些好處？
What are the Benefits of Vibration Analysis?
振動(dòng)分析可以在機(jī)器故障變得嚴(yán)重到足以被視為故障模式的幾個(gè)月前就識(shí)別出正在發(fā)生的機(jī)器故障。早期測(cè)試為維護(hù)團(tuán)隊(duì)提供了充足的時(shí)間進(jìn)行維修，而不會(huì)打亂生產(chǎn)計(jì)劃或產(chǎn)生意外停機(jī)成本。
振動(dòng)分析可以：
? 診斷現(xiàn)有機(jī)器故障
? 確定故障嚴(yán)重程度
? 指導(dǎo)維護(hù)優(yōu)先級(jí)
? 全面了解資產(chǎn)健康狀況
? 大幅減少機(jī)器故障
? 協(xié)助預(yù)測(cè)、預(yù)算和庫(kù)存
? 提高工廠安全性
? 減少突然、意外的工作停工
? 延長(zhǎng)資產(chǎn)使用壽命
Vibration analysis can identify developing machine faults many months before they become critical enough to be considered a failure mode. Early testing gives maintenance teams plenty of time to make repairs without disrupting production schedules or incurring the cost of unexpected downtime.
Vibration analysis can:
? Diagnose existing machine faults
? Determine fault severity levels
? Guide maintenance priorities
? Create an overall picture of asset health
? Drastically reduce machine breakdowns
? Assist in forecasting, budgeting, and inventory
? Improve plant safety
? Reduce sudden, unexpected work stoppages
? Increase asset lifespan
振動(dòng)分析可以檢測(cè)什么？
What Can Vibration Analysis Detect?
雖然有 1,200 多種可識(shí)別的故障情況，但許多常見(jiàn)的機(jī)械故障都是由于以下四個(gè)因素之一引起的：
? 不平衡
? 松動(dòng)
? 錯(cuò)位
? 軸承退化
強(qiáng)大的振動(dòng)分析程序可以在這些故障變得嚴(yán)重之前診斷出來(lái)。越早發(fā)現(xiàn)，維修設(shè)備就越容易，也越經(jīng)濟(jì)高效。
While there are more than 1,200 identifiable fault conditions, many common machinery failures happen due to one of four factors:
? Unbalance
? Looseness
? Misalignment
? Bearing degradation
A robust vibration analysis program can diagnose these faults before they become severe. The sooner they’re identified, the easier and more cost-effective it will be to repair your equipment.
以下是振動(dòng)分析在特定情況下的工作原理：
Here’s how vibrational analysis works in specific cases:
使用振動(dòng)分析糾正不平衡
Using Vibration Analysis to Correct Unbalance
旋轉(zhuǎn)不平衡是泵、風(fēng)扇、渦輪機(jī)和壓縮機(jī)等旋轉(zhuǎn)設(shè)備損壞的主要原因。即使是相對(duì)較小的不平衡也會(huì)導(dǎo)致軸承磨損。機(jī)器通常會(huì)增加能耗和過(guò)熱，從而導(dǎo)致故障。
旋轉(zhuǎn)不平衡可能是制造缺陷的結(jié)果。但它也可能隨著時(shí)間的推移而發(fā)展，原因是：
? 安裝錯(cuò)誤
? 熱變形
? 腐蝕或退化
? 軸彎曲或斷裂
? 缺少平衡重量
振動(dòng)分析是找到不平衡源的最佳方法之一。優(yōu)秀的旋轉(zhuǎn)平衡工具可以在現(xiàn)場(chǎng)讀取振動(dòng)讀數(shù)，并指導(dǎo)維護(hù)團(tuán)隊(duì)完成糾正不平衡的過(guò)程。
平衡工具足夠靈敏和精確，可以在早期診斷不平衡，此時(shí)修復(fù)仍然很容易且具有成本效益。
Rotational unbalance is a leading cause of damage in rotating assets, like pumps, fans, turbines, and compressors. Even relatively minor unbalance can cause wear and tear on bearings. Machines will often increase energy consumption and overheat, leading to breakdowns.
