One of the key factors in the course of technnological products manufacturing is testing of products resistance to mechanical impacts.These tests are performed in order to reveal structural and manufacturing defects and to evaluate perfomance charatceristics of the product in complex use environment. Tests complexity for mechanical factors impact is caused by the possibility of partial or complete tested sample destruction. In the case of tested sample destruction information of the tests perfomance may be useful in finding out the reason of the sample destruction, hence, the more detailed information is, the better. In the case if tested sample destruction is inadmissible, there should be determined a treshold for test perfomance suspension.

In the course of tests perfomance for classical shock impact the tested sample is exposed to a considerable force impact for a short period of time. Main portion of the energy transmitted to the tested object comes to the displacement of shaker stand together with the sample attached to it – the remaining portion of energy is consumed by the sample and leads to sample deformation. The amount of the energy consumed by the sample determines degree of the tested object deformation. The purpose is to determine the tested object deformation without using the fault detector (tested object deformation estimation shall be performed based on system response on external impact).

Figure 1 – sensors positioning

In this case a modelling clay piece (total weight – 100g) is used as a vibration damper – each fragment has a cube shape with dimensions 41×41×41 mm (see Figure 1). Modelling clay piece is placed in the middle of the shaker table.The first sensor was placed near the modelling clay cube at the extension platform. The second one is placed onto the modelling clay cube. The tests were performed by means of ZETLAB vibration control system – a software used for shaker control based on ZET 017 FFT spectrum analyzer. Vibration impact tests consisted of half-sine shape classical shock with an amplitude of 1 g and 4 ms duration. An input signal is forwarded to the shaker system so that the control accelerometer could make a diagram of the pulse having corresponding shape. In this case “BK” control accelerometer is used, necessary pulse shape is a half-sine signal.

Figure 2 depicts “Multichannel oscillograph” window with a “valley value” at the signal peak received from the second sensor. This “valley value” is caused by damping properties of the modelling clay. The energy used for shaker platform movement if partially absorbed by the modelling clay and leads to its deformation.The Software “Modal analysis” uses sensors signals for calculation of measured system parameters including its perfomance – “Integral F*s”. In accordance with the measurements, the modelling clay cube has consumed the following amount of energy:

ΔЕ=Е12=0,0938-0,0510=0,0428 J

This very amount of energy was spent for modelling clay cube deformation and has partially been dissipated as heat. Modelling clay cube deformation leads to a change of FR characteristics. FR value change is well seen in the narrow-band spectrum.

Figure 2 — ZETLAB Virtual laboratory – tests perfomance – “Classical shock” Software application (top left section), “Modal analysis” (at the bottom), “Multichannel oscillograph” (at the right). 

Figure 3 shows instant spectrum diagram at the end of tests perfomance, averaged spectrum diagram for the first 100 sec of the test and a difference chart of the first two sensors. In Figure 3 one can see that the biggest difference between the spectrum diagrams lays within the range of 110-150 Hz. Since the impact signal is a half-sine wave with 4 ms duration, full cycle has 8 ms duration, frequency value is 125 Hz. So, the biggest FR value change in the modelling clay cube occured in the ipact frequency area (which confirms the test results validity).

Figure 3 — shock spectra: instant, average and their difference

Instant spectrum RMS is  0,001316 g, average spectrum RMS – 0,001293 g, spectrum difference RMS – 0,000075 g, relative change value –  5.8%.

In the case of continuous tests perfomance the deformation value of tested object is gradually increasing. In order to determine deformation value we shall use the method of comparing the shock pulse spectrum with that of a sample spectrum. As a sample spectrum value we shall use arithmetical average of the first shock impacts pulses. In the course of vibration tests perfomance the sensor placed onto the modelling clay cube has declined from the vertical position, which definetely has affected the transfer characteristics.

During tests it is necessary to have control over deviations of the sample spectrum in a real time mode (there is no need to have the deviation value only upon tests completion). Control software operating principle is quiet simple: during specified time period at the beginning of tests perfomance spectrum measurements results data are obtained for the purpose of further sample spectrum parameters calculation, which are further used for referencing and deviation diagram construction. In the case of the set threshold level exceeding a signal is sent to the operator.

