Introduction to Order Analysis

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Brel & Kjr Sound & Vibration Measurement A/S.
Copyright Brel & Kjr. All Rights Reserved.

Introduction
Contents
Sources of Machine Vibration
Principles of Order Analysis
Various Methods of Order Analysis

FFT based Order Tracking

Order Analysis.

Vold-Kalman Order Tracking Filter Technique

Additional tools

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Auto-Tracking, no tacho signals available

DC Speed Ramp signal

Signal enhancement

Merits of Machines

Machines have been designed to

perform certain tasks

However, due to design and/or

manufacture flaws, wear/tear, machines
vibrate and make noise.
Lets have a look at the sources of this
noise and vibration

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Energy Transfer in Machines

1
Vibration excitation
due to imperfections
in rotating parts
2
Transfer of energy
to other parts of the
machine through
the machine
structure

4
and emission
of noise
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3
. causing
vibration in all
parts of the
machine

Measure on the Outside to Learn about the Inside

and measurement of
noise near the machine

From measurement of
vibration on the
outside of the machine

we can get
information about what
happens inside the
machine

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Moving and Fixed Parts in Machines

Lets have a look at what a machine contains..
A machine contains one or several rotating and
reciprocating parts like shafts, gears, and pistons.
During operation these moving parts are the
main causes of noise and vibration

in addition, the machine contains a large number of fixed parts which

vibrate when excited by the vibration generated by the rotating parts.
When the frequency of this vibration coincides with one of the resonance
frequencies of the fixed parts (structural resonances) the structure will
amplify the vibrations.
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Forces and Vibration

Input
Forces

System
Response
(Mobility)

+
Frequency
Forces caused by
Imbalance
Shock
Friction
Acoustic

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891875

Vibration

=
Frequency
Structural
Parameters:
Mass
Stiffness
Damping

Frequency
Vibration
Parameters:
Acceleration
Velocity
Displacement

Sources of Machine Vibration

The moving parts of machines create vibration at different frequencies.

Vibration
level

1st 2nd 3rd 4th 5th 6th 7th 8th 9th

12th

Order
Frequency, Hz
(Frequency, Hz)

Misalignment
the
shaft
vibration
at
Vibrations
NOISE,
at of
50
i.e.,
or vibrations
60
Hzcauses
(incl.
caused
harmonics)
thof
st due
Vibration
Vibration
Vibration
Harmonics
Extra high
at
(suborders
amplified
the
level
of
rotational
speed
of
by
6
at
structural
42-48%
harmonic/order
main
frequency
shaft
of
resonances
RPM)
(1
caused
order)
caused
by
to
inof
lower
harmonics
orders
causedby
Vibration
byother
electromagnetic
machines
caused by
or=worn
forces
ambience
gear
or electric
bythe
oil main
film
imperfect
the
whirl
shaft,
machine
misalignment
orfan
caused
whip
with
structure
in 6
journal
blades
unbalance
bearing
e.g.,noise
windpicked
excitation
up from
or acoustic
power
excitation
(rotational
frequency
by
1, 2,cables
3,)
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The Frequency Spectrum

When we remove the colors used in the
previous example
it becomes very difficult to tell which
vibration component account for which
property/defect!
Vibration
level

Order
(Frequency, Hz)

We will therefore now demonstrate how we can identify

and analyze different frequency components using
Order Analysis
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Principle of Order Analysis

The key to sound and vibration analysis on rotating machines is
measurement of the rotational speed of the machine
simultaneously with measurement of sound and vibration.
When the analysis is related to the rotational speed it is called

Order Analysis or Order Tracking

(Rotational speed = RPM = Revolutions/minute = 1st order)
The speed is normally measured with a Tacho probe giving one (or more)
tacho pulse(s) for each revolution of the rotating part (shaft).
Tacho

Vibration

Machine
T

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Speed
= RPM
= 1/T

Sound

Older Analog Analysis techniques

Analog tracking filter and
Analog recording

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Older Analog Analysis techniques

Analog tracking filter and
Analog recording

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Todays numerical method - Storage in Multi-buffers

Storage of Spectra (Method 1)

Storage of Slices

+ Tags

(Method 2)

Speed values from Tachometer

Average Speed values from Analyzers
Time
Process parameter (Overall level)

(based upon speed interval, time interval,..)

#
#

Time

Spectra
FFT, Order,
1/n Octave, etc...

