Industrial Vibration Investigations

Vibremo engineers have experience working in the manufacturing industry, and in the renewable and traditional energy sectors, to solve any type of issue related to vibration. Data collected on site allows us to identify the source of unwanted vibration, which can be related to the structure of the machine or its internal components, and recommend corrective actions.

Causes and consequences of vibration

Any sudden change of load or speed, or any deviation in the movement of internal parts of equipment can generate vibration. The resulting disturbances can have a negative impact on both the operational efficiency and safety of a plant, potentially shortening machinery lifespan. In the context of industrial or residential structures, the effects extend to the well-being and safety of workers or residents. To prevent the negative consequences of unwanted vibration, proactive measures can be implemented during the prototyping, commissioning or operational phases.

Component issues

Vibration is inherent to industrial machinery. However, excessive levels can be generated by specific internal components, resulting in distinct vibration signatures and revealing some common issues, which can include:

Misalignment

Misalignment occurs when the level of precision required to correctly assemble pairs of shafts, pulleys, bearings or coupling elements is not achieved, and results in components’ centrelines being offset from one another or crossed at an angle. This can happen during installation, after reassembly, during maintenance, or develop over time as a result of components shifting.

Component Defects

Various components can become worn over time and cause vibration. Bearings can deteriorate and present defect frequencies generating identifiable vibration signatures. Drive pulleys may present worn out belts and improper tension. Gears can be subject to fatigue resulting in root cracks and gear tooth spall, leading to machine failure.

Imbalance

Rotating elements within an industrial machine are imbalanced when their centres of rotation do not coincide with their centres of gravity, generating centrifugal forces. Imbalance can come from various sources including: eccentricity of pulleys or gears, dust on fan blades, bent shafts and unequal distribution of mass in cast parts, pump impellers or motor rotor windings.

Looseness

Mechanical looseness can happen when internal rotating elements such as couplings, rolling elements or sleeve bearings, rotors, etc. have not been fitted correctly. When this occurs, other sources of excitation can generate amplified levels of vibration and result in more severe damage to the machine.

Structural issues

The problems highlighted above stem from forced vibrations and are all inherently self-excited. However, the structural properties of machines can also cause vibration to be amplified. Every mechanical system has natural frequencies where the structure tends to oscillate when disturbed. If any of the forced frequencies get too close to a natural frequency of the machine structure, resonance occurs leading to the amplification of the vibration. This can potentially lead to damage to both the manufactured products and the machine itself.

If signs of structural issues become apparent during operational measurements, a decision can be made to conduct a modal analysis on the machine. This in-depth examination identifies the machines dynamic properties, its structural modes, and any potential weaknesses that can impact the manufacturing process. Vibremo engineers have substantial experience carrying out modal analysis and have helped clients reinforce their machine structures, and install Tuned Mass Dampers to effectively counteract specific disturbing frequencies.

These methodologies have been frequently applied in the aluminium and steel industries, on roll grinders and rolling mills in particular. These techniques are also widely used in the renewable or traditional energy production sectors, on machinery such as turbines, centrifuges, pumps, compressors, and more. Vibremo is dedicated to providing customised solutions that enhance the structural integrity and operational efficiency of industrial machinery across a wide range of applications.