SKF Reliability Systems

Synchronous Time Averaging/

Machine Balancing
Abstract

Transducer

Machine balancing is a maintenance

requirement that extends machine
component life and improves process
performance. Programs have been written
to calculate the required corrective balance
weights from amplitude and phase data
relative to a shaft reference. Precision
balancing depends on stable, accurate
phase and amplitude measurements.
Synchronous time averaging insures phase
stability by discriminating against noise
and machine cross talk during trim balance
runs. This paper discusses the concept of
synchronous time averaging as applied to
order tracking balancing methods for
multiple cooling tower fans arranged side
by side in a weather protected housing.

Generally, the transducer used in making

synchronous time average measurements is
an accelerometer incorporating an
integrated amplifier. The amplifier
provides a low impedance output that
allows its sensitivity to be independent of
cable length.

Analyzer
The FFT analyzer used in making
synchronous time average measurements
incorporates a current source to energize
the transducers amplifier. The analyzers
input gain amplifier auto-ranges to insure
optimum dynamic range without circuit
saturation. In accordance with FFT
conversion techniques, the collected raw
signal is filtered to attenuate all signal
components above the selected frequency
domain, thereby minimizing aliasing errors.

Definition
A synchronous time average is an average
of only those synchronous rotational
components which are coherent with a
machine shaft reference. Noise and nonsynchronous signals tend to average to
zero.

A/D Converter
After filtering, the analog-to-digital
converter periodically samples the filtered
signal at a sample rate of 2.56 x the
maximum frequency range. That is, if the
frequency range is 1 kHz then the sample
rate is 2.56 kHz.

Block Diagram
Figure 1 is a simplified block diagram of a
generic FFT analyzer.

Block Diagram FFT Analyzer

Current
Source

Overload

Number of Samples =
2.56 Number of Lines
T = Number of Samples
Sample Rate

Anti-Aliasing
Accelerometer
Transducer

Fmax

Sample
Time

A To D
Converter

Filter

Data Buffer
FFT

Sample Rate = 2.56 Fmax

Processor
Spectrum
External
Trigger

Pulse
Circuit

Sample
Clock

Display

Application Note
CM3023

Figure 1. A Simplified Block Diagram.

Sampled Data Buffer

The samples are next stored in the sampled data buffer
whose memory length is 2.56 x number of FFT lines of
resolution. If 400 lines of resolution is selected, then the
length of sampled memory is 1024 sample points. The
memory length in terms of the data time interval is equal to
the number of data samples divided by the sample rate, that
is:

T=

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Synchronous Time Averaging/Machine Balancing

2.56 x Number of Lines

2.56 x Fmax

if number of lines = 400 and Fmax = 1000

rotation. This is implemented by sensing the trigger signal

to initiate a count of the sampled data entering the buffer.
When the count equals the buffer sample length (1,024 in
this example), each time sample ensemble is summed until
the selected average number is reached.
Each sample point sum is divided by the average number to
obtain the mean. Since the high spot amplitudes are always
delayed the same amount of time from the trigger, the
sequential sums of these coherent signals will be enhanced
while noise and non-synchronous signals tend to a zero
average. The result is that synchronous time averaging
stabilizes and improves phase and amplitude measurement
accuracy.

Phase Measurement Accuracy

then, T = 400 millisec.

ABSOLUTE PHASE
Once the buffer is full, the data is converted from the time
domain to a spectrum domain by the FFT processor.

Normal Averaging
In the normal averaging mode, each converted spectrum
ensemble is sequentially summed together, divided by the
number of spectrum ensembles and displayed as the
average. For example, if the number to be averaged is 10,
then each of 10 sequential spectrums are summed and the
sum divided by 10 to obtain the mean.

Synchronous Time Averaging

The measurement of absolute phase of the 1-per-revolution

imbalance component requires special circuit considerations
to achieve repeatability and accuracy.
A normal single channel FFT analyzer operation, with fixed
range anti-aliasing filters and a sample rate independent of
rotation, contributes significant errors to phase measurement
calculations. The following is a discussion of these major
error sources.

TRACKING ALIAS ERRORS

Synchronous time averaging is different from normal

averaging in that the time domain buffer is summed and
averaged prior to the FFT conversion process.

It is necessary that measurements not be affected by large

speed variations which can introduce aliasing components.
These problems are avoided if the anti-aliasing filter is
converted to a tracking filter whose high frequency cutoff
tracks the rotational speed.

The averaging process is meaningful only if a trigger

synchronizes the sampling process so it is coherent with

Since sample rate is related to the selected maximum

frequency range, the sample clock must proportionately

Order Tracking Block Diagram

Accelerometer
Signal

Tracking
Filter
Gain

NX (1X)

Trigger
N
Wide
Narrow
Normal

NX (1X)
Wide
Narrow
Normal

A/D

NX (1X) 2.56

= Maximum Orders
= 20% = 20 (1X)
= 5% = 5 (1X)
= 10% = 10 (1X)
Figure 2. An Order Tracking Block Diagram.

FFT

Synchronous Time Averaging/Machine Balancing

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track the shaft trigger signal. This changes the spectrum

display from a fixed frequency plot to an order diagram
where the machine speed is the first order and maximum
range is the number of orders selected from a menu option.

