How can equipment faults be detected through vibration?

How can equipment faults be detected through vibration?

Abstract: Equipment cannot speak, but every “heartbeat” (vibration) it emits conveys information. Understanding this language is key to achieving predictive maintenance and avoiding unexpected downtime.

In daily industrial production, massive fans roar, precision machine tools spin rapidly, and conveyor belts operate tirelessly... Behind this seemingly ordinary scene lies a common physical phenomenon—vibration.

For equipment managers, vibration is both the most familiar “companion” and the most troublesome “hidden threat.” How can one distinguish between normal operational vibration and abnormal vibration that signals impending failure? Today, let's lift the veil on the mystery of “vibration.”

1. What is vibration?

Simply put, vibration is the back-and-forth motion of an object around an equilibrium position. Imagine this:

When you pluck a guitar string, its up-and-down movement is vibration.

The swinging motion of a pendulum is also vibration.

Pressing your hand against a tabletop causes minute deformations and rebounds—this too is vibration.

In industrial equipment, any rotating or reciprocating component—such as motor rotors, gears, bearings, or fan blades—constantly vibrates. Moderate vibration is an inevitable byproduct of operation, but excessive or abnormal vibration signals that the equipment is “sick.”

When describing vibration, we primarily focus on three core elements:

Amplitude: The “severity” of vibration, representing its intensity. Similar to earthquake magnitude, greater amplitude indicates stronger destructive force.

Frequency: The number of vibrations per unit time. It indicates the “speed” at which vibrations occur. Different faults correspond to distinct characteristic frequencies, serving as the “fingerprint” for fault diagnosis.

Phase: The relative “timing” of vibrations, used to determine the relative motion between vibrating components. This is crucial in precision diagnostics.

2.How can you determine equipment malfunctions through vibration?

Equipment is like a patient, and abnormal vibration is its “symptom.” Experienced “equipment doctors” (engineers) can accurately diagnose the “cause of the illness” by analyzing vibration signals. Below are several common “vibration languages” and their corresponding faults:

1) Unbalance – “Jittery” Vibration

Symptoms: The vibration frequency closely matches the equipment's rotational frequency (1X), much like how a wheel's vibration intensifies with speed when unbalanced. Causes: Uneven mass distribution in the rotor, such as blade buildup, component detachment, or manufacturing errors. Our vibration sensors detect a stable signal with abnormally high amplitude at the rotational frequency.

2) Misalignment – “Stiff” Vibration

Symptoms: Vibration frequencies include twice the rotational speed (2X) and even higher multiples. It feels like two connected components are “fighting” against each other. Cause: The centerlines of the two shafts connected by the coupling are misaligned, exhibiting parallel or angular deviation. Sensor data shows that axial (thrust direction) vibration amplitude increases significantly, comparable to radial (rotational direction) amplitude—a classic sign of misalignment.

3) Bearing Damage – “Squeaky” Vibrations

Symptoms: High-frequency “impact” signals appear in the vibration signal, sounding like a rustling or squeaking noise. Their frequency correlates with the geometric dimensions of the bearing balls and inner/outer rings (i.e., bearing failure frequency). Causes: Pitting, spalling, or cracks develop in the bearing due to fatigue, poor lubrication, improper installation, etc. Our vibration sensors sensitively capture these transient impact pulses. Through spectral analysis, we can precisely pinpoint which bearing component is failing.

4) Looseness – “Disorganized” Vibration

Symptoms: Multiple harmonic frequencies (2X, 3X, 4X…) appear in the vibration signal, with chaotic waveforms and unstable vibration values. Causes: Loose anchor bolts, unstable foundation base, excessive component clearance. The sensor detects abnormal increases in vibration amplitude across multiple frequencies, with time-domain waveforms exhibiting distinct “clipping” or disordered patterns.

5) Gear Failure – “Periodic” Vibration

Symptoms: Vibration frequencies are concentrated at the gear meshing frequency and its harmonics. When gears exhibit wear or tooth breakage, sidebands appear around the meshing frequency. Causes: Gear wear, pitting, tooth breakage, or assembly errors. Analysis of sensor data clearly reveals increased amplitude at the meshing frequency and the emergence of sidebands, enabling assessment of gear health.

3.The value of vibration sensors?

The human ear cannot accurately quantify vibrations, nor can it detect subtle abnormalities in the early stages of failure. This is where a professional “stethoscope” comes in—the vibration sensor.

The vibration sensors we produce are designed precisely for this purpose:

Early Warning: Detect characteristic high-frequency impact signals during the initial stages of failure (e.g., when bearings exhibit minor pitting) to enable predictive maintenance, preventing minor issues from escalating into major problems.

Precise Localization: Through accurate measurement and analysis of vibration frequency, amplitude, and phase, engineers can rapidly pinpoint the root cause of faults—whether stemming from bearing issues, imbalance, or misalignment—reducing time spent on blind troubleshooting.

Quantitative Management: Establish vibration profiles for each critical piece of equipment and set alarm thresholds to achieve digital, visual control over equipment health.

Conclusion: Vibration is no longer an annoying “noise,” but rather the “language” through which your equipment communicates with you. By deciphering this language, you can shift from reactive maintenance to proactive prediction, minimizing unplanned downtime, ensuring production safety, and reducing maintenance costs.

Let our vibration sensors serve as your equipment's “personal translator” and “health advisor,” working together to safeguard stable and efficient production!

Yangzhou Xiyuan Electronic Technology Co.,Ltd.

#77 Yeqiao Road, Liandong U Valley slender West Lake Innovation port, building 10-2,Hanjiang District, Yangzhou,Jiangsu,China

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Tel: +86 514-82885589

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