Order Tracking Analysis

Order tracking analysis is a tool to determine the operating condition of the rotating machines such as resonances, stable operation points, determining a cause of vibrations. Dewesoft provides a flexible order analysis software and data acquisition hardware for every rotating machinery and rotordynamics. 

The tool is extremely powerful in combination with other modules like torsional vibration analysis, combustion analysis or power analysis and can provide complete diagnostics of generators, combustion engines, and rotating shafts.

Order Tracking Analysis for Rotating Machinery from Dewesoft
IEPE
IEPE
Charge
Charge
Voltage
Voltage
Counter/Encoder
Counter/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

Main Features

  • TIME, FREQUENCY AND ORDER DOMAIN - AT THE SAME TIME: Due to high sampling and advanced alias-free resampling mechanism, data is available in all three domains (time, frequency and order), everything at the same time in one screen and data file, perfectly synchronized
  • ANGLE SENSOR SUPPORT: All angle sensors from tacho, encoder, gear tooth, gear tooth with missing or double teeth, tape sensors and others are supported to perfectly determine the angle and rotational speed with 10 nanoseconds resolution using Dewesoft Supercounter technology
  • RICH VISUALIZATION: Frequency and order 3D plots provide a great tool to determine the health of the machine, Nyquist, bode 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.
  • ADVANCED MATH: Any order and time-domain harmonics can be easily extracted with amplitude and phase, available versus rotational speed or time in the run-up or coast down modes.
  • REAL-TIME CALCULATION: Our order tracking analysis solution provides real-time data acquisition, storing, visualization, and calculation on unlimited input channels. Multiple rotating types of machinery can be observed and analyzed at the same time.
  • LIFETIME FREE SOFTWARE UPGRADES AND SUPPORT: Our data acquisition systems come 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

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.

With order analysis, you can identify and isolate these patterns to analyze the performance and quality of each machine part individually. 

Dewesoft SuperCounter Patented Technology

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

Counter inputs can measure RPM and 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, and torsional vibrations.

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

Order Tracking FFT Setup

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

  • Order FFT vs. time - monitors orders over time and not only the current values.
  • Order FFT vs. RPM - monitors current values of orders.
  • Order domain harmonics - complex channels displayed on a 2D graph (we define which harmonics we want to extract).

But don't worry you can always change these settings after you have recorded your measurement. Since Dewesoft X stores the raw data all parameters can be changed and results recalculated in the offline mode. 

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).

Delta RPM will define when a new update of the waterfall spectrum and also the extracted order domain harmonics are calculated. In case, the RPM is not changing only channels from Time FFT setup can be calculated according to the maximum time limit setting.

Time FFT Setup

The order tracking module creates a waterfall plot out of the RPM change. So every time the RPM changes for the defined delta RPM, an FFT is calculated for that data block and shown in the Time FFT diagram.

  • FFT waterfall vs. RPM - monitors calculated FFT
  • Time domain harmonics - complex output channel showing the amplitude of harmonics in a time domain

Campbell Diagram

Visualization of 3-dimensional values on a single plane is mostly used in order tracking analysis applications. A Campbell diagram plot represents a system's response spectrum as a function of its oscillation regime

The range of values is segmented in a defined number of levels and each level is represented by a circle, whose radius and color depend on 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.

Data Averaging and Update Criteria

Based on the delta RPM (e.g. 50) the RPM range is split into blocks/classes - e.g. 2050, 2100, 2150, etc. Depending on the situation the user can decide if the result is placed at the center of the block or averaging should be done between blocks (noisy situations).

Orbit Plot Analysis - Visualize Movement of a Rotating Disc

The orbit analysis graph is a visual control where you can visualize the movement of a rotating disc.

The orbit analysis 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.

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?

The common application, often referred to as Run Up/Run Down, is used to survey a machine’s dynamic response when the operating RPM is varied across the entire operating span. In this case, the RPM can range from a few RPM to 10,000 RPMs. Such tests are performed on automotive or aircraft engines and when commissioning new or refurbished stationary processing equipment. The measurements can be any physical quantities such as sound, displacement, velocity, acceleration, torque, etc. The analysis measure can be the amplitude or the power of an order, the energy over a fixed frequency band, a bin of octave filter, etc. The most important result for this type of measurement is the magnitude of the response versus RPM

Another common application is monitoring measured machine displacement, velocity, acceleration, pressure, current or sound while the machine is performing its normal duty. The data acquisition system measures the amplitudes of specific orders and their phase relative to a reference tachometer input signal. The phase is calculated relative to the tachometer input or a separate reference input. This application is common for machine diagnosis and balancing. In this case, the operating RPM is relatively stable. Order tracking technology is useful to increase the accuracy of the estimation of orders.

Order Track signals with phase are useful in the study of rotating machines during Run Up/Run Down. This is often presented as a Bode Plot, useful in characterizing resonance/excitation intersections. The Bode Plot is a concept borrowed from control theory. It provides simultaneous Amplitude and Phase data over a changing speed range. 

What instrumentation do I need to perform order tracking analysis?

To perform an order tracking analysis on rotating machinery you will need one vibration sensor (usually accelerometer sensor, a microphone or a pressure sensor) mounted on the chassis of the device and a counter/encoder sensor to read 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.

Dewesoft offers turnkey order tracking analysis solution from sensors, data acquisition system, and software for real-time visualization, analysis, and reporting.

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.

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