Rotational unbalance can be the result of a manufacturing defect. But it can also develop over time, due to:
? Faulty mounting
? Heat distortion
? Corrosion or degradation
? Bent or broken shafts
? Missing balance weights
Vibration analysis is one of the best ways to locate the source of unbalance. An excellent rotational balancing tool can take vibration readings in the field and guide maintenance teams through the process of correcting unbalance.
The Balancer is sensitive and precise enough to diagnose unbalance early on, when it’s still easy and cost-effective to repair.
使用振動(dòng)分析識(shí)別軸錯(cuò)位
Using Vibration Analysis to Identify Shaft Misalignment
軸錯(cuò)位是導(dǎo)致電機(jī)驅(qū)動(dòng)設(shè)備故障的另一個(gè)主要原因。短期內(nèi)，錯(cuò)位會(huì)導(dǎo)致泄漏、零件過(guò)度磨損和生產(chǎn)率下降。隨著時(shí)間的推移，錯(cuò)位的軸和聯(lián)軸器會(huì)損壞零部件并導(dǎo)致計(jì)劃外停機(jī)。
實(shí)現(xiàn)精確對(duì)準(zhǔn)并不總是那么容易，但它至關(guān)重要。即使看似微小的錯(cuò)位也會(huì)影響用戶的生產(chǎn)計(jì)劃并增加運(yùn)營(yíng)和維護(hù)成本。振動(dòng)分析是識(shí)別錯(cuò)位的最佳方法之一。優(yōu)質(zhì)的激光軸對(duì)中工具可以幫助以高精度解決該問(wèn)題。
Shaft misalignment is another leading cause of failure for motor-driven equipment. In the short term, misalignment can cause leaks, undue wear and tear on parts, and a slowdown in productivity. Over time, misaligned shafts and couplings can break down component parts and cause unplanned shutdowns.
It’s not always easy to achieve precision alignment, but it’s critical. Even seemingly minor misalignment can impact your production schedule and increase operational and maintenance costs. Vibration analysis is one of the best ways to identify misalignment. And a quality laser shaft alignment tool can help resolve the issue to a high degree of precision.
使用振動(dòng)分析識(shí)別軸承故障
Using Vibration Analysis to Identify Bearing Faults
隨著時(shí)間的推移，工業(yè)機(jī)械不可避免地需要維修或更換。在部件發(fā)生故障之前盡早進(jìn)行測(cè)試，可以使設(shè)備運(yùn)行更長(zhǎng)時(shí)間，并使維修更容易管理。
振動(dòng)分析是監(jiān)控設(shè)備軸承和其他部件健康狀況的好方法。了解正在經(jīng)歷的軸承磨損類型對(duì)于根本原因故障分析 (RCFA) 至關(guān)重要，它可以幫助用戶診斷和處理問(wèn)題的實(shí)際原因。診斷軟件可以在這里發(fā)揮重要作用，加快分析振動(dòng)數(shù)據(jù)的過(guò)程。
使用振動(dòng)分析意味著用戶將主動(dòng)更換部件。一般來(lái)說(shuō)，這種方法比基于間隔的維護(hù)方法更具成本效益。用戶無(wú)需按照固定的時(shí)間表更換可能無(wú)故障的組件，而是根據(jù)需要更換它們，從而節(jié)省時(shí)間、勞動(dòng)力和不必要的成本。
Over time, industrial machinery will inevitably need to be repaired or replaced. Testing components early, far before they fail, can keep equipment operating longer and make repairs easier to manage.
Vibration analysis is a great way to monitor the health of your equipment bearings and other components. Knowing the type of bearing wear you are experiencing is crucial for root cause failure analysis (RCFA), which helps you diagnose and treat the actual cause of a problem. Diagnostic software can make a big difference here, speeding the process of analyzing your vibration data.
Using vibration analysis means that you’ll replace components proactively. In general, this approach is significantly more cost-effective than an interval-based maintenance approach. Instead of replacing potentially fault-free components on a fixed schedule, you’ll change them as needed which saves you time, labor, and unnecessary costs.
