Seeing is believing – Motion Amplification in action!
At IVC Technologies, our analysts are some of the top minds in the condition monitoring (CM) industry. Yet, as smart and knowledgeable as they are, they’ll be the first ones to tell you that an analyst is only as good as the tools available to them.
Certain machine conditions can be difficult and time-consuming to pinpoint using traditional CM technologies such as vibration analysis, phase analysis, and operating deflection shape (ODS) testing. However, by incorporating motion amplification into the mix, analysts are able to literally visualize the movement of a machine in minutes.
Using Iris M, a revolutionary video-processing and software package developed by RDI Technologies, our analysts use a high speed, high definition camera to collect video data. The software and processing algorithms detect subtle motion and amplify it, essentially converting every pixel into an independent sensor, creating millions of data points in a matter of seconds.
If motion amplification isn’t a part of your CM toolbox…it should be.
Let’s take a deeper dive into how motion amplification can greatly enhance some of the traditional condition monitoring technologies:
Vibration Analysis
Vibration analysis has proven to be an indispensable condition monitoring tool for predictive maintenance as well as maintenance troubleshooting and is typically the foundation of most CM programs. However, it’s not without its challenges:
- Measurements are generally made only on bearing locations.
- These bearing measurement locations need to be physically accessible to the analyst, and the surface where the sensor is mounted must be somewhat clean.
- General purpose accelerometers often used to collect vibration data can have difficulty detecting faults in the low-frequency portion of the spectrum.
- The data generated (spectra and waveforms) needs to be analyzed by an experienced and certified vibration analyst.
- Unfortunately, sometimes vibration data is inconclusive, which means more troubleshooting needs to be performed (e.g. phase analysis, ODS, etc.) in order to identify the root cause of the machine problem.
- Data collection between measurement locations is typically NON-Simultaneous, meaning phase information needs to be obtained via a separate process.
How motion amplification can help
The fundamental measurement motion amplification makes is displacement, which is most pronounced at low frequency, diminishing as the frequency increases. This makes motion amplification particularly well-suited for low-speed applications such as kilns, mixers, and structural resonances, in addition to traditional vibration faults. Since most accelerometers are less sensitive in the low-frequency range, supplementing traditional vibration analysis with motion amplification enables analysts to detect vibrations at all ends of the spectrum.
Phase Analysis
When vibration analysis is unable to identify a machine issue, phase analysis is typically the first line of advanced troubleshooting conducted by a vibration analyst. With data acquired via phase analysis, an analyst can identify not only at what frequency and amplitude a machine is vibrating but also the timing of when one part of the machine is moving in comparison to when another part of the machine is moving. This information provides an analyst with valuable insights into things like misalignment, soft foot, looseness, bent shaft, etc.
How motion amplification can help
The challenges with phase analysis are essentially the same as those associated with spectrum and waveform analysis. This includes that fact that the resulting data (which with phase analysis, is often a bubble diagram) is only useful to an experienced vibration analyst, who can interpret it and then put it into language that mechanics and other maintenance personnel can understand and act upon.
With motion amplification, all of the data of the entire image is collected simultaneously so phase information is available without having to use a separate process and in locations where a sensor could not be physically mounted.
In addition, there is no simpler way for an analyst to “show” someone where and how a machine is vibrating than by showing them an actual video depiction of exactly what is happening. When maintenance personnel can literally see what is happening with a machine asset, they’re more likely to act.
ODS (Operational Deflection Shape)
ODS is simply an advanced method of performing phase analysis and is the next logical step in advanced troubleshooting and providing an analyst with a better understanding of how a machine is moving. However, unlike phase analysis, the analyst can view a detailed animation of the machine’s movements instead of just looking at a bubble diagram. When done properly, ODS can go a long way in solving even the most complex vibration related problems. However, ODS has its drawbacks:
- Separate ODS software is required.
- The time spent modeling a machine is typically measured in hours and days.
- The time spent collecting the data is typically measured in hours.
- There is a very high risk of errors when assigning measurements points to the model.
- Even with hundreds of measurement locations, important ones can still be missed.
- There is a very high risk of getting questionable data at one or more measurement points.
- Typical ODS animations include movement from “interpolated” points which are not actually measured. The motion at these points is mathematically estimated from adjacent points where data was measured.
How motion amplification can help
ODS is an incredibly valuable tool and one that customers find valuable if the long-term plan is to build out; but ODS takes time and when you’re facing a potential shutdown, time is not a luxury you can afford. With motion amplification, each pixel can be used as a vibration measurement location. So, instead of the 12 to 16 measurements from a typical motor-driven piece of equipment, an analyst can get vibration data from millions of locations.
Motion amplification is excellent to use on the front end of ODS to provide a custom and easy-to-understand visual representation of their machine asset, all within a matter of minutes
Seeing is believing
IVC Technologies is incredibly excited to be able to offer motion amplification to our customers. It has already proven to be an invaluable addition to our already tech-forward CM toolbox. Contact us to see this amazing technology in action.