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Slices
Order, Frequency band
Overall L,A,B,C levels

#
#

#
#

#
#

Speed 1 Speed 2 Average Average

Speed 1 Speed 2

Tags

#
#

Overall
level

Principle of Order Tracking

To investigate the machine during operation, e.g., during a run-up, we
measure vibration spectra at certain RPM intervals. Since each spectrum
is tagged with the actual RPM, we can show Waterfall plot and Contour
plots of the vibration spectra as a function of RPM (z-axis).
Notice how the contour plot makes it very easy to separate spectral
components related to the speed of the machine from other
components, e.g., structural resonances.
Vibration level
10
[m/s2]

1800 Speed
[RPM]
1400

1000

Frequency [Hz]
1800 Speed
1600 [RPM]
1400
1200
1000

Vibration 10
level
5
[m/s2]
0

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Frequency [Hz]

Principle of Order Analysis

From the plots we can extract just the information we want: Order or
Structural Resonance slices.
[m/s2]

10

1st order
[m/s2]

5
0

10

6th order

5
0

Speed [RPM]

Speed [RPM]

Vibration level
10
[m/s2]

1800 Speed
[RPM]
1400

5
0

1000

Frequency [Hz]
[m/s2]

10

Structural
Resonance

5
0

Speed [RPM]

These slices can be viewed during the measurement or extracted from the
stored spectral information after the measurement as post-processed slices.
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Analysis Methods of Order Analysis

[m/s]

Mlt UP FFT spectrum(Vibration Z)

Working : Input : Order Run-up : FFT Analyzer

FFT based Order Tracking (Real Time)

Only lower orders are of interest

Orders are well separated
Rotational speed variation is limited

0
5k

4k

3k

2k

40

80

120

160

Digital Re-sampling Order Analysis (Real Time)

200
[Hz]

240

280

320

360

High orders are of interest

Rotational speed variation is wide and/or fast

Vold-Kalman Order Tracking (Post processing)

Measurement situations are difficult

Crossing orders
Very fast RPM change (high slew rate)
Gear shift

Order waveform of 1. and 3. order

Order waveform is wanted for playback

3. order
1. order

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400
[RPM] (Speed Tacho 1)

Speed processing for FFT and Order analysis

Tacho processing method
Pulse train, n pulse per revolution
Auto Tracking, no Tacho signal
DC Voltage ramp

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A
B

1- FFT based Order Tracking

Analysis based on ordinary FFT spectrum analysis.
FFT spectra and slices, shown as function of RPM measured by the
tachometer.
Time
Signals

FFT
Analyzer

FFT
Spectra

Use:
RPM tagging
Extraction of
order slices
Tacho
Signals

Tachometer
Order
and
Frequency
Slices

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Simple Contour plot and waterfall

[m/s]

Mlt UP FFT spectrum(Vibration Z)

Working : Input : Order Run-up : FFT Analyzer

FFT based water

fall analysis.

Waterfall and Contour plot of

the same run-up test of the
Vibration-Z sensor.

0
5k
4k
3k
2k

40

80

120

[m/s]

160

200
[Hz]

240

280

320

360

400
[RPM] (Speed Tacho 1)

Mlt UP FFT spectrum(Vibration X) - slice

Working : Input : Order Run-up : FFT Analyzer

4
3.6
3.2
2.8
2.4
2

The contour plot has a delta

order cut cursor at an oblique
angle used to make slice cut
of key orders vs RPM.

1.6
1.2
800m
400m
0
1.2k

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1.6k

2k

2.4k

2.8k
3.2k
3.6k
[RPM] (Nominal Values)

4k

4.4k

4.8k

5.2k

FFT based Order Tracking

Advantage:
Low cost
(more channels for a given processing power)
On-line analysis
Slice extraction with multiple tacho references

Limitation:
Smearing of higher orders
Only for lower, well separated orders over a
limited RPM range and relatively slow run-up.

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2- Order Analysis (re-sampling)

The Sampling rate of an Order Analyzer changes in accordance with
the rotational speed of the machine under investigation (tracking). The
result is that individual orders remain on the same order line on the
plot and smearing is avoided.
With this technique close orders
and very high orders can be
identified and analysed.
Order
Time
Signals

Order
Analyzer
Use:
Tracking
reference
RPM tagging
Extraction of
order slices

Tacho
Signal
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Tachometer

Spectra

Order
Slices

FFT based vs. Order based: Whats the Difference?

a) Original signal

Time

b) Fixed sampling frequency (FFT Based)

FFT Spectrum (no tracking)

fs = 2,56 fmax
Samples analyzed

fmax

Time

c) Sampling according to tacho (Order Based)

Frequency

Order Spectrum (tracking)

Example: fs = 8 ffundamental
Samples analyzed

Revolutions
(periods)
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810110/1

Orders

Run-up/down Tests with re-sampling

Constant Frequency Curves

Rotational
Speed
RPM
3000

f = 150 Hz
2400

f = 100 Hz

1800

f = 50 Hz

1200
600

1
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880491

10

Order No

Constant Frequency cursor in Order Contour

Plots
White cursor
line indicates
a resonance
in an Order
based
contour plot.