使用振動(dòng)分析診斷松動(dòng)
Using Vibration Analysis to Diagnose Looseness
松動(dòng)有幾種不同的類型：
? 支腳、底板或基礎(chǔ)處的 A 型松動(dòng)。
? 緊固件的 B 型松動(dòng)或由于框架結(jié)構(gòu)中的裂縫而導(dǎo)致的松動(dòng)。
? 組件配合不當(dāng)和磨損導(dǎo)致的 C 型松動(dòng)。
振動(dòng)分析可以幫助用戶查明松動(dòng)的確切來(lái)源，以便用戶在問(wèn)題導(dǎo)致系統(tǒng)故障之前糾正它。
Looseness comes in several different varieties:
? Type A looseness at the feet, baseplate, or foundation.
? Type B looseness of the fasteners or due to cracks in the frame structure.
? Type C looseness caused by improper component fits and wear.
Vibration analysis can help you pinpoint the exact source of looseness, so that you can correct it before the problem leads to a system failure.
使用振動(dòng)分析診斷其他機(jī)器故障
Using Vibration Analysis to Diagnose Other Machine Faults
當(dāng)今的一些人工智能軟件可以使用振動(dòng)數(shù)據(jù)診斷各種系統(tǒng)中的數(shù)百種故障。例如，泵葉輪、電機(jī)定子和電動(dòng)機(jī)繞組。
經(jīng)驗(yàn)豐富的技術(shù)人員可以使用振動(dòng)分析設(shè)備執(zhí)行 RCFA 并診斷常見(jiàn)和不常見(jiàn)的缺陷。擁有的機(jī)器狀況數(shù)據(jù)越多，就能越有效地利用這些數(shù)據(jù)找出嚴(yán)重故障的根源并保持機(jī)器正常運(yùn)行。
總體而言，振動(dòng)分析設(shè)備可以提高安全性、減少計(jì)劃外的工時(shí)、削減預(yù)算并提高生產(chǎn)率。這就是為什么它是任何狀況監(jiān)測(cè)或預(yù)測(cè)性維護(hù)計(jì)劃的必備工具。
Some of today’s AI-powered software can use vibration data to diagnose hundreds of faults in various systems. Think pump impellers, motor stators, and electric motor winding, to name a few examples.
Experienced technicians can perform an RCFA and diagnose both common and uncommon defects with vibration analysis equipment. The more condition data you have for a machine, the more effectively you can use it to get to the heart of serious faults and keep your operation running.
Overall, vibration analysis equipment can improve safety, reduce unplanned labor hours, cut your budget, and increase productivity. That’s why it’s an essential tool for any condition monitoring or predictive maintenance program.
如何測(cè)量振動(dòng)
How to Measure Vibration
根據(jù)需求，簡(jiǎn)化的監(jiān)視器或?qū)I(yè)的手持式振動(dòng)分析儀可以幫助進(jìn)行基于路線的振動(dòng)數(shù)據(jù)收集。
多功能無(wú)線傳感器和集成有線工具可自動(dòng)收集振動(dòng)數(shù)據(jù)。要測(cè)量的資產(chǎn)類型以及想要設(shè)置的任何參數(shù)都可以指導(dǎo)用戶選擇工具。
Depending on your needs, a simplified monitor or expert handheld vibration analyzer can help you conduct route-based vibration data collection.
Versatile wireless sensors and integrated, wired tools collect vibration data automatically. The kind of assets you’re measuring, as well as any parameters you’d like to set, can guide your choice of tool.
以下是一些用于測(cè)量振動(dòng)水平的最有用的工具：
Here are some of the most helpful tools for measuring vibration levels:
加速度計(jì)
Accelerometers
加速度計(jì)是大多數(shù)振動(dòng)分析應(yīng)用的核心。它們測(cè)量資產(chǎn)或組件發(fā)出的沖擊和振動(dòng)。
大多數(shù)加速度計(jì)都有一個(gè)內(nèi)部壓電 (IEPE) 傳感器或電容式 (MEMS) 傳感器。兩者都將物理振動(dòng)轉(zhuǎn)換為電信號(hào)，然后將其記錄并存儲(chǔ)為振動(dòng)數(shù)據(jù)。
加速度計(jì)以加速度（力的量度）的形式收集數(shù)據(jù)。然后可以將這些數(shù)據(jù)轉(zhuǎn)換為速度（速度的量度）或位移（距離的量度）。
Accelerometers are at the core of most vibration analysis applications. They measure the shocks and vibrations emitted by an asset or a component.
