Abstract:
A proximity probe device for detecting rotating shaft deviation, wherein a rigid body has a pair of flat magnets for forcibly seating against a substantially flat surface area of a shaft bearing housing of magnetizable material, a threaded bore through the body for holding a proximity probe having a mating threaded casing, an angle indicator for assisting in placing the body on the surface area and a pair of spaced shoulders on a proximate edge surface of the body, wherein a sight plane for each of the shoulders is substantially tangential to the surface of a shaft in the shaft bearing housing to aid in aiming the probe at a desired location on the shaft surface.

Description:
This application claims priority under 35 U.S.C. 119(e)(1) based on Applicants Provisional U.S. Patent Application Ser. No. 61/343,752 filed May 3, 2010 and titled “CMS REMOVABLE PROXIMITY PROBE MOUNTS”. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field 
     This invention concerns a unique mounting device for eddy current or capacitive probes or the like which are typically used to detect and measure deviations in shaft balance, misalignment, rotor rubs, vibration or the like of rotating shafts, and finds particular use for mounting a proximity probe accurately on the face of a sleeve bearing housing whereby high visibility is afforded by way of the geometric configuration and other features of the device for aiding the mounting procedure. 
     2. Prior Art 
     Proximity (Eddy Current or Capacitive) probes typically are installed either internally, i.e., to the bearing housing (see  FIG. 18 ) or externally (see  FIG. 19 ). Referring to prior art  FIG. 18 , proximity probe body is typically ⅜-24 thread (English) and is screwed into the probe mounting blocks. Two probes are typically installed at each bearing 90 degrees apart. The probe mounting blocks may be fabricated of steel, aluminum or non-conductive material. The blocks are attached to the end of the bearing with small screws. The probe wire is tied using safety wire ties to prevent damage from the spinning shaft. Among the disadvantages of this type of mounting are that the installation requires an extensive shutdown of the machine, and once installed, the probes are not easily accessed for adjustment or replacement since the machine must again undergo an extensive shutdown involving adequate cooling of the machine and then proper removal of the bearing housings before the probes can be accessed. 
     Referring to prior art  FIG. 19 , the probes are screwed into a threaded holder which is then screwed into a probe holder or housing. This probe housing typically has 1″ National Pipe Thread and is screwed into a tapped hole in the bearing housing. Disadvantages of this type of mounting include (a) as with the internal mounting described above, installation requires an extensive shutdown of the machine in order to accurately machine the bearing housings for probe use, and (b) a mechanic or technician climbing on the machine may use the probe housings for a hand hold or may step on the probes causing distortion or damage to the probe housing or holder. Also, the probes could then, after the repairs are made, be screwed closer to or further from the shaft than required giving a false reading in the shaft position within the bearing. Further, if the probe housing were loosened then the probe itself may be loose and the readings would not be stable or accurate. 
     Applicants principal objective is to provide a probe mounting device that permits temporary, releasable mounting of proximity probes (also called Eddy Current probes or Capacitive Probes) to a standard sleeve bearing housing such as a Dodge Sleevoil type. The present temporary mounting of proximity probes is particularly useful when diagnosing shaft deviation such as vibration of the shaft relative to the bearing housing of fluid film bearings which bearings generate a hydrodynamic oil wedge which supports the shaft or journal. The journal can be thought of as floating on the oil wedge similar to a ship floating on water. 
     Detailed information on Capacitive Proximity Probes can be found in the following articles. 
     Uprating and Refurbishing Hydro Powerplants VI 
     October 1997 
     Montreal, Canada 
     A New Capacitive Proximity Probe to Overcome 
     Eddy Current Probe Limitations 
     Jackson Lin, B.Sc., MBA 
     Vibrosys™ Inc. 
     Longueuil (Quebec) CANADA 
     And 
     CIGRE/IEEF/EPRI Rotating Electric Machinery Colloquium 
     September 1999, Lake Buena Vista, Fla., USA 
     Using a Capacitive Proximity Probe 
     To Solve Electrical Runout Problems for a 
     Chrome-plated Rotor of a Boiler Feed Pump 
     
         
         
           
             Authors:
           Elton Floyd, TXU   Roger Wrenn, Fluor Global Services   Jackson Lin, VibroSystM   
         