PHASE MEASUREMENT ACCURACY OPTIMIZED

Phase measurement accuracy is optimized when the ratio of
FFT lines per order is an integer. For example, if the FFT
line resolution is 400, a maximum order of 20, 10, or 5
would be desirable whereas 3, 7, or 9 would not.

Figure 3. A Stationary Sine Tone.

Whenever an integer line-per-order relationship is used, the

FFT phase process is said to be bin centered and the FFT
phase error contribution is zeroed.

TRACKING FILTER ERROR

A phase error is introduced by the tracking filter. The filter
phase is not constant but increases with higher orders.
These filter errors are eliminated by subtracting the known
filter phase shift from each integral order. Essentially, the
filter is modeled in firmware to provide a tabular listing of
order vs. phase.

Figure 4. Sine Tone plus Swept Sine Frequency Domain Averaging.

Figure 2 shows a simplified order tracking block diagram.

VIBRATION SIGNAL GAIN

The vibration signal gain is again optimized by auto-ranging
the input amplifier. The signal is filtered by the tracking
filter whose cutoff is continuously adjusted by the 1X
trigger. In this case the Fmax cutoff is equal to N (maximum
orders) x (1X) rotation speed. The filter cutoff frequency
varies with rotation. The sample clock also tracks the
rotation speed where SR (sample rate) equals 2.56 x N x
(1X).
This maintains the zero bin relationship required for zero
FFT phase contribution. The final phase calculation is
corrected by subtracting the known filter phase shift by
means of a firmware modeling algorithm.

Comparison Of Phase Accuracy Methods

FREQUENCY AVERAGING VS. SYNCHRONOUS TIME
AVERAGING
An experimental setup was arranged with a Signal
Generator that allows for simulated rotation signals
precisely phase shifted relative to a reference. A signal
from this setup was combined with a non-synchronous
nearby rotation signal.

SIMULATED MACHINE BALANCING MEASUREMENTS

The first measurement was to establish the reference run
under the most stable conditions. A 61.4 Hz sine wave was
programmed with a phase lead and was measured in

Figure 5. Sine Tone plus Swept Sine Synchronous Time Averaging.

conjunction with a square wave reference. Both normal

averaging and synchronous time averaging measurements
were the same in both amplitude and phase.
Figure 3 shows the tabulated results of these measurements
under the reference run heading.
Next, a signal sweeping between 59 and 62 Hz at a slow rate
was summed with the original sine wave. Figure 4 shows
the results of normal averaging where the amplitude was
measured as 1/3 the first reading and the phase was more
then 20 lag from the correct measurement.
The last tabulated measurement was performed with
synchronous time averaging (Figure 5) where both
amplitude and phase were within 0.2% of the correct value.
Since synchronous time averaging tends to zero out the noncoherent signal, using a long enough averaging process
causes the resultant data to converge to the stable coherent
component.
The following plots graphically compare the time signal

"Synchronous
Time Averaging/
Machine
Balancing"

averaging results of
synchronous time
averaging and normal
frequency domain
averaging of signals with
nearby crosstalk
components. Figure 6
shows the effects of the
beat frequency.
Figure 7 displays the
results of time averaging
where the crosstalk signals
are incoherent with the
reference and averages
towards zero.
Figure 8 is signal without
crosstalk. The time
averaging process
amplitude compares
precisely with the signal
alone.

SKF Reliability Systems

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USA
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Web: www.skf.com/reliability

Although care has been taken to

assure the accuracy of the data
compiled in this publication, SKF
does not assume any liability for
errors or omissions. SKF
reserves the right to alter any part
of this publication without prior
notice.
SKF is a registered trademark
of SKF.
All other trademarks are the
property of their respective
owners.

CM3023 (Revised 6-04)

Copyright 2004 by
SKF Reliability Systems
ALL RIGHTS RESERVED

The regular averaging

method shows
considerable large
amplitude discrepancy
relative to the coherent
rotational component.
This approach can prove
to be advantageous during
a precision balancing
operation where the final
trim run amplitude is
either buried in noise or in
close proximity to a
crosstalk signal from a
nearby machine.

10.0

2.0
Gs/Div

-10.0
80.0

160.0

MS
OVERALL
6.8124

240.0

320.0

400.0

Figure 6. Frequency Ensemble: AveragingMachine and Crosstalk.

10.0

2.0
Gs/Div

-10.0
0

80.0

160.0

MS
OVERALL
3.9454

240.0

320.0

40

Figure 7. Synchronous Time AveragingMachine and Crosstalk.

10.0

2.0
Gs/Div

Conclusion
Accurate and repeatable
phase measurement is a
difficult problem at best
with single channel FFT
analyzers. It requires a
tracking filter for speed
variations, adjustable
clock sampling
proportional to speed, and
filter phase compensation
for measurement
precision.
In the practical world,
both noise and nearby
rotational signals often

-10.0
0

80.0

160.0

MS
OVERALL
3.9006

240.0

320.0

400.0

Figure 8. Signal (No Crosstalk) Frequency Ensemblee Averaging.

introduce variables that cause significant unstable results.

Synchronous time averaging minimizes these variable
components to levels that allow for accurate and stable onsite phase readings. Precision machine balancing
measurements can be performed under circumstance which
introduce substantial noise and nearby rotational amplitudes
from the normal production operation. These measurements
can simply be accomplished with a battery operated handheld analyzer incorporating resident balancing firmware.