Order Analysis ​​​​​​​​​​​
for Rotating Machinery

Order analysis is a technique for analyzing noise and vibration signals in rotating or reciprocating machinery that runs at a steady or varying speed. It can provide complete diagnostics of generators, combustion engines, compressors, turbines, pumps, and rotating shafts.

The Dewesoft solution is extremely powerful. In combination with other measurement and analysis features like orbit analysis, torsional vibration, combustion engine analysis, and power analysis, it is the only available solution on the market that provides a complete set of tools for rotating machinery analysis.

Dewesoft offers a real-time, simple-to-use order tracking analysis solution at an attractive price, bundled with an industry-leading 7-year warranty, lifetime FREE software updates, and FREE technical support.

IEPE
IEPE
Charge
Charge
Voltage
Voltage
Counter and Encoder
Counter and Encoder
Vibrations
Vibrations
Acceleration
Acceleration
Angle
Angle
RPM
RPM
DSI compatible
DSI compatible
High-speed video
High-speed video
Video
Video
TEDS compatible
TEDS compatible
USB 2.0
USB 2.0
USB 3.0
USB 3.0
EtherCAT
EtherCAT
Ethernet
Ethernet
IP67
IP67
-40°C to +85°C
-40°C to +85°C

Main Features

  • REAL-TIME RESULTS ON UNLIMITED CHANNELS: Dewesoft order analysis solution provides data acquisition, storing, visualization, and calculation on unlimited input channels online. Multiple rotating machinery can be observed and analyzed in parallel.
  • TIME, FREQUENCY, AND ORDER DOMAIN: High sampling rate and advanced alias-free resampling mechanism allow measurement in all three domains - time domain, frequency domain, and order domain. All data is available in parallel in real-time, visualized on the same screen, and stored in the same data file, fully synchronized.
  • MULTI FUNCTIONALITY: Dewesoft system is very flexible and offers many additional functionalities. FFT analysis, orbit analysis, or torsional vibration can be added for an in-depth insight into machine dynamics. In addition, other types of sensors can be connected to simultaneously capture vibration, strain, temperature, video, sound, etc. with precise synchronization.
  • ANY ANGLE SENSOR SUPPORT: We support any type of angle sensors for determining the angle and rotational speed: tacho sensors, encoders, gear tooth sensors, gear tooth sensors with missing or double teeth, zebra tape, and analog angle sensors. Our system can perfectly determine the angle and rotational speed with 10 nanoseconds resolution using Dewesoft Supercounter technology.
  • HARMONIC ORDER EXTRACTION: Supporting full or fractional order extraction with amplitude and phase, that can be coupled with multiple representation options versus rotational speed and in the time domain. A complete representation of unlimited orders on a 2D or 3D graph. 
  • RICH VISUALIZATION: Frequency, 2D, and 3D plots provide a great visualization tool to determine the health of the machine. Additional Nyquist, Bode, and Campbell plots are available for the perfect presentation of the data, orbit analysis with raw or order view is a great tool for turbomachinery analysis.
  • CONFIGURABLE AVERAGING AND UPDATE CRITERIA: To prevent jumps between spectral bins you can define Delta-RPM and hysteresis and split the RPM range into corresponding bins for calculation. Decide whether data is collected continuously or at the center of bins. Bin update defines how order spectra in bins are calculated and can be set to first, always, averaging or maximum.
  • RELATE ORDERS TO OTHER MEASURED QUANTITIES: Analyze order spectra over time, speed (rpm), or in relation to another user-selected reference channel in 3D spectrograms. Select a user-defined channel as a reference tag axis and correlate other measured physical quantities with the order spectra. E.g. inspecting order levels vs. temperature, wind speed, flow, or thrust. Single click creation of FFT and order waterfalls versus speed or any other reference quantity.
  • ADVANCED MATH CAPABILITIES: Analyze order spectra over time, speed (rpm), or in relation to another user-selected reference channel in 3D spectrograms. Select any channel as a reference and correlate other measured physical quantities with the order spectra. E.g. inspecting order levels vs. temperature, wind speed, flow, or thrust. Single click creation of FFT and order waterfalls versus speed or any other reference quantity.
  • LONG-TERM MONITORING CAPABILITIES: Orbits (raw, averaged, H1, H2, etc.), FFTs, cascade plots, Bode plots, and polar plots can be uploaded to the Historian time-series database for long-term or permanent condition monitoring applications.
  • TEDS SENSOR SUPPORT: Dewesoft systems feature plug-and-play sensor detection for accelerometer and angle sensors that support TEDS IEEE 1451.4 standard.
  • DIRECT GEARBOX SUPPORT: Use a single-speed source and perform extraction on different gear stages of your machine by using the tacho divider & multiplier functionality.
  • DEWESOFT QUALITY: Enjoy Dewesoft’s industry-leading 7-year warranty and world-class quality assurance. Your investment into the Dewesoft order analysis solution is protected.
  • SOFTWARE INCLUDED WITH LIFETIME FREE UPGRADES AND SUPPORT: Our data acquisition systems are bundled with award winning Dewesoft X data acquisition software. The software package is always evolving and new features are being added. We offer lifetime FREE software upgrades and technical support to all our users.