           
         
       
    
     SUMMARY OF THE INVENTION 
     A proximity probe device for detecting rotating shaft deviation, wherein a rigid body has a pair of magnets for forcibly seating against a substantially flat surface area of a shaft bearing housing of magnetizable material, a threaded bore through said body receiving a proximity probe having a mating threaded casing, and positioning means on said body for aiming the probe at a desired location on the shaft surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be understood further from the drawings herein and the following description wherein: 
         FIG. 1  is a top view of a machine shaft mounted in a bearing housing and with two of the present devices with probes mounted on the housing face; 
         FIG. 2  is a front view taken along line  2 - 2  of  FIG. 1 ; 
         FIG. 3  is a cross-sectional view taken along line  3 - 3  in  FIG. 2 ; 
         FIG. 4  is a cross-sectional view taken along line  4 - 4  in  FIG. 2 ; 
         FIG. 5  is an enlarged view of the encircled area in  FIG. 1 ; 
         FIG. 6  is a side view taken along line  6 - 6  in  FIG. 1 ; 
         FIG. 7  is a perspective front and downward view of  FIG. 1 ; 
         FIG. 8  is a front view of the device in an operable position adjacent a shaft surface; 
         FIG. 9  is a partially cross-sectioned view taken along line  9 - 9  in  FIG. 8  and rotated front to back; 
         FIG. 10  is a rear view of the device; 
         FIG. 11  is a top view of the device; 
         FIG. 12  is cross-sectional view of the device taken along line  12 - 12  in  FIG. 8 ; 
         FIG. 13  is a front view of two devices each mounted at 45° to a vertical diameter “TDC” of a shaft, wherein the shaft can be horizontally or vertically mounted; 
         FIG. 14  is a frontal perspective view of the device; 
         FIG. 15  is a front view of the device with the extension bar; 
         FIG. 16  is a cross-sectional view taken along line  16 - 16  in  FIG. 15 ; 
         FIG. 16A  is a cross-sectional view of a shaft end mounted probe variation of the present device for detecting and measuring liner motion (deviation) of the shaft; 
         FIG. 17  is a frontal perspective view of  FIG. 15 ; 
         FIG. 17A  is a cross-sectional view taken along line  17 A- 17 A in  FIG. 8 ; 
       FIG&#39;s.  18  and  19  are self explanatory views of prior art probe devices; and 
         FIG. 20  shows the probe holders positioned at 45° right and left of top dead center (TDC); 
         FIG. 21  shows one probe holder positioned at top dead center (vertical) and another probe holder positioned at horizontal; 
         FIG. 22  shows the Probe Driver; 
         FIG. 23  graphically shows operating characteristics of the Probes installed in true horizontal and vertical directions; 
         FIG. 24  graphically shows operating characteristics of the probes installed at 45° to either side of TDC; and 
         FIG. 25  graphically shows DC (Gap) voltage changes of a probe relative to distance of the probe tip to the shaft. 
     
    
    
