UTILIZING VIBRATION ANALYSIS IN

PREVENTIVE MAINTENANCE

Compiled by :

Group 2 :

Agung Sukma R

Bagus Permadi S. L

Dani Purnama P

Fahrul Razi

Farid Surya R

Ignatius Armando F

2nd year of Mechanical B

 POLYTHECHNIC OF GAJAH TUNGGAL

CHAPTER I

PREFACE

I. Background
As the technology develop nowadays, it also affects the manufacturing processes
that required to produce quality products that can compete with other similar
products in the market. Hence, to produce quality products, utilizing up-to-date
machines with latest technology is required to support the purpose. In this case, the
engineers are required to do treatment and maintenance to the machines to unsure
its stability, reliability, and durability. The main purpose of maintenance is to prevent
further or severe damage in the future. These damages can be detected early by
detecting symptoms such as vibrations. Vibrations as a result in machine wear may
have negative effects such as noise, precision, and product defect, but on the other
hand, these vibrations can be utilized in detecting damages to decide the
appropriate maintenance. This is method well known as vibration analysis.
II. Problems Definitions
1. Why the vibration analysis is required in a machine?
2. What are the importance of vibration analysis?
3. What are the positive and negative effects of utilizing vibration analysis
system?
4. What are the advantages of the vibration analysis application compared to
other methods?
5. What are the example of vibration analysis applications in a machine?
6. Why we must aware of the vibration?
7. How to analysis vibration?
III. Problem Limitations
1. Positive and negative effects of vibration analysis
2. Benefit of understanding the vibration analysis
3. Example of vibration analysis applications
 4. Lowering the failure risk by vibration analysis

IV. Literature Purposes

V. Literature Benefit
VI. Literature Systematize
 CHAPTER II

THEORETICAL BASIC

I. Literature Study
Preventive maintenance implemnted in most of the modern factories are based on
analysis such as vibration analysis. These vibrations are analyzed using many kinds of
censors with different function, such as:
1. Velocity Censor
This censor functions in measuring vibration alteration rate of a moving
object, in the mm/s unit. The range of detected frequency are between 10-
1000 Hz or 600-6000 rpm.
2. Displacement Censor
This censor functions in measuring the distance of moving components from
the base point, with inch or mm unit. the frequency wich this censor could
detect range from 10-600 rpm. the example of this is the vibration of a shaft
in a low rotating motor.
3. Accelerometer Censor
This cencor functions in measuring the rate of high frequency vibrations or
ultrasonic vibrations in the mm/sec2 unit. the frequency rate of this censor
range above of 1000Hz or above 6000 rpm. the examples of these vibrations
are ; ball bearing, gear, and aerodynamic vibration source with high
frequency.
 Picture 2. Components GearBox
Vibration is a back and forward movement or osilating movement of a moving object
caused by its unbalance.
Preventive Maintenance is an act of further damage prevention by early
maintenance.
Vibration Analysis is a method of analysis using vibration.
Gearbox or transmission is one of the core components of a motor system, which
often called a force transfer system. A transmission functions in transferring and
alter the force of a running motor, which then used to rotate a machine spindle or
making a feeding movement.
The gearbox is often used to lower the rpm of a motor an at the same time
amplifying it’s torque to adjust the system’s need.

Picture 1. GearBox

The use of Vibration analysis in the proses of preventive maintenance.

Benefit / Importance :
 1. Vibration is a good indicator of machine performance.
2. Vibration is one of the effect of component wear / machine damage.
Vibration has some negative effect, such as :
1. Damaging components
2. Lower the machine’s precision
3. Noise level (increase)
4. Comfortability Issue
5. Safety Issue

II. Theoretical Background

 CHAPTER III

RESEARCH METHOD

I. Research Location
We choose to conduct our research in Plant M (Mixing) of PT. Gajah Tunggal, Tbk as
it is the production location of the main material in the process of tire
manufacturing. That material is known with the name ‘compound’.
II. Time
We conduct our research in 7 days, 4 hours each day between 08.30 and 12.30.
III. Instrument

The vibration data was obtained from the research object by using accelerometer
equipped with acquisition data that connected with a computer. Data retrieval and
storage is done using a computer equipped with data storage and management
software; YE 7600TM.

Picture 2. Vibration measurements chart in the Gearbox

Next, the collected data will be converted into math in order to be processed and
analyzed further using software MathlabTM.

The measurement point or the pick-up point are CDE (drive end of compressor), axis
1 and 2 in the horizontal and vertical direction.

The purpose of this testing are to find out the effect of load variation to the alteration
of amplitude, time domain, and frequency domain.

