Patent Publication Number: US-