     Briefly described the present device uses preferably two rare earth flat magnets on a body of the device to hold the body securely to the face of a bearing housing. A bubble level mounted on a protractor angle gauge pivotally mounted on the body allows positioning of the device with its center or vertical axis (and the probe axis)  38  at the desired angle, e.g., 45 degrees to the vertical diameter “TDC” of the machine shaft. Two or more jacking screws are provided as aids to overcoming the strong magnetic force when removing the device from the bearing housing or when adjusting the position of the device thereon. Two machined surfaces on proximal edges of the body of the device facilitate alignment of the probe axis with the centerline (axis) of the machine shaft by contact of the surfaces with a machined raised surface typically provided on large sleeve bearing housings concentric with the shaft on the bearing housing, or by visual adjustment of the device on the bearing housing face using the surfaces as sight lines. Other machined surfaces are provided on the body for use with a bubble level or other straight edge to help orient the device to the desired angular position about the shaft. 
     In certain situations it would be preferable to permanently install proximity probes on rotating shaft machinery using either the internal or external bearing mounting procedures. However, due to both the cost and time typically involved to install such systems, it is not always practical or feasible to do so. The present device is intended, primarily, to be used for temporary or short duration mounting of proximity probes for taking accurate measurements of shaft deviation either during load changes or transient conditions such as startup or shutdown. 
     Sleeve type bearings are typically used on large Induced Draft Fans (ID), Forced Draft Fans (FD), process fans, turbines, large motors, and the like. Temporary mounting of the present proximity probes is particularly useful, e.g., when diagnosing shaft vibration and the shaft position within the bearing clearance relative to the bearing housing of fluid film bearings. Probes and cables are available from several vendors including CTC, GE Bently, SKF, etc. Data may be acquired from the probes using instruments available from GE Bently, SKF, Shinkawa, IOtech, CSI, and National Instruments. 
     DETAILED DESCRIPTION 
     Referring to the drawings and with particular reference to the claims herein, the present device comprises a rigid body  20  having a flat magnetic rear face portion, preferably rare earth flat magnets  22  secured to body  20  by screws  21  and set screws  23  and adapted to magnetically, forcibly seat against a substantially flat surface area  24  of a shaft bearing housing  26  of magnetizable material such as iron or steel, structural means such as threaded bore  28  on said body and lock nut  29  for holding a proximity probe  30 , an adjustment mechanism  32  such as threads on said structural means for spacing said probe a desired distance from the surface  33  of shaft  35 , and angular positioning means  34 ,  36  on said device for aiming the probe axis  38  at a desired location such as  39  on the shaft surface  33 . 
     Body  20  is composed of any strong rigid material including aluminum, steel, brass, ceramic, plastic such as butyrate, polyamide or polyurethane and preferably is provided with a cut-out  40  for accommodating an extension bar  41  affixed by a pair of screws  37  ( FIG. 17 ) to the body, said body having threaded bores  42  whereby a probe can be affixed to the bar and positioned longitudinally along the shaft at a desired distance from the bearing housing such as, for example, to avoid rust pits or other defects in the shaft surface which could cause incorrect probe readings. 
     Angular positioning means  34  is used for horizontal shaft readings and comprises a protractor type of angle indicator having an angle marked face plate  44  rotatably mounted by screw  46  and compression washer  48  on body  20 . A horizontal line  50  is marked on the body and is normal to the probe axis  38  and is used as a zero angle set line when aligned with 90° markings on the face plate. The probe axis positioning procedure would be to rotate and lock plate  44  either clockwise or counterclockwise at a desire angle, e.g., 45° as marked on the face plate and then angularly move body  20  around and in close proximity to the shaft until bubble level  52  which is affixed to plate  44  and is parallel to the 90° marking on the plate comes to a horizontal posture as shown, e.g., in  FIG. 13 . It is noted that as shown by the dotted lines in  FIGS. 8 and 13  for shoulder surfaces  54  and  56 , these shoulders provide lines of sight  57  (dotted) easily visible for accurately moving the body on the bearing housing face to position  54  and  56  at the same or very close to the same distance from shaft surface  33 . This will insure that the probe face  58  will lie substantially tangential to shaft surface  33 . Jacking screws  60  when threaded further against area  24  of the bearing housing face will force the magnets away from area  24  sufficiently to allow the device to be slid on area  24  to the desired position thereon. 
     The CMS Proximity Probe Mount uses two rare earth flat magnets to secure the mounts to the face of the bearing. A moveable bubble level with protractor angle gauge allows easy positioning of the probe bracket to the desired angle (such as 45 degrees). Two ¼-20 thread jacking screws are provided as aids to overcoming the strong magnetic pull when positioning or removing the probe mounts from the bearing housing. The mount body has machined surfaces which are provided as an aid to precise mounting. Extension brackets or bars are provided in two lengths to allow positioning the probes to a more desirable shaft region. 
     Step 1: 
     8 mm proximity probes (not supplied with Part No. 5067) should be screwed into the probe holders so that the probe tip extends about ½ to 1 inch from the holder as shown in  FIG. 8 . The jam nut should be tightened after the probe is accurately positioned to sense the shaft with a gap voltage of approximately −10V. The preferred mounting location of the probes is as close to the bearing housing as possible. 
     Step 2: 
     With the machine shutdown and the shaft not turning, clean the bearing housing and/or seal housing surfaces of all oil and grease where the probe holders will be attached. The surfaces where the magnets attach should be clean and free of burrs, loose paint, oil and grease. 
     The shaft surface that the proximity probes will sense will typically require cleaning or light dressing with 280 grit wet/dry abrasive paper especially if rust is present. The shaft surface that the probe will sense should be free of keyways, oil slingers, mechanical damage, plating or metal spray buildup. Where needed, the extension brackets can be employed to move the probes away to a more desirable shaft location. 
     Step 3: 
     With the machine shut down and the shaft not turning, position either one of the Removable Probe Holders on the end of the bearing housing where it is desired to measure shaft vibration. Adjust the ¼-20 thread jacking screws as needed to prevent the flat rare earth magnets fully contacting the end of the bearing housing or seal housing. The intent is to make moving the probe holders into position easier before allowing the magnets full contact with the bearing or seal housing. Position the Removable Probe Holders so that the probes are in the desired location usually True Horizontal (X) and True Vertical (Y), see  FIG. 21 , or 45 degrees right (X) and 45 degrees left (Y) of top dead center, see  FIG. 20 . 
     Take care when positioning the probe holders to no hit the probe tips against the shaft causing potential damage to the probes. A gap of between ¼″ to ½″ should be maintained between the probe tips and shaft surface. One initial positioning of the probe holders is complete, the gap between the two probe tips and shaft should be roughly the same. The adjustable level can be set to aid in positioning the probe the probe holder at the desired angle. Once the Removable Probe Holders are in the desired position, screw the jack screws out allowing the magnets to make full contact with the bearing housing or the seal housing. Insure that the removable probe holders are securely attached to the bearing housing or seal housing and cannot be easily moved by hand. If the mounting is not secure, the probe holders may move once the machine is started especially if the bearing housing has high vibration. 
     Step 5: 
     Connect the Extension Cable to the Probe Cable. See  FIG. 22 . Then connect the extension cable to the Proximity Probe Driver. Provide −24V DC power to the Driver. Read the DC Gap Voltage at the Driver terminals OUT &amp; COM with a vole meter or at the BNC. Adjust the prove tip distance to the shaft by rotating the probe body until −10V is read on the voltmeter. Then, tighten the probe jam nut to securely lock the probe in position. 
     Step 6: 
     Secure the probe cables using plastic wire ties or other acceptable means so that the cables cannot come into contact with the shaft during operation and potentially become entangled. Always use CAUTION when working around rotating equipment and follow all plan and government safety guidelines. Failure to follow these instructions could result in damage to the machine, process downtime, personal injury or even death. 
     Applications of CSM Removable Proximity Probe Mounts 
     1. Mounting a Proximity Probe to Generate a Once per Revolution Signal. 
     
