FORM - 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
Title:
VIBRATION ANALYZER SYSTEM FOR MEASURING AND ANALYZING MACHINE VIBRATIONS & METHOD THEREFOR
Applicant: MAHINDRA & MAHINDRA LIMITED
GATEWAY BUILDING, APOLLO BUNDER,
MUMBAI-400001,
MAHARASHTRA, INDIA.
Inventors:
HARSHAD PAPADKAR ARUN NALLAWAR
Both Indian Nationals.
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

FIELD OF INVENTION
The present invention relates to a vibration analyzer system for machines. In particular, the present invention relates to a low-cost vibration analyzer system for machines. More particularly, the present invention relates to a displacement measurement based vibration analyzer system for machines. The present invention also includes a method for measuring and analyzing machine vibrations.
BACKGROUND OF THE INVENTION
The machine vibration is one of the most important factors for precisely machined products during manufacture thereof. For achieving better quality machined products, the machine vibration needs to be observed closely and maintain within specified standards for the required interchangeability during mass production.
In Hydraulics, performance group accuracy is most crucial parameter. Further, grinding wheels are used for maintaining the accuracy of the machined components. Even a small vibration in motor will affect the results achieved by the grinding wheel, which may disturb of the actual accuracy of machined components obtained.
Until now, in a normal shop-floor, the machine vibrations are not being measured. Usually, only a spirit level gauge is being used for checking and maintaining the level of the machine, e.g. grinding wheels used for manufacturing precision machined products.
Every machine has rotating as well as sliding parts subjected to vibrations produced during machine operation. If these vibrations are maintained within the permissible limit, there is no effect the quality of machined part produced, however if these vibrations cross the permissible limit, they significantly affect the quality of machined parts produced. This also frequently causes machine non-available for bring vibrations under control by appropriate maintenance thereof.

One of the vibration testing equipment presently available in the market is Fluke 810 Vibration Tester. This can ccontrol unplanned downtime, prevent recurring problems, set repair priorities and manage resources as well helps in locating and diagnosing the common mechanical problems in order to prioritize the machine repair actions with no prior machine history. However, the major disadvantage of this testing equipment is substantially higher cost of the order of at least INR 6 lacs depending on the model thereof.
Another system available in the market is Wave Catcher vibration testing tool, which delivers site survey analysis. This delivers comprehensive environmental data in a compact, user-friendly package and also designed to be accessible for any user for obtaining precise measurements by streamlining the process to understand the environment in which a user is operating. By using adjustable software features and robust hardware options, it can acquire complex and comprehensive environmental data within a short time. However, the cost of this vibration testing tool is also very high and thus increases the overall manufacturing costs tremendously.
Every machine has rotating as well as sliding parts subjected to vibrations produced during machine operation. If these vibrations are maintained within the permissible limit, there is no effect the quality of machined part produced, however if these vibrations cross the permissible limit, they significantly affect the quality of machined parts produced. This also frequently causes machine non-available for bring vibrations under control by appropriate maintenance thereof.
DISADVANTAGES WITH THE PRIOR ART
In case, the vibration was monitored, it was used only for indicating the vibration values and there was no arrangement for recording and analyzing machine vibrations during operation thereof. Moreover, another disadvantage with using the vibration monitoring gadgets, e.g. vibration pen available in the market is their high cost. These standard (e.g. Fluke-810 costing about USD 900 or INR 6 lacs) and even sophisticated products (e.g. vibration analyzer, costing about INR 11 lacs) available in the market are very expensive.