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Tacho Gearing
Ratio

Factor

1:2
A

N pulses / rev
Probe

Probe

A
B
Speed A
Factor = N, ex: 32 or 64ppr

Ratio =

Speed B

Combined gearing = N Ratio

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23
=

17

Ateeth
Bteeth

Order Analysis
Advantage:
Accurate identification of higher orders, no smearing
Analysis of high orders over a wide RPM range
Analysis of close orders
On-line analysis
Fast runup can be handled with accurate Tacho (ex:60ppr)
Limitation:
Depends on a reliable and accurate Tachometer
No frequency slices

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FFT based vs. Order based: Whats the Difference?

Frequency Analysis

Order Tracking Analysis

Time: When ?

Time: When ?

Referenced to
the clock
[sec]

Referenced to
the revolution of the shaft
[Rev]

Frequency spectrum:
How often?
[per second]

Order spectrum:
How often?
[per revolution]

Signal
Spectrum

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Frequency Analysis

Order Tracking Analysis

Time [sec]

Revolutions [Rev]

Frequency [Hz]
[per sec]

Harmonics [Order]
[per revolution]

Time signals for FFT and Order analyzers

[m/s]

Rev (Vibration X)
W orking : Input : Input : Sync Avg Order Analyzer

On the left:

8
6

Time trace from and Order

analyzer with an horizontal
axis showing revolutions

-2

-4

-6
[m/s]

-8
0

5
[Revolution]

Time(Vibration X) - Input
Working : Input : Input : FFT Analyzer

On the right:
-2

Time trace from and FFT

analyzer with an horizontal
axis showing seconds.

-4

-6
0

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10m

20m

30m

40m

50m

60m
[s]

70m

80m

90m

100m

110m

120m

Analysis without and with re-sampling

Analysis of a
vibration signal
from a machine
with slightly
varying speed

Without tracking

With tracking
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Comparison of Order vs. FFT Analysis

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Order Analysis - with or without re-sampling

Run-up/down tests using
frequency spectra, i.e.
without re-sampling:
Advantages:
Fast
Orders referenced to different
speeds can be extracted from the
same spectra
Easy to identify resonances (fixed
frequencies) from contour plot
Easily understood

Run-up/down test using order

spectra, i.e. with re-sampling:
Advantages:
No smearing
Identification of higher harmonic
orders
Low no. of lines in the spectra
Wider slew rate
Time data in crank domain

Disadvantages:

Disadvantages:

Smearing of components
High no. of FFT lines if wide RPM
and frequency range is required

More processing power required

Accurate tacho required

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Vold Kalman Filtering

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Vold-Kalman Order Tracking Filtering

Two step post-process on captured data:
Step 1: Extraction of accurate RPM profile.
Step 2: Filter out orders according to the
RPM profile.
Order
Waveforms
for playback

Time and tacho signals

captured using
Time Capture Analyzer
Time
Signals
PC
Memory
Tacho
Signals

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VoldKalman
Filter
RPM
profile
extraction

Order waveform of 1. and 3. order

3. order
1. order

Magnitude of 4 selected orders

Order
Levels

1. order

9. order
3. order
10. order

Gear Shift Event: RPM Profiles

Light truck, V-8 engine

light load condition

Gear shifting events

first, second, third and forth
gear engaged

Engine and drive-shaft RPM

profiles

Gear shifting event analyzed

from second to third gear

RPM profiles
raw and curvefitted RPM
two hinge points

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Editing of single orders: Waveform extraction

Sound Quality synthesis studies

Removal or attenuation of
orders in run up/down
measurements

Total signal

9th order waveform

9th order
removed
or attenuated

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Vold-Kalman Order Tracking Filtering*

Advantage:
Can handle complicated situations like:
Crossing orders
Gear shifts
Tacho drop-out

Unlimited slew rate/speed variation

Useful for Sound Quality work

Limitation:
Off-line analysis
More time consuming

* For a detailed description see Sound and Vibration, April 1999, p. 34 - 44:
Characteristics of the Vold-Kalman Order Tracking Filter
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Tacho Processing - AutoTracking

Autotracking
Functionality in PULSE LabShop and Reflex
Order tracking without direct access to the rotating parts of the machine

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Brel & Kjr Sound & Vibration Measurement A/S.
Copyright Brel & Kjr. All Rights Reserved.