Order Analysis Application Overview

Order analysis is a technique for analyzing noise and vibration signals in rotating or reciprocating machinery such as engines, compressors, turbines, and pumps. The first order refers to the speed at which the machine rotates. Each order thereafter is a corresponding multiple of the rotational speed.

These machines have a variety of parts, each of which contributes unique noise and vibration patterns to those of the whole machine. With order analysis, you can identify and isolate these patterns to analyze the performance and quality of each machine part individually. 

Since orders are independent of the speed of the machine, order analysis is the preferred analysis tool to use when measuring non-stationary vibration of machinery that run with varying rotational frequency. 

The Dewesoft order analysis solution is an indispensable tool for analyzing the operating condition of the rotating machinery such as resonances, stable operation points, and determining the cause of vibrations. Analyze vibration on engines or other rotating machinery, both in development & optimization as well as in diagnostic & troubleshooting instances. Powerful software and flexible data acquisition instruments, make up a smart portable solution for both developers and service engineers.

Learn more about order analysis in this The ultimate guide to the order analysis article

Order Analysis Application Overview

Applications
​​​​​​​for Order Tracking Analysis

Rotating machines are a major and critical component of many mechanical systems throughout the industry. Almost every industrial process uses at least one rotating machine, which is crucial in the production line. Just ask yourself which machine would cause the biggest cost in the event of a failure? 

Engines, power trains, turbines, pumps, compressors, electric motors, ventilation units, etc. can be designed and developed, as well as evaluated and maintained by performing order tracking and analysis:

  • Investigation and troubleshooting of instabilities in rotating machinery
  • Determination of critical engine speeds
  • Gearbox failures
  • Bearing element failures
  • Mechanical looseness
  • Imbalance
  • Bent shaft
  • Misalignment
  • Electrical faults in motors
  • Cavitation in pumps
  • Separation of rotational and structural noise and vibration phenomena
  • Other vibration related problems in e.g. gear, belts, fans, pumps, compressors, and turbines
Applications ​​​​​​​for Order Tracking Analysis

Dewesoft Hardware
Typical Configurations

Basic order analysis DAQ system:

  • SIRIUS Mini data acquisition system
  • DualCoreADC technology, dual 24-bit sigma-delta ADC, 200 kS/s, up to 160 dB dynamic range
  • Up to four IEPE accelerometers
  • Up to one tacho sensor

Advanced order analysis DAQ system:

  • SIRIUS modular DAQ system
  • DualCoreADC technology, dual 24-bit sigma-delta ADC, 200 kS/s, up to 160 dB dynamic range, +-1000 V galvanic isolation
  • Up to eight IEPE accelerometers
  • Up to eight tacho sensors

Portable order analysis DAQ system:

  • SIRIUS R1DB or SIRIUS R2DB DAQ systems
  • DualCoreADC technology, dual 24-bit sigma-delta ADC, 200 kS/s, up to 160 dB dynamic range
  • Up to 16/32 IEPE accelerometers
  • Up to 16/32 IEPE accelerometers
  • Up to 16 tacho sensors
  • Built-in computer, SSD storage, display, Li-Ion battery


Dewesoft HardwareTypical Configurations

SuperCounters®
Patented Angle Measurement Technology

Dewesoft data acquisition systems utilize a patented and registered trademark technology called SuperCounter®.