DESCRIPTION OF THE PRESENT INVENTION
It was decided by the applicants to improve the quality of machined products by ensuring precision machining by monitoring machine vibrations and controlling the same.
They also needed a cost-effective solution for reducing the overall cost of manufacture of machined components. Therefore, it was proposed to develop a vibration analyzer to be deployed on precision machines, e.g. grinding wheels used in mass production of the various machined components.
Accordingly, the inventors devised a method and system for analyzing vibrations developed in a machine, e.g. grinding wheels, by using a vibration meter developed in-house, which costs less than INR 30000, thereby saving a large amount of money for the applicants, i.e. about INR 270000 to 350000.
The vibration analyzer in accordance with the present, invention is a novel electronics system or device consisting of electronic controller provided with a 12 volt DC supply, data transmission cable, digital gauge provided with a magnetic stand. The controller includes a small display which can show live vibration value even as low as 1 micron/sec. This value is counted or measured by a digital gauge and displayed on this display. This way, the machine operator can easily observe and maintain machine vibration within desirable and acceptable limits. However, the vibration analyzer needs to be calibrated, which requires a digital gauge calibration and therefore, necessitates monitoring from time to time.
OBJECTS OF THE INVENTION
Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:
An object of the present invention is to reduce the cost of vibration measurements in precision machines used in mass production of machined products.

Another object of the present invention is to provide a simple arrangement for vibration measurements in precision machines.
Still another object of the present invention is to provide a vibration analyzer which provides audio signals and/or visual indication to the machine operator for easy recognition of the amount of machine vibrations.
Yet another object of the present invention is to provide a light-weight vibration analyzing unit.
Still further object of the present invention is to provide a vibration analyzer which can also record vibration data so obtained for analysis and comparison purposes.
Yet further object of the present invention is to provide a vibration analyzer which can be preset by means of an electronic controller to display the status of machine vibrations in terms of OK or NOT OK signals.
These and other objects and advantages of the present invention will become more apparent from the following description when read with the accompanying figures of drawing, which are, however, not intended to limit the scope of the present invention in any way.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a machine vibration analyzer system for measuring and analyzing machine vibrations, the system comprises:
(i) at least one magnetic stand detachably connected to the machine;
(ii) at least one vibration detector for detecting deflections produced due to vibrations generated on the machine; and
(iii) at least one vibration analyzer unit:

wherein the machine vibration analyzer unit detects and displays the machine vibration status as 'OK' or 'Not OK' and every 'Not OK' status is recorded in terms of date, time and exceeded value in the memory configured therein for subsequent analysis and comparison process.
Typically, the vibrations analyzer unit comprises at least one control panel includes:
(a) at least one microprocessor for receiving signals from the vibration detector and forwarding the same to the converter and for receiving 'Not OK' alarm logs from the
(b) at least one converter for converting analog values received from the microprocessor into digital signals corresponding to the detected machine vibration,
(c) at least one comparator stored with preset permissible vibration values for comparing the detected vibration value with the stored preset permissible vibration value and issuing an alarm if the detected vibration value is beyond the preset permissible vibration value stored in the comparator,
(d) at least one pair of vibration status indicators for indicating 'OK' and 'Not OK' status of machine vibrations depending on the comparison of the detected vibration value with the preset permissible vibration value by the comparator; and
(e) at least one memory chip embedded for storing the alarm logs of the alarms of each 'Not OK' status issued by the comparator based on the actual detected machine vibration and set as one bit in the microprocessor.
Typically, the issued alarm logs comprise date, time, and amount by which the preset permissible vibration limit is exceeds the preset permissible vibration value both on positive and negative side thereof.

Typically, the machine vibration status 'OK' or 'Not OK' is indicated by means of green and red light respectively.
Typically, each 'Not OK' status is recorded in the memory in terms of date, time and exceeded value for subsequent analysis and comparison process.
Typically, the machine operation is stopped on recording an actual vibration value beyond the preset permissible vibration limit.
Typically, the vibration analyzer unit stores at least the last 100 readings can be extracted in the form of an excel sheet on a personnel computer for analyzing the actual vibration characteristics on the machine.
In accordance with the present invention, further a method is provided for analyzing the actual vibration generated on a machine and controlling the operation of a machine depending on the comparison of the actual measured vibrations with the preset permissible vibration limit on the machine.
Typically, the method comprises the following steps:
• detecting vibration generated in a machine by means of the vibration detector by measuring the displacement due to such vibration, preferably in a range of 1 micron/sec up to e.g. 10 mm or even higher values depending on the detector used;
• converting these displacement value measured as analog signals into digital signals, preferably in a range of 4 mA to 20 mA;
• comparing detected digital vibration signals with the preset permissible vibration value stored in the comparator for determining the 'OK' or 'Not OK' vibration status of the machine;
• indicating the determined 'OK' or 'Not OK' vibrations status of the machine by means of colored indicators;