Most accelerometers have an internal piezoelectric (IEPE) sensor or a capacitive-type (MEMS) sensor. Both convert physical vibrations into electrical signals, which are then recorded and stored as vibration data.
Accelerometers collect data in acceleration, a measure of force. This data can then be converted into velocity, a measure of speed or, displacement a measure of distance.
振動(dòng)計(jì)
Vibration Meters
振動(dòng)計(jì)是一種簡(jiǎn)化的手持設(shè)備，內(nèi)置加速度計(jì)和顯示屏。它提供資產(chǎn)整體振動(dòng)水平的即時(shí)讀數(shù)。
儀表提供振動(dòng)速度、加速度和位移的即時(shí)讀數(shù)。大多數(shù)儀表還可以存儲(chǔ)振動(dòng)測(cè)量值，以便用戶可以輕松地跟蹤資產(chǎn)隨時(shí)間推移的健康狀況。
振動(dòng)計(jì)用于日常監(jiān)測(cè)。它們是熟練的工業(yè)機(jī)器操作員手中的強(qiáng)大工具，使他們能夠篩查新機(jī)器故障或正在發(fā)生的機(jī)器故障的跡象。
當(dāng)資產(chǎn)已經(jīng)出現(xiàn)故障跡象時(shí)，振動(dòng)計(jì)還可以排除故障并診斷機(jī)器故障。收集振動(dòng)數(shù)據(jù)可以幫助查明資產(chǎn)故障的原因，以便工作團(tuán)隊(duì)可以進(jìn)行維修并恢復(fù)工作。
A vibration meter is a simplified handheld device with a built-in accelerometer and a display screen. It provides instant readings of an asset’s overall vibration levels.
Meters provide instant readings of vibration velocity, acceleration, and displacement. Most meters can also store vibration measurements so that you can easily track an asset’s health over time.
Vibration meters are used for day-to-day monitoring. They are a powerful tool in the hands of a skilled industrial machine operator, allowing them to screen for signs of a new or developing machine fault.
Vibration meters can also troubleshoot and diagnose machine faults when an asset already shows signs of trouble. Collecting vibration data can help you pinpoint the cause of an asset malfunction so that your teams can make repairs and get back to work.
振動(dòng)測(cè)試儀
Vibration Testers
振動(dòng)測(cè)試儀將振動(dòng)計(jì)的功能與診斷功能相結(jié)合。該工具可以測(cè)量整體振動(dòng)水平，并利用它們現(xiàn)場(chǎng)診斷機(jī)器故障。
優(yōu)質(zhì)的振動(dòng)測(cè)試儀還可以報(bào)告故障嚴(yán)重程度并提供具體的維修建議。對(duì)于專業(yè)知識(shí)有限的團(tuán)隊(duì)，振動(dòng)測(cè)試儀可以大大彌補(bǔ)技能差距。
A vibration tester combines a vibration meter’s functionality with diagnostic capabilities. The tool can measure overall vibration levels and use them to diagnose machine faults on the spot.
A quality vibration tester can also report on fault severity levels and provide specific repair recommendations. For expertise-constrained teams, a vibration tester can go a long way to filling the skills gap.
振動(dòng)分析儀
Vibration Analyzers
振動(dòng)分析儀和振動(dòng)測(cè)試儀有許多相似之處。這兩種工具都可以提供即時(shí)振動(dòng)讀數(shù)，診斷和評(píng)估常見(jiàn)故障，在某些情況下還可以提出維護(hù)建議。
現(xiàn)代振動(dòng)分析儀具有多個(gè)通道，可以即時(shí)測(cè)量振動(dòng)水平。除了測(cè)量整體振動(dòng)水平外，它還可以進(jìn)行多相測(cè)量和 FFT 頻譜數(shù)據(jù)。因此，它是一種功能強(qiáng)大的工具，可以高效收集高質(zhì)量的振動(dòng)數(shù)據(jù)，快速查明任何不平衡的確切來(lái)源，并持續(xù)進(jìn)行故障排除，直到問(wèn)題得到糾正。
Vibration analyzers and vibration testers have many similarities. Both tools provide instant vibration readings, diagnose and assess common faults, and in some cases, can make maintenance recommendations.
