[Field Wisdom] How Pros Combine "Numbers" and "Senses"! A Realistic Guide to Reading Vibration Data

"Reading specialized books on vibration analysis is too difficult; I feel like I can't do it." "I'm collecting data, but I'm unsure when to actually perform maintenance."

We often hear these voices. While textbook "precision diagnosis" is certainly important, simpler and more realistic judgments are made in actual fields. Based on experience watching many sites, we will share realistic operational methods on how to combine "field intuition" with "digital data."

1. Basically, Trend Management of "Velocity" is Enough

What relies most on the field is actually the simplest metric: "Velocity RMS value." According to Nakayama's rule of thumb, the "Velocity value" and the "discomfort felt by humans on-site" match very well.

Field Sensations When Velocity Values Rise

Go to the site. There should be changes perceivable by your five senses, such as "it sounds louder than usual" or "I feel a large vibration tingling when I touch the machine."

Operational Advice

Don't think about difficult things; first, just look at the trend of the "Velocity RMS value" with conanair. If this is not rising steadily, the machine is generally healthy. If the numbers go up and you feel "it's kind of noisy" on-site, start preparing for greasing or parts replacement. For general equipment, this works for 90% of cases.

2. "Acceleration" is the Modern "Listening Stick"

So, what do we look at "Acceleration" for? This is used to hear "early screams that humans cannot yet perceive."

In the past, veteran maintenance workers used a "listening stick" against their ears to distinguish minute metallic sounds inside the machine (clicking, grinding). People using listening sticks are becoming an "endangered species" now, but conanair's "Acceleration" data is exactly the replacement for this listening stick.

When Only Acceleration is Rising

Even if you go to the site, the sound and vibration might seem unchanged from usual (Velocity values are also low). You might think, "Is something wrong?" but this is highly likely to be the "very early stage of an anomaly."

Operational Advice

There is no need to stop it in a panic. Recognize that "Oh, something (oil shortage or small scratch) has started inside the machine," and simply increase the frequency of monitoring to see how it goes.

3. Precision Diagnosis (FFT) Can Be Just "Spot the Difference"

Normal Case

Case with Bearing Outer Race Damage

"Identifying the cause of an anomaly with Frequency Analysis (FFT)" sounds like it requires specialized knowledge. However, the reality in the field is simpler. It is sufficient just to check: "Has the shape changed compared to when it was normal?"

Textbooks vs. Reality

Theoretically, there are calculation formulas like "if this frequency appears, it's an outer race defect," but in reality, it often doesn't appear exactly as per theory. Even pros often face situations where "we know something is wrong, but we can't pinpoint the specific cause."

Operational Advice

You don't need to worry about identifying the cause 100%. "A clear peak (mountain) appears that is different from normal times." This alone is sufficient to judge that "some kind of anomaly is occurring." From there, you can use it as supporting material for budgeting or to consider the timing of periodic repairs.

4. Recorded Data Becomes Your Company's "Asset"

At first, you may not understand the meaning of the data well, but there is no need to overthink it. As you collect data every day, you will start to see habits like, "Ah, when this machine gets in bad shape, this graph moves like this."

Continuing to record vibration data is the same as digitalizing a veteran's intuition. Eventually, it will become know-how (assets) for future equipment management and will definitely come in handy.

Conanair is the tool to start that "first data accumulation" most easily and at a low cost. Why not start a health check for your equipment casually? First, why not actually measure and look at the waveforms?

If you don't know how to set it up or read the waveforms, please feel free to contact us.