• displaying the preset permissible vibration limit and actual vibration
value on the machine on a live visual display;
• issuing each 'Not OK' vibration status of the machine vibration in by
sounding an alarm, setting each alarm log as one bit in the
microprocessor and storing each alarm log in terms of date, time
and actual vibration value exceeded beyond the stored preset
permissible vibration limit in the memory.
Typically, at least the last 100 readings are extracted in the form of an excel sheet on a personnel computer for analyzing the actual vibration characteristics on the machine.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The present invention will be briefly described with reference to the accompanying drawings, which include:
Figure 1 shows a machine without any vibration analyzing system.
Figure 2 shows a machine equipped with vibration analyzer system in accordance with the present invention.
Figure 3 shows the arrangement of the vibration system shown in Figure 2 above.
Figure 4 shows an enlarged view of the vibration analyzer shown in Figure 2 above.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
In the following, different embodiments of the present invention will be described in more details with reference to the accompanying drawings without limiting the scope and ambit of the present invention in any way.

Figure 1 shows a machine without any vibration analyzer and vibration detector.
Figure 2 shows a machine equipped with a vibration analyzer system in accordance with the present invention consisting of a vibration analyzer 10 and vibration detector 12. The vibration status detector 12 is connected to a magnetic stand 14. The vibration analyzer 10 includes at least one pair of vibration indicators 16, a control panel 18 and an electronic or digital display 20. The vibration analyzer 10 continuously monitors the machine vibrations developed on the machine and displays the actual value on display 20 along with the preset permissible limit of vibrations. Whenever, the monitored vibration value exceeds this preset permissible limit of vibration, it gives an alarm and also displays the value by which the actual machine vibration exceeds. The vibration analyzer 10 also records the alarm log in an in-built memory chip (see Figure 3) which can be extracted in excel sheet format at any time. This facilitates the machine operator to stop the machine operation as soon as the actual observed vibration value exceeds the permissible vibration limit on the machine.
Figure 3 shows a detailed arrangement of the vibration analyzer system shown in Figure 2. The vibration analyzer system consists of two units, i.e.
(A) vibration detector 12 which transfers the displacement value, which is basically a probe for detecting the displacement due to vibrations and
(B) vibration analyzer unit 10 (made in-house), which further includes microprocessor 22, digital signal converter 24 to convert analog signals into digital signals, comparator 26 and memory chip 28 for record alarm logs therein for future analysis and comparisons.
Figure 4 shows an enlarged view of the vibration analyzer unit 10 shown in Figure 3, which consists of a pair of vibration indicators 16, a control panel 18 and an electronic or digital display 20.