A modern vibration analyzer has multiple channels, allowing it to measure vibration levels instantaneously. In addition to measuring overall vibration levels, it can also take multi-phase measurements and FFT spectrum data. The result is a powerful tool that can efficiently collect high-quality vibration data, pinpoint the exact source of any unbalance quickly, and keep troubleshooting until the issue is corrected.
無(wú)線振動(dòng)傳感器
Wireless Vibration Sensors
無(wú)線振動(dòng)系統(tǒng)幾乎無(wú)需人工干預(yù)即可監(jiān)控多臺(tái)機(jī)器。這種聯(lián)網(wǎng)傳感器技術(shù)將振動(dòng)監(jiān)控集成到工廠中傳統(tǒng)路線程序無(wú)法覆蓋的區(qū)域。
無(wú)線振動(dòng)系統(tǒng)使用簡(jiǎn)單：只需將每個(gè)傳感器安裝在資產(chǎn)或組件上，它就會(huì)全天候收集振動(dòng)數(shù)據(jù)。每個(gè)傳感器都會(huì)將數(shù)據(jù)傳輸?shù)皆贫耍ㄟ^(guò)強(qiáng)大的人工智能軟件進(jìn)行處理。
無(wú)線振動(dòng)傳感器可以成為預(yù)測(cè)性維護(hù)策略的關(guān)鍵組成部分。它們提供關(guān)鍵數(shù)據(jù)，以便準(zhǔn)確、具體地預(yù)測(cè)用戶的資產(chǎn)何時(shí)可能需要維修。當(dāng)與分析軟件配對(duì)時(shí)，振動(dòng)傳感器可以幫助團(tuán)隊(duì)大幅減少停機(jī)時(shí)間并提高生產(chǎn)力。
Wireless vibration systems can monitor many machines with little human intervention. This connected sensor technology integrates vibration monitoring into areas of a plant that would be excluded from a traditional route-based program.
Wireless vibration systems are simple to use: Just mount each sensor on an asset or component and it will collect vibration data around the clock. Each sensor streams data to the cloud for processing via powerful artificial intelligence software.
Wireless vibration sensors can be a key component of predictive maintenance strategies. They provide crucial data to make accurate, specific predictions about when your assets are likely to need repairs. When they’re paired with analytic software, vibration sensors can help teams dramatically reduce shutdowns and increase productivity.
有線在線狀態(tài)監(jiān)測(cè)
Wired Online Condition Monitoring
有線在線狀態(tài)監(jiān)測(cè)系統(tǒng)顧名思義就是：一個(gè)有線加速度計(jì)網(wǎng)絡(luò)，通過(guò)互聯(lián)網(wǎng)連接，向分析程序報(bào)告。專業(yè)人員通常使用這些系統(tǒng)來(lái)監(jiān)控高度關(guān)鍵、復(fù)雜的機(jī)器。
有線在線狀態(tài)監(jiān)測(cè)系統(tǒng)提供卓越的監(jiān)測(cè)能力。這些系統(tǒng)旨在收集關(guān)鍵資產(chǎn)的高質(zhì)量、連續(xù)數(shù)據(jù)。當(dāng)這些數(shù)據(jù)由強(qiáng)大的軟件與 AI 分析引擎結(jié)合處理時(shí)，它可以為用戶運(yùn)營(yíng)的關(guān)鍵設(shè)備提供動(dòng)態(tài)、深入的洞察。
有線和無(wú)線振動(dòng)傳感器系統(tǒng)都是監(jiān)控資產(chǎn)的有效工具。但最適合企業(yè)的系統(tǒng)取決于運(yùn)營(yíng)規(guī)模、設(shè)備的關(guān)鍵程度以及預(yù)算。
Wired online condition monitoring systems are just what they sound like: a network of wired accelerometers, connected by the internet, that report back to an analytic program. Professionals typically use these systems to monitor highly critical, complex machines.