Counter inputs can measure the RPM signal and the angle of rotating machines. In comparison to standard counters, which only output integer numbers one sample later (e.g. 1, 1, 2, 2, 3, 4), SuperCounters are able to extract the accurate values like 1.37, 1.87, 2.37, etc. fully synchronized for time and amplitude. This is done by measuring the exact time of the rising edge of the signal with an additional counter. Our SuperCounters work on a 102.4 MHz time base, independent from the current sampling rate.

Counter inputs are fully synchronized with analog, CAN bus, and other data sources to enable easy applications like balancing, order tracking, orbit analysis, and torsional vibrations.

For more information on our SuperCounter inputs please navigate to the Digital Counter PRO training course.

SuperCounters®Patented Angle Measurement Technology

Run-Up/Coast-Down
Waterfall Run-Up and Coast-Down Analysis

Due to the rotational order tracking process order analysis is the preferred tool for test, diagnostics, and troubleshooting of machines and other rotational components that run with variating speeds. 

Order tracking provides stable spectral results across speed variations with no spectral smearing. Clear vibrational patterns of the individual rotational machine components will be kept throughout the measurements enabling the ability to compare the measured order pattern to reference graphs and to configure individual tolerance and alarm levels for all relevant rotational components.
 

Run-Up/Coast-Down
Waterfall Run-Up and Coast-Down Analysis

Order Analysis Setup
As Simple as It Gets 

The order tracking module allows you to select several options before starting the test:

  • Order waterfall vs. time - monitors order spectra over time and not only the current spectrum.
  • Order waterfall vs. reference - monitors  order spectra over RPM or any other measured channel you want to use as bin axis.
  • Order domain harmonics - complex channels displayed on a 2D graph, for each  user-defined harmonic.

You can always change these settings after you have recorded your measurement. DewesoftX always stores the raw data which allows order analysis results to be recalculated in the post-processing. 

Select the RPM limits (upper and lower RPM limit), and whether you want to calculate the waterfall spectrum and order extraction while run-up, while coastdown, or both (to cover the whole frequency spectrum).

Order Analysis Setup
As Simple as It Gets 

Frequency Analysis Setup
Fast-Fourier Transform (FFT)

Next to order spectral results Dewesoft Order analysis also gives the option to output in parallel FFT spectra over time and over RPM or over another selected bin channel:

  • FFT waterfall vs. reference- monitors calculated FFT over the selected bin channel.
  • Time-domain harmonics - complex output channel showing the amplitude of harmonics over time.
  • Overall RMS vs reference - monitors the overall (full frequency range) RMS value over the selected bin channel.
Frequency Analysis Setup
Fast-Fourier Transform (FFT)

Peak Calculations in the Frequency and Order Domain

Peak calculations can be performed in both the frequency and order domains. By selecting the Bin update parameter to Maximum, the maximum values of individual spectral lines are kept throughout the test. Such results can indicate worst-case scenarios by showing the highest peak values across time, RPM, or other bin channels.

Peak Calculations in the Frequency and Order Domain

Campbell Diagram
2D and 3D Visualization of Response Spectrum

Visualization of 3-dimensional values on a single plane is commonly  used in order analysis applications. 3D graphs and Campbell  plots represents a system's response spectrum as a function of its oscillation regime

With Campbell plots the range of values is segmented in a defined number of levels and each level is represented by a circle, whose radius and color depending on the level's index. Bigger values are represented with larger circles and colors higher on the color map. For a better analysis of data, a cutoff of lower levels can be applied.
 

Campbell Diagram
2D and 3D Visualization of Response Spectrum

Bin Settings
Freely Configurable

How spectra should be collected across the measured range of time, RPM, or another bin axis can be freely configured in Dewesoft. 

To prevent jumps between spectral bins you can define Delta and Hysteresis to split the range (e.g. RPM speed range) into corresponding bins for calculation. 