This Software application has been realized in SCADA-system ZETVIEW. Figure 4 shows the project allowing to implenent the algorithm described above. Top left section of the scheme has “input channel” element – the signal from it (blue circles and connecting lines) is forwarded to the input of “narrow-band spectrum”. At the output of “narrow-band” spectrum there are formed spectra arrays and frequency bands (violet circles and connecting lines) – they are depicted on “spectrum diagram”. Spectra arrays are also forwarded to the element “array stacking”, which stepwise summarizes spectra arrays with the results of previous stacking within first 100 sec. The number of seconds is prescribed in the element “number of averagings” – the reverse count is performed by “increment” level (bottom left part). Upon completion of the specified time period the “multiplexer” will be switched over to the first channel used for transmission of zero array from “zero array” element having the same parameters with the spectrum. Upon stepwise division of the array by the number of averagings specified in the “averaged spectrum” element there is formed an averaged array for 100 sec of spectrum duration which is further forwarded to “spectrum diagram” and is deducted from the instant spectrum. From the array at the output of “spectra deduction” element RMS value is calculated (green circles and connection lines), which is then compared  with the “threshold value”, forwarded to the “RMS difference” indicator and recorded by “diagram timer” signal (red circles and connection lines) at the end of “deviation” array. Simultaneously, by signal from “diagram timer” in the “increment” element (in the right section) a time from the test beginning is calulated and is then forwarded to “measurements” counter element and is recorded at the end of “time” array.  “Deviation” arrays are depicted on”RMS difference diagram” at the axis set by “time” array.

Figure 4 — SCADA-project ZETView – average spectrum deviation recording 

SCADA-project ZETView consists of two parts – project view (Figure 4) and operator view (Figure 5). Operator can see all necessary information relating to the project perfomance – diagrams, indicators and project control keys. The project is activated by “On” key (the key name will be changed for “Activated”), key “Reset” is used to restart measurements. Upon completion of the specified “accumulation time” the color indication switches over to red color. Digital indicators below depict current “RMS deviation” of instant spectrum from average one as well as the current test time. Upon exceeding of the “threshold deviation value” the indicator turns red. Upper diagram depicts averaged and instant spectrum. Lower diagram shows deviation of instant spectrum from average one during tests perfomance time.

The lower diagram clearly shows that the difference between averaged spectrum at the beginning of the test and instant spectrum eventually increases. External accidental impacts sometimes lead to “splashes” in the diagram, however, minimum difference value constanly increases. Constant growth of minimum deviation values  is a result of irreversible deformations occuring inside of the modelling clay cube. In the case of continuous and intensive tests modelling clay deformations may become visible.

Since the modelling clay is a lamillated material, growth of deformations number will not lead to its destruction. Products made of more fragile materials (like tempered steel, glass, etc.) may be partially or completely split into pieces as the deformation impacts achieve certain degree. Hence, control of FR characteristics change allows to determine tested sample destruction moment. As sufficient statistical spectral characteristics and NDT data is obtained, it becomes possible to determine exact deformation degree using spectral characteristics change information.

Figure 5 — SCADA-project ZETView – average spectrum deviation recording  – operator’s interface view

SCADA-system ZETView enables fast and simple (the above described project has been implented within an hour) implementation of algorithms of any complexity as well as results representation in a format, convenient for further analysis. Signals processing operations are represented in a clear view depicting operations sequence. SCADA-system ZETView is simple and user-friendly. Ordinary user without any programming skills can make a complex program for data acquisition and objects control with neat and convenient human-machine interface.

Spectral characteristics control is necessary not only in the case of vibration tests perfomance, but also in many other scientific and technological spheres. Similar tasks also arise in the case of buildings structural control (intrinsic frequency oscillation changes), machinery defects detection and so on. The above algorithm and its implementation in SCADA-system ZETView can be easily used for solving similar tasks.