Slow roll run out instrument - user manual

SRI – USER INSTRUCTIONS SRI instrument measures mechanical imperfections such as out-of-roundness and non-concentricity with respect to the bearing journal surface, with relative displacement probes positioned over track area that is adjacent to each bearing. The result from these imperfections, usually known as runout, must be reduced if it exceeds the recommended value. SRI instrument (figure 1) provides measurements required for machine centring. Figure 1 SRI INSTRUMENT CONCEPT AND DESIGN The SRI instrument consists of a processing unit with a real-time controller, which performs the acquisition and processing of the measurement data, obtained by the relative displacement sensors and a tacho sensor. The measuring sensors are connected to the measuring module with connectors located on the embedded instrument panel. The relative displacement sensors and the tacho sensor are supplied with magnetic base holders, what makes the installation to metallic parts of the machine easy. SRI instrument performs an analysis of the measuring signals and provides the orbits locally on the instrument touch screen. Additional feature of this instrument is a magnetic belt which can be fitted to any shaft. The tacho sensor reads impulses from the magnetic belt. For every impulse, data from SRIupper gen. bearinglower gen. bearingturbine bearing all relative sensors are acquired and drawn on a screen of the instrument. With this feature, the measuring results are more accurate. Data overview, parameters adjustment as well as the operating mode of the instrument is enabled on the device by the touch screen. A detailed overview of the measurement data is provided through TCP/IP protocol and additional client application, which can be installed on a laptop or a personal computer. All the measurement data are stored in a device flash memory with 2 GB capacity, which can be increased if necessary. SENSORS AND ACCOMPANYING EQUIPMENT Sensors are installed on the magnetic transducers. Usually there are two sensors on each bearing and they are at a 90° in relation to each other in the same plane. There also has to be a tacho sensor, which gives information on a precise position on the shaft. Figure 2 shows sensors for measuring relative displacement and tacho sensor as well as a magnetic belt. The magnetic belt is adjustable to any shaft size and it does not need any support. Figure 2 The instrument is provided with the appropriate number of sensors, which depends on a specific measurement, one tacho mark and a magnetic belt. INSTRUMENT HMI SRI system runs automatically as soon as the power supply voltage 110 V -240V AC or DC appears on the input terminals. No additional actions for the system start are required. The home screen of the local HMI on the instrument is shown in figure 1. Figure 3 Home screen 2D graph shows orbits for each bearing. They are marked with colors as shown in the figure. In this configuration the instrument works for four planes. For each pulse of the tacho sensor, one point is measured for each of the relative displacement sensors. Table 1 shows the used icons. Home Returns the user to the home screen. Start recording Activates a new measurement. Alarm Alarm icon is active if sensors are not set within the allowed range. This is seen on the setup screen. Setup Leads to the setup screen, where sensors initial values can be seen and where number of tacho marks, as well as the file name for the data storage can be set. AC orbit plot Leads to the AC orbit plot, where orbits are shown without the DC components. DC orbit plot Leads to the DC orbit plot, where orbits are shown with both AC and DC components. Allowed & measured values Leads to the screen with aggregate dimensions, which have to be entered by the user, and with the allowed and measured Smax values for each measuring plane. Graph Shows signals from the x and y sensor. Values Shows tables with max and min measures values for each of the measurement sensor with the number of accompanying tacho mark, as well as all measured Smax values. Back Moves the cursors along the orbit graph in the counter clockwise direction. Forward Moves the cursors along the orbit graph in the clockwise direction. Save Saves the setup configuration. INITIAL SETUP Before the measurements, relative displacement sensors have to be set in the middle of the measuring range (cca. 4 -6 V). After positioning the relative displacement sensors, check their values on the Setup screen and change their distance to the shaft until the square icon turns from red to green. An alarm indicator is active if one of the sensors is out of the measuring range. If all the sensors are set correctly, the alarm icon will not be active anymore. It is also necessary to enter the number of tacho marks that are used. File name is by default determined by the time when the measurement is taken. The user can enter additional name which will be added to the default file name. Setup window is shown in figure 4. Figure 4 Setup window New measurement can be made after selecting a PLAY button from the home screen. The graph is then reset, as shown in figure 5. Figure 5 New measurement While doing the measurement, the PLAY icon is changed to STOP icon. There is a progress bar at the bottom left corner of the screen, indicating which tacho mark is active at the moment. It is necessarily to make one turn of the machine. When the number n reaches the total number of tacho marks entered by the user in the setup window, the measurement is finished. Figure 6 Measurement in progress Figure 7 Measurement is finished