Introduction

Rotating Machinery
Knowing the RPM of the rotating parts is
important for analysis and diagnostics
Order Analysis

Limitations of the Tacho Solution

Requires direct access to
rotating parts and dedicated sensors
Mounting is time consuming and difficult
(compact engines, safety requirement)

Benefits of Autotracking
Indirect measurements
Accelerometers, Microphones

Order Analysis
Tacho signal not available or difficult to get

Applications
Drivetrain, Turbocharger, Turbine, Engine

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01

Autotracking Basic Idea

An frequency tracking method where the
fundamental frequency is indirectly extracted from
the measured vibration or acoustic signal rather
than directly from a tacho probe

Method based on Bayesian statistics, where the

posterior distribution of the fundamental frequency is computed
conditioned on the measured data and a harmonic model of the signal

p 0n 0n 1, 0n 2 , 0n 3 ,, 0n N , d , I

where d: measured signal; I: prior knowledge in the estimation model;

n: record index; N: Number of previous records
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03

How to select harmonics, 1 ?

Acoustic signal from

5 cylinder engine

7.5

Expected harmonics:
2.5, 5, 7.5 etc.
Pretest
Inspection

5
2.5

Experimental data
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09

3 Cylinder engine example

FFT waterfall showing the key
orders = 1 and 1.5

Speed versus time for regular tach

pulse signal (blue) and AutoTracking
generated speed siignal (orange). The
two are identical until the end of the run
down.

Order analysis waterfall using the

AutoTracking Tacho signal

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Autotracking Benefits

State-of-the-art solution
Based on Bayesian statistical methods using measured data
harmonic structure and tracking profile

Supplement to current Tachometer

No need for direct access to rotating parts

A direct tacho signal may not be available
The tacho signal may be of bad quality

No need for dedicated tacho probes and tacho channels

Less and inexpensive equipment (indirect meas using accs and mics)
Reduced channel count (use existing channels)
No problems with e.g. ground loops

Ease-of-use
No time-consuming and difficult mounting (compact engines)

Reduced safety requirements

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19

Tacho Processing DC Ramp

Feature introduced in Pulse 11

Order Spectrum Fourier Phase is

independent of the RPM

Tracking using Aux.Signal Input [V/rpm] as

tracking reference

The DC speed signal can come from the

CAN bus.

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Special for Order Analysis Advance feature

Signal Enhancement
Spectrum Enhancement

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Signal Enhancement
Signal enhancement or Synchronous time domain averaging

Extraction of a periodically repeating signal

from additive contaminating noise
Applications
Wave form analysis
Reduce background noise
Enhance orders
Separaton of mechanical and
electrical vibrations

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Application Example
Contaminating
Background Vibration
Accelerometer
Vibrating
Machine

Machine
Vibration

Tacho
Probe
Vibration

Signal enhancement in machine analysis

Vibration measurement on a machine shop floor

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Traditional Average vs. Signal Enhancement

Time

Time

Time

Time

Time

Time

Average

FFT

FFT

FFT
Time

Average

FFT

Traditional Spectrum
Averaging

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FFT

Signal Enhancement

Time Averaging vs. Synchronous Time Averaging

Time averaging
i.e. no trigger

Time synchronous averaging

i.e. trigger

1
N

Averages to zero

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a1( t )

a1( t )

a2 ( t )

a2 ( t )

.
.
.

.
.
.
1
N

a j ( t )
Extracts waveform

a j ( t )

Enhancement Order specturm

Order spectrum data with and without Time
Synchronous averaging after 50 averages only.
Sync Order spectrum(Vib 1)
Working : Input : Input : Sync Order Analyzer

[dB/1.00 in/sec]
0
-10
-20
-30
-40
-50
-60
-70
-80
16

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18

20

22

24

26

28
[Order]

30

32

34

36

38

40

Literature for Further Reading

Time Capture Type 7705
(Brel & Kjr Lecture Note BA 7653-11:)

Vold-Kalman Order Tracking Filter

(Brel & Kjr Lecture Note BA 7645-11:)

Frequency Analysis by R.B.Randall

(Brel & Kjr Theory and Application Handbook BT 0007-11)

Order Tracking Analysis by

by S. Gade, H. Herlufsen, H. Konstantin-Hansen, J. Wismer
(Brel & Kjr Technical Review No. 2, 1995)

Non-stationary Signal Analysis using Wavelet Transform,

Short-time Fourier Transform and Wigner-Ville Distribution

by S. Gade, Klaus Gram-Hansen
(Brel & Kjr Technical Review No. 2, 1996)

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Annual Sound & Vibration Conference

Detroit, MI
September 24-26, 2013
Dont miss the chance to register early for our
upcoming Sound & Vibration Conference.
Please visit us on the web at www.bksv.com to learn
more about the conference and to register early.

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Brel & Kjr Sound & Vibration Measurement A/S.
Copyright Brel & Kjr. All Rights Reserved.

Questions?

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