         
         A once per revolution electrical pulse from a rotating shaft is used to generate a trigger signal to trigger sampling of a spectrum analyzer. The spectrum analyzer uses this signal to calculate the phase lag angle of the rotor&#39; vibration and the RPM of the shaft. This information is used analysis of the cause of high amplitude rotor vibration and also for rotor housing. The CMS Removable Proximity Probe Mount is attached to the end of a bearing housing such as a motor bearing housing. The Probe Mount is positioned so that the proximity probe can sense the keyway in the shaft. As the shaft rotates, an electrical pulse is generated each time the keyway passes the proximity probe.
 
2. Mounting a Thrust Bearing Proximity Probe
 
         Proximity probes are used to monitor the axial position of a rotor that is supported by fluid film bearings. The rotor can move a distance equal to the thrust bearing clearance (also called the thrust float). The CMS Removable Proximity Probe Mount can be mounted on the end of the bearing housing of some machines to support a proximity probe that is sensing the end of the shaft.
 
3. Mounting X &amp; Y Radial Probe on a Bearing Housing (fluid film bearings)
 
         The CMS Removable Proximity Probe Mounts can be mounted on the end of the typical fluid film bearing housing. The Probe Mounts are oriented 90 degrees apart to position the proximity probes to sense the shaft radial surface. The signal from the proximity probes is used to measure the orbital motion of the shaft as well as the shaft position within the fluid bearing clearance. The signals from the proximity probes are processed by data acquisition systems common to this application but no provided by CSM.
 