Wired online condition monitoring systems provide superior monitoring capacity. These systems are engineered to collect high-quality, continuous data on your most critical assets. When that data is processed by powerful software coupled with AI analytical engines, it provides dynamic, in-depth insights into your operation’s critical equipment.
Both wired and wireless vibration sensor systems are effective tools for monitoring your assets. But the system best for your enterprise depends on the size of your operation, criticality of your equipment, and your budget.
振動(dòng)分析工具如何評(píng)估振動(dòng)
How Vibration Analysis Tools Assess Vibration
借助振動(dòng)分析工具，可以通過(guò)評(píng)估兩個(gè)重要指標(biāo)來(lái)研究振動(dòng)數(shù)據(jù)：時(shí)間波形和頻譜。
時(shí)間波形將振動(dòng)數(shù)據(jù)呈現(xiàn)為一系列峰值和谷值，并與時(shí)間成比例。從加速度角度來(lái)看，時(shí)間波形本質(zhì)上是原始數(shù)據(jù)。波形圖將準(zhǔn)確指示機(jī)器的峰值振動(dòng)水平發(fā)生的時(shí)間。它還表明峰值振動(dòng)的嚴(yán)重程度。
雖然時(shí)間波形很有用，但它很復(fù)雜，難以分析。它并不總是提供診斷機(jī)器狀況的確切性質(zhì)所需的簡(jiǎn)明信息。這就是頻譜分析和 FFT 的用武之地。
快速傅里葉變換 (FFT) 將現(xiàn)有的波形數(shù)據(jù)轉(zhuǎn)換為頻率數(shù)據(jù)。它使用轉(zhuǎn)換后的波形創(chuàng)建所有組件頻率的圖形表示。
為什么這很有用？每個(gè)組件都以自己的頻率振動(dòng)，頻率分析會(huì)顯示哪些組件的振動(dòng)強(qiáng)度最大。這樣，就可以查看單個(gè)組件的頻率，以確定潛在故障的根本原因。越早發(fā)現(xiàn)問(wèn)題，就能越快解決問(wèn)題并恢復(fù)正常業(yè)務(wù)。
With the help of a vibration analysis tool, you can study vibration data by assessing two important metrics: the time waveform and the frequency spectrum.
The time waveform presents vibration data as a series of peaks and valleys, mapped against time. When viewed in acceleration, the time waveform is essentially raw data. A waveform graph will indicate exactly when your machine’s peak vibration level occurs. It also indicates how severe the peak vibration is.
While the time waveform is useful, it is complex and difficult to analyze. It does not always provide the concise information you need to diagnose the exact nature of your machine’s condition. That’s where frequency spectrum analysis and FFT come in.
The fast Fourier transform, or FFT, takes your existing waveform data and turns it into frequency data. It creates a graphical representation of all component frequencies with the converted waveform.
Why is this useful? Every component vibrates at its own frequency, and frequency analysis shows you which components are vibrating with the greatest intensity. That way, you can look at individual component frequencies to identify the root cause of a potential failure. The sooner you can identify the problem, the more quickly you can resolve it and resume business as usual.
三個(gè)關(guān)鍵振動(dòng)分析參數(shù)
The Three Key Vibration Analysis Parameters
振動(dòng)專家使用三個(gè)主要參數(shù)來(lái)評(píng)估機(jī)器健康狀況：振動(dòng)位移、速度和加速度。
位移是振動(dòng)物體從其中心或起點(diǎn)移動(dòng)的距離。它是識(shí)別低頻范圍內(nèi)故障的最有力指標(biāo)。位移用于診斷不平衡和軸頸（或滑動(dòng)）軸承健康狀況。
速度是振動(dòng)物體在規(guī)定時(shí)間或速度內(nèi)移動(dòng)的距離。它測(cè)量中等頻率，可以幫助診斷大多數(shù)機(jī)器故障的嚴(yán)重程度。速度讀數(shù)通常是狀態(tài)監(jiān)測(cè)的首選測(cè)量顯示，因?yàn)樗趯掝l率范圍內(nèi)具有平坦的幅度響應(yīng)。
加速度是力的量度，指的是速度隨時(shí)間變化的速率。它在測(cè)量非常高的頻率時(shí)最有用。加速度可以幫助診斷早期軸承故障并發(fā)現(xiàn)泵系統(tǒng)中的氣蝕和湍流等問(wèn)題。
所有三個(gè)參數(shù)對(duì)于深入了解資產(chǎn)健康狀況都很重要。好的振動(dòng)測(cè)量工具可以顯示基本信息，但最好的振動(dòng)測(cè)量工具還提供整體振動(dòng)水平、時(shí)間波形和 FFT 數(shù)據(jù)。
Vibration experts use three main parameters to assess machine health: vibration displacement, velocity, and acceleration.