Working of the Invention:
This vibration analyzer 10 receives vibration in the form of analog signals for the detected deflection due to machine vibrations (in the range of minimum 1 micron up to maximum 10 mm) by means of a vibration detector 12, which is mounted on machine by means of a magnetic stand 14. The machine vibrations detected in terms of analog signals are then fed to the microprocessor 22 configured as a control panel, which forwards them to the converter 24 for converting these analog signals into digital form (e.g. in a range of 4 mA to 20 mA) for displaying their value on the vibration analyzer display 20. The microprocessor 22 is configured to measure even very low vibration of the order of 1 micron, which is otherwise very difficult to measure by means of other available devices. Further, the comparator 26 of the system compares this preset value with the actual value detected in terms of digital value obtained from the microprocessor 22 and calculates the difference of the pre-set value fed into the system and the detected value of vibrations. If the difference of these vibration values is beyond the preset value (both on negative and positive sides of the preset value), an alarm signal is issued and this is set as one bit in the microprocessor 22 and this alarm log is saved in the memory chip 28. The alarm data login facility is not available in any other device presently available in the market. Once the vibration analyzer system according to the invention is connected to any machine and/or device for measuring vibrations developed therein, all vibrations alarms are logged in the memory chip 28 in the form of Date, Time, and exceeded vibration values. Thanks to this capability of detecting such low vibration value (1 micron), the vibration analyzer system in accordance with the present invention is particularly useful on the machines requiring very high accuracy, such as grinding machines, honing machines, etc. The allowable vibration limit may be preset on this system both in negative as well as positive value. This vibration analyzer system can work with any type and make of vibration detector.

The vibration analyzer system in accordance with the present invention detects the vibrations developed on the machine and emits signals. The vibration detector shown in Figure 2 has two main functions:
- to preset the vibration level to a permissible limit for comparison in the comparator, and
- to transfer the vibrations signals in the form of electrical signals to the vibration analyzer.
After receiving these signals, the analyzer starts operation. The digital display of vibration analyzer unit shows the preset permissible value as well as the actual value of vibrations recorded on the machine. Thereafter, it compares both these values and accordingly generates an output in the form of green and red indicators. In case of the actual vibration value being recorded beyond the permissible limit, it stops machine operation. The vibration analyzer unit can also store at least the last 100 readings, which can be extracted in the form of an excel sheet on a personnel computer for analyzing the vibration characteristics on the machine.
Therefore, the invention provides a novel use of a 'Displacement Gauge' for measurement of vibration characteristics on any machine, e.g. a grinding machine, which gives the range of vibration values.
Further, this system is configured as a handy device (the compact box of approximately 6" x 8" size) that can be run on even a PC/computer / 5V). This system can be easily and conveniently connected to any SKADA or such system and does not require any specific software therefor. The interlocking with machine can also be provided, so that the machine does not operate upon recording a particular threshold beyond the acceptable or pre-set limit. Thus, it avoids any further problems or process errors due to defective parts.
Technical advantages and economic significance
The machine vibration analyzer in accordance with the present invention has the following advantages:

- Cost of vibration measurements in precision machines used in mass production of machined products is substantially reduced.
- Simple arrangement is provided for vibration measurements in precision machines.
- Compact unit, easily and conveniently connectable to SKADA or such systems.
- Audio signals and/or visual indication are made available to the machine operator for easy recognition of the extent of machine vibrations present therein.
- Light-weight vibration analyzing unit as compared to the systems available until now.
- Recording of vibration data is possible for analysis and comparison purposes.
- Electronic controller can preset the vibration analyzer to display machine vibrations status in terms of 'OK' or 'NOT OK' signals.
Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", shall be understood to implies including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.
The use of the expression "a", "at least" or "at least one" shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention.
The exemplary embodiments described in this specification are intended merely to provide an understanding of various manners in which this embodiment may be used and to further enable the skilled person in the relevant art to practice this invention.

Although, only the preferred embodiments have been described herein, the skilled person in the art would readily recognize to apply these embodiments with any modification possible within the spirit and scope of the present invention as described in this specification. Therefore, innumerable changes, variations, modifications, alterations may be made and/or integrations in terms of materials and method used may be devised to configure, manufacture and assemble various constituents, components, subassemblies and assemblies according to their size, shapes, orientations and interrelationships.
The description provided herein is purely by way of example and illustration. The various features and advantageous details are explained with reference to this non-limiting embodiment in the above description in accordance with the present invention. The descriptions of well-known components and manufacturing and processing techniques are consciously omitted in this specification, so as not to unnecessarily obscure the specification.
While considerable emphasis has been placed on the specific features of the preferred embodiment described here, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiments without departing from the principles of the invention. These and other changes in the preferred embodiment of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