The analysis used in this research are amplitude analysis, time domain analysis, and
frequency domain analysis using comparative, trending, and descriptive method as
the research parameter.
 The testing of load effect to the characteristics of the vibration is done with stable
rotation and 5 load variations given that are valve opening 100%, 89%, 75%, 67%,
and 55%.

IV. Plot
V. Diagram
VI. Schedule
 CHAPTER IV

RESULTS

Measurements results

The signal measurements results in the shaft of two side drive end, at the horizontal
position with 3 load variations is shown in the picture below.

The signal in the gearbox axis 2 side drive end at the vertical direction with 3 load
variations is shown in the picture below.

Vibration signal at the gearbox axis 2 side drive end at the horizontal or vertical direction are
showed that the signal in 100% open, 75% open and 55% open differs and also showed that
as the valve opening reduced, the amplitude of the vibrations occurred will increase. This
occurrence is caused when the delivery valve is being shut, the higher the pressure is made.
Spectrum Measurements Results
The spectrum in in the gearbox axis 2 side drive end at the horizontal direction with 3 load
variations is shown in the picture below.

The spectrum at the G2DEH showed that the high amplitude is located in the frequency range
of <1000 Hz, 3000-4000 Hz, and between 5000-7000 Hz.

To further understanding the characteristics of vibration frequency, the frequency analysis are
divided in the narrow frequency range as shown below.

The picture of spectrum at G2DEH with the range between 1-300 Hz showed that the
Gearbox’s fundamental frequency is located at 26 Hz, the motor’s fundamental frequency
located at the frequency of 49.2 Hz, and as of the harmonics of two belt pass frequency
showed at the frequency of 15.4 Hz.

To clarify the frequency characteristics at G2DEH, the spectrum of G1DEH at the valve
closing 0% range 0-300 Hz, is shown in the picture below.

The spectrum of the range between 1-300 Hz, with the valve fully opened also showed that
the the fundamental frequency first gearbox’s harmonics is located at 25.8 Hz the motor’s
fundamental frequency is at 49.0 Hz. The highest amplitude is occurred in 7 fundamental
frequency gearbox 7FFG : 181 Hz, followed at 5FFG : 129.2 Hz. The highest amplitude is
occurred at around 7FFG : 181 Hz. The effect of load toward amplitude and the alteration of
frequency, those changes is shown as the picture below.

The picture shows that 7FFC: 181 Hz consistent that the higher (tighter) the valve closing, the
higher amplitude occurred will get. Furthermore, the closing of the valve also affect the
frequency shift. Hence, the higher the valve closing, the lower the frequency shift occurred.
This happens because the existence pressure resistance to the impeller or lobe.
 CHAPTER V

STUDY AND ANALYSIS

I. Study
The results showed that there are abnormalities in the vibration of the gearbox.
With the normal gearbox vibration of 540 Hz, the result shows that the abnormal
vibration of 720-780 Hz resulting in the deformation of the shaft. The unbalance
rotation of the gearbox will result in the incomplete transfer of rotation. This
incomplete rotation will produce an insufficient torque, with noise way off
standards. These effects have potential of wearing out the components of the
gearbox / the damages in some components of left unhandled. Based on the study
carried out, that problem was caused by some factors, such as the chipped gears
caused by the lack of oil (lubrication) resulting in a high friction, a loose bolt, or a
bent shaft caused by a high pressure resulting in an unbalance, or a loose bearing.

II. Analysis
After an analysis from study above have been carried out, it was concluded that the
dominant cause of the abnormal vibration is the chipped gear, which is caused by
the lack of lubrication with the core cause of a human error in maintenance resulting
in a fatal problem. The consequence is the existence of an over friction at the gear,
caused by the lack of lubrication function, therefore, if the friction doesn’t have
enough damper, it will cause the wear of the components.
 CHAPTER VI

CONCLUSION AND SUGGESTIONS

I. Conclusion
The whole research conducted showed that the abnormal vibration is caused by a
chipped gear in the gearbox. The vibration analysis had shown its value in assisting
the engineering team in the preventive maintenance process.
As for overcoming the over vibration, there is some way/solution such as :
1. Utilizing a damper / pads at the base of a machine
2. Using (masking) a deep foundation as the machine base.
3. Fastening the buffer bolt and a periodic check-ups.

II. Suggestions
We suggest in the implementation of vibration analysis in the future, in order to aid
the process of preventive maintenance, and in order to prevent damages that may
cause a system failure of the machine. Therefore, it is expected to extend the
lifetime of the machine and in order to make sure a continuous production process,
resulting in effective and quality products.