Displacement is the distance a vibrating object moves from its center or starting point. It’s the strongest metric to identify faults in the lower frequency range. Displacement is used to diagnose unbalance and journal (or plain) bearing health.
Velocity is the distance a vibrating object moves over a defined time, or speed. It measures mid-level frequencies and can help diagnose the severity level of most machine faults. The velocity reading is commonly the preferred measurement display for condition monitoring because it has a flat amplitude response over a wide frequency range.
Acceleration is a measure of force and refers to the rate at which velocity changes over time. It’s most helpful when measuring very high frequencies. Acceleration can help diagnose early-stage bearing faults and spot issues like cavitation and turbulence in pump systems.
All three parameters are important for building a strong understanding of your asset health. A good vibration measurement tool can display the basics, but the best vibration measurement tools also provide overall vibration levels, time waveform, and FFT data.
AI 工具如何增強(qiáng)振動(dòng)分析
How AI Tools Can Amplify Vibration Analysis
如果希望從振動(dòng)測(cè)量工具中獲得更多功能，那么下一代支持 AI 的設(shè)備將提供非凡的分析能力。最好的 AI 軟件可以快速診斷機(jī)器故障，準(zhǔn)確度令人印象深刻。
AI 解決方案可以診斷幾乎任何類型資產(chǎn)中的 1200 種不同的機(jī)器和組件故障。它還可以確定嚴(yán)重程度并推薦解決方案。
AI 軟件可以改變繁忙團(tuán)隊(duì)的游戲規(guī)則。如今，許多工廠已經(jīng)在收集振動(dòng)數(shù)據(jù)，但他們沒(méi)有時(shí)間進(jìn)行分析。AI 工具可以接管大多數(shù)功能機(jī)器的分析審查工作，讓人類專家可以專注于更復(fù)雜的問(wèn)題。
長(zhǎng)期使用 AI 工具也有好處。AI 程序分析機(jī)器數(shù)據(jù)的時(shí)間越長(zhǎng)，它們?cè)\斷問(wèn)題的效率就越高。就像人類員工一樣，AI 軟件也會(huì)從經(jīng)驗(yàn)中學(xué)習(xí)。只需確保選擇的 AI 軟件已在足夠大的數(shù)據(jù)集上進(jìn)行了正確的訓(xùn)練，這樣就可以從高水平的專業(yè)知識(shí)開(kāi)始。
If you want even more from your vibration measurement tools, the next generation of AI-enabled equipment offers extraordinary analytic capabilities. The best AI-driven software can quickly diagnose machine faults with an impressive degree of accuracy.
AI solutions can diagnose 1200 different machine and component faults in almost any kind of asset. It can also determine severity levels and recommend solutions.
AI software can be a game changer for busy teams. Many plants today are already collecting vibration data, but they don’t have the time to analyze it. AI tools can take over the drudgery of analytic review on mostly functional machines, freeing up human experts to focus on more complex problems.
There are benefits to using AI tools long-term, too. The longer AI programs analyze your machine data, the more effective they’ll become at diagnosing problems. Just like human employees, AI software learns from experience. Just make sure that you’re choosing AI software that’s been trained correctly on a large enough data set so that you’re starting with a high baseline of expertise.
與振動(dòng)分析專家合作
Work with the Experts on Vibration Analysis
軟件工具可以在很大程度上診斷機(jī)器故障，但它們并非單獨(dú)工作。人工智能工具和其他軟件與人類專家協(xié)同工作時(shí)才能發(fā)揮最佳作用。
Software tools can go a long way to diagnose machine faults, but they are not designed to work alone. AI tools and other software are at their best when they work in tandem with human experts.
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