We claim:
1. A vibration analyzer system for measuring and analyzing machine
vibrations, the system comprises:
(i) at least one magnetic stand detachably connected to the machine;
(ii) at least one vibration detector for detecting deflections produced due to vibrations generated on the machine; and
(iii) at least one vibration analyzer unit:
wherein the machine vibration analyzer unit detects and displays the machine vibration status as 'OK' or 'Not OK' and every 'Not OK' status is recorded in terms of date, time and exceeded value in the memory configured therein for subsequent analysis and comparison process.
2. Vibration analyzer system as claimed in claim 1, wherein the vibrations
analyzer unit comprises at least one control panel includes:
(a) at least one microprocessor for receiving signals from the vibration detector and forwarding the same to the converter and for receiving 'Not OK' alarm logs from the
(b) at least one converter for converting analog values received from the microprocessor into digital signals corresponding to the detected machine vibration,
(c) at least one comparator stored with preset permissible vibration values for comparing the detected vibration value with the stored preset permissible vibration value and issuing an alarm if the detected vibration value is beyond the preset permissible vibration value stored in the comparator,
(d) at least one pair of vibration status indicators for indicating 'OK' and 'Not OK status of machine vibrations depending on the comparison

of the detected vibration value with the preset permissible vibration value by the comparator; and
(e) at least one memory chip embedded for storing the alarm logs of the alarms of each 'Not OK' status issued by the comparator based on the actual detected machine vibration and set as one bit in the microprocessor.
3. Vibration analyzer system as claimed in claim 2, wherein the issued alarm logs comprise date, time, and amount by which the preset permissible vibration limit is exceeds the preset permissible vibration value both on positive and negative side thereof.
4. Vibration analyzer system as claimed in claim 2, wherein the machine vibration status 'OK' or 'Not OK' is indicated by means of green and red light respectively.
5. Vibration analyzer system as claimed in claim 2 to 4, wherein each
'Not OK' status is recorded in the memory in terms of date, time
and exceeded value for subsequent analysis and comparison
process.
6. Vibration analyzer system as claimed in claim 2 to 5, wherein the machine operation is stopped on recording an actual vibration value beyond the preset permissible vibration limit.
7. Vibration analyzer system as claimed in claim 2 to 6, wherein the vibration analyzer unit stores at least the last 100 readings extractable in the form of an excel sheet on a personnel computer for analyzing the actual vibration characteristics on the machine.
8. A method for analyzing the actual vibration generated on a machine and controlling the operation of a machine depending on the comparison of the actual measured vibrations with the preset permissible vibration limit on the machine.

9. Method as claimed in claim 8, wherein the method comprises the
following steps:
• detecting vibration generated in a machine by means of the vibration detector by measuring the displacement due to such vibration, preferably in a range of 1 micron/sec up to e.g. 10 mm or even higher values depending on the detector used;
• converting these displacement value measured as analog signals into digital signals, preferably in a range of 4 mA to 20 mA;
• comparing detected digital vibration signals with the preset permissible vibration value stored in the comparator for determining the 'OK' or 'Not OK' vibration status of the machine;
• indicating the determined 'OK' or 'Not OK' vibrations status of the machine by means of colored indicators;
• displaying the preset permissible vibration limit and actual vibration value on the machine on a live visual display;
• issuing each 'Not OK' vibration status of the machine vibration in by
sounding an alarm, setting each alarm log as one bit in the
microprocessor and storing each alarm log in terms of date, time
and actual vibration value exceeded beyond the stored preset
permissible vibration limit in the memory.
10. Method as claimed in anyone of the preceding claims, wherein at least
the last 100 readings are extracted in the form of an excel sheet on a
personnel computer for analyzing the characteristics of the actual
vibrations generated on the machine.