Decide whether data is collected continuously over each bin or only at the center of bins. 
You can  choose between different methods for how to calculate the spectral result: 

  • keep the first calculated bin spectrum in each bin
  • always update the bins with new calculated spectra
  • average all spectra belonging to  the same bin
  • hold the maximum spectral values in each bin.
Bin Settings
Freely Configurable

Orbit Plot Analysis
Visualize Movement of a Rotating Disc

The Dewesoft orbit analyzer is a solution for analyzing and visualizing the movement of a rotating disc.

The orbit plot shows the rotational direction of the shaft. The arrow that shows the direction of rotation is displayed in the top right corner of the graph. 

The direction of the arrow is CCW (counterclockwise), therefore we need to choose the channels on-orbit graph in the right sequence.

Learn more about the Dewesoft orbit analyzer.

Orbit Plot Analysis
Visualize Movement of a Rotating Disc

Great Investment
Future-Proof Application

Dewesoft order tracking analysis is a great investment in your future. Our solutions are constantly being improved, and new features are being added all the time. All updates to the order testing software suite are free of charge.

Our industry-leading 7-year warranty on Dewesoft data acquisition systems means worry-free measurements for you. We are committed to ensuring that your investment in our measurement equipment was a good one - even when the unexpected occurs. 

Together with world-class data acquisition technology, Dewesoft provides the best order analysis solution your money can buy.

Great InvestmentFuture-Proof Application

FAQ

What is order tracking analysis?

Order analysis is a technique for analyzing noise and vibration signals in rotating or reciprocating machinery (engines, compressors, turbines, and pumps). These machines have a variety of parts, each of which contributes unique noise and vibration patterns to those of the whole machine.

Which are the applications for order tracking analysis?

Order tracking is used with the development or condition monitoring of rotating machinery such as engines, power trains, turbines, pumps, compressors, electric motors, ventilation units, etc. Order tracking applications:

  • Investigation and troubleshooting of instabilities in rotating machinery
  • Determination of critical speeds
  • Gearbox failures
  • Bearing element failures
  • Mechanical looseness
  • Imbalance
  • Bent shaft
  • Misalignment
  • Electrical faults in motors
  • Cavitation in pumps
  • Separation of rotational and structural noise and vibration phenomena
  • Other vibration related problems in e.g. gear, belts, fans, pumps, compressors, and turbines

What instrumentation do I need to perform order tracking analysis?

To perform an order analysis you need one vibration sensor (usually an accelerometer, a microphone, or a pressure sensor) mounted on the chassis of the machine and an angle sensor to read the RPM of the rotating shaft.

Both senors will need to be time-synchronized and connected to the data acquisition (DAQ) system for reading. Once data is read you will need data analysis software to perform order tracking analysis.

Can order tracking analysis be performed without the RPM sensor?

Dewesoft allows performing order tracking analysis only with an accelerometer sensor. To get the rotational frequency of the motor, the exact frequency math is used, with the option to track the first harmonic.

This math calculates the frequency of the highest peak in FFT and this can be used further in the order tracking analysis instead of the reading from external RPM sensor. For more details see this guide.

What is an engine order?

We refer to Engine orders or harmonics of vibration when we describe multiples of the fundamental frequency. So again using the engine as an example, a 4 cylinder 4 stroke engine generates 2 combustion events per engine revolution.

How is order tracking caluclted?

How is Order tracking done?
    Order tracking is done by measuring a signal, typically vibration and calculating FFT’s for each predefined area (class) of rotational speed.
 

What is displayed on a FFT waterfall vs. Time?

On the FFT waterfall vs. Time you display an FFT, that was calculated from an acquired signal, for each time that it was calculated. This gives you an overview of all calculated FFT’s over the time of measurement.

What is displayed on a FFT waterfall vs. RPM?

Opposed from the FFT waterfall vs. Time that is updated on each FFT calculation, the FFT waterfall vs. RPM is updated on predefined RPM change.

What is displayed on an Order FFT waterfall vs. RPM?

Order FFT waterfall vs. RPM displays harmonics and their amplitudes over the speed of the rotating shaft.

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