There are four cursors on the graph, one for each orbit. Corresponding values of x and y sensor for each of the measuring planes are shown in the table to the right. By using arrows, it is possible to move the cursors and see the values of x and y for the desired dots in the table. The number of accompanying tacho mark is shown above the table. It is also possible to zoom in or zoom out the graph by clicking anywhere on the graph itself. Figure 8 Graph zoomed out AC GRAPH The orbits can be shown with and without the compensation (with or without the removal of a DC component). By clicking the AC button, the AC graph is shown (figure 9). The AC graph shows the orbits without the DC component, so each of the orbits is centered on zero. Relative displacements are shown in the table to the right. There are Smax values for each of the measuring planes, as well as relative displacement values which correspond to the cursors on the graph. Smax1, Smax2 and Smax3 show the maximum value for the corresponding orbit. Figure 9 RAW SIGNALS Figure 10 shows the Raw signals window. Signals from the x sensors are shown on the upper graph, and signals from the y sensors are shown on the lower graph. Figure 10 Allowed & measured values Figure 11 shows the screen with allowed and measured values of Smax. The user has to enter the aggregate dimensions shown in the figure (H1, H2, H3, H4 and d) in the table, as well as the koefficioent k. The allowed values of Smax will then be calculated and they can be compared to the measured Smax values for each measuring plane. Figure 11 LIST OF MAX AND MIN VALUES The screen with the table of max and min values for each of the sensors is show in figure 12. Numbers of corresponding tacho marks are shown too. Smax values are shown in the table on the right. Figure depicts the magnetic belt installation. Figure 12 The instrument automatically records measuring data and stores it in a memory so that it can be used later. SRI – USER INSTRUCTIONS – PC APPLICATION Data recorded with the SRI instrument can be loaded into the PC application designed for detailed analysis of the measured data. The used PC has to be connected to the SRI by using Ethernet cable. The home screen of the PC HMI is shown in figure 2. Desired measurement can be chosen from the measurement list (Figure 1), and the latest measurement is reached and automatically shown after selecting the refresh button . Figure 1 Figure 2 Home screen The 2D graph on the right of figure 2 shows orbits for each bearing. They are marked with colors as shown in the figure. On the left side of the screen there are graphs with the signals from x and y sensors. For each pulse of the tacho sensor, one point is measured for each of the relative displacement sensors. Cursors can be moved by using arrows, and the number of the corresponding tacho mark is shown between them ( ). Cursors can be moved along one orbit at the time. Desired orbit is selected by clicking on the number of the current selected orbit ( ). Values of x and y sensor, current relative displacement values and Smax values are shown on the left. The values correspond to the places on the graphs where cursors are positioned. Table 1 shows the used controls. Measurement list Shows the list with all available measurements. Refresh Loads the latest measurement. Cursors control Cursors can be moved by using arrows, and the number of the corresponding tacho mark is shown between them. Report Generates the report. AC orbit plot Leads to the AC orbit plot, where orbits are shown without the DC components. DC orbit plot Leads to the DC orbit plot, where orbits are shown with both AC and DC components. Position Gives max and min measures values for each of the measuring sensor with the number of accompanying tacho mark, as well as data for bearing adjustment. Setup Gives comparison of allowed and measured Smax values. 2D orbit Shows 2D orbit plot. 3D orbit Shows 3D orbit plot. Projection Shows projection lines. Table Gives values of all measures points. AC GRAPH The orbits can be shown with and without the compensation (with or without the removal of a DC component). By clicking the AC Signal button, the AC graph is shown (figure 3). The AC graph shows the orbits without the DC component, so each of the orbits is centered on zero. Figure 3 3D orbit Figure 4 shows the 3D orbit without the DC compensation. By clicking and dragging the orbit plot, 3D orbit can be rotated, as shown in figure 5. Figure 4 Figure 5 Figure 6 shows 3D orbit with the DC compensation. Figure 6 Position The screen with the table of max and min values for each of the sensors is show in figure 7. Numbers of corresponding tacho marks are shown as well. Smax values are shown in the table as well as values for the bearing adjustment. Figure 7 Setup The user can enter the aggregate dimensions shown in the figure and the coefficient k, and the allowed Smax values will be calculated. They can then be compared to the measured Smax values. Figure 8 Projection lines Figure 9 shows the projection lines. They are shown for 8 measurement positions at 0, 45, 90, 135, 180, 225, 270 and 315 degrees. Projection lines connect the measured positions of all the planes, which correspond to the same tacho mark. Figure 9 Table Table shows all the measured points, for x and y sensors in all measurements planes. Figure 10 Report After selecting Report icon, the Report window is shown. The user can enter report number, subject, contract number, contractor, manufacturer, test type, test location, measurement date, notes and conclusion. Report window is shown in figure 11. Figure 11