4. Mounting Proximity Probes on a Balance Machine
 
         For critical high speed rotors that are to be instrumented with radial proximity probes, the surface of the shaft that is sensed by the proximity probes (also called probe track) must be finished to very low mechanical and electrical runout. The runout is typically measured in the shop that is either manufacturing the rotor or that is repairing the rotor. One method of measuring the probe track runout is to mount the CSM Removable Proximity Probe Mounts on the bearing support frame of a balance machine and while rotating the rotor slowly the runout is measured using a volt meter. The volt meter is connected to the proximity probe driver electrical terminals. Another method uses a data acquisition system to the measure the voltage signal from the proximity probe driver electrical terminals.
 
5. CMS Removable Proximity Probe Mount Used With Capacitance Proximity Probes
 
         Capacitance proximity probes are immune to many of the effect that influence the vibration signal to the eddy current probe. This include chrome plated probe track, roughness, magnetic field and inconsistent target metallurgical irregularities. The physical mounting is similar and the CSM Removable Probe Mount is used in the same manner as with the eddy current type probe.
 
6. Vibration shaft Vibration
 
         The shaft runout of vertical pumps can be measured by attaching the CSM Removable Proximity Probe Mount (90 degrees apart radially) to the pump bearing housing.
 
7. Rotor Orbit Analysis
 
         The analysis of the shaft orbital path within a fluid film bearing offers much information about the condition of the machine and the source of excessive vibration. 
         Rotor Unbalance is indicated by an orbital path that is circular to slightly elliptical depending on the bearing design. The frequency of vibration is 1× the rotor rotational frequency. 
         A cracked rotor can be indicated by an increase in vibration at 1× and 2× the running speed frequency of the shaft and changes in the phase lag. The orbit may show size change over time. 
         Partial rotor rubs can be indicated by orbital 1× and 2× components. The rotor rub may modify the rotor natural frequency (critical speed). The orbits will be highly elliptical and may show reverse components (reverse precession of the rotor). 
         Full rotor annular rub generates vibration at 1× the rotor run speed. 
         Depending on the dry friction between the rotor and the seal, seal susceptibility, damping, and unbalance, the system can exhibit either forced response predominantly 1× forward response or self excited predominantly reverse response. 
         Fluid Induced Whirl is predominantly forward orbit with internal loops (a combination of whirl and 1× components). 
         Fluid Induced Whip is predominantly forward orbit with internal loops (a combination of whip and 1× components). Usually some reverse 1× and subsynchronous components are present due to the bearing pedestal stiffness anisotropy (horizontal and vertical stiffness differs). 
         Rotating Stall can be differentiated from a fluid induced instability by its disappearance with increased flow through the compressor. 
       
    
     The proximity probe has a linear range (probe tip distance from the target material versus DC Voltage) as shown in  FIG. 25 . When measuring data with the proximity probes, the DC Voltage is used to plot the position of the shaft within the bearing clearance. Two probes must be used arranged 90 degrees apart. The resultant vector is plotted and this describes the shaft centerline movement in the bearing clearance during spinup or coastdown. This average shaft centerline movement is used to determine where the shaft is running within the bearing clearance and the thickness of the oil film. 
     Referring to  FIG. 13 , where shaft  35  is vertically mounted, levels  52  and the protractor type positioning means  34  cannot be used, however, the flat surface type of positioning means  36  on the distal edge surfaces  45  (see  FIGS. 2 ,  7  and  13 ) of the body are at 45° to the probe axis  38  and when a straight edge such as  62  (dotted line) is laid across these two surfaces the axes of the two probe will be 90° apart. 
     Referring to  FIG. 16A , the present device is adaptable for measuring linear shaft motion by way of the downward right angled configuration of the extension bar  41 . The exact alignment of the probe axis  38  with the centerline (shaft axis)  43  or with any other point on the shaft diameter can be made by adjusting the position of the present device on the bearing housing face  47 . This variation of the present device is particularly useful for assessing the condition of structure such as thrust bearings  49  of any structure type. The one shown is merely an example and consist of annular ball bearing races  51  and  53  press fitted into housing  26  and annular race  59  press fitted onto shaft  35  and each race running on ball bearing  61 . 
     The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications will be effected with the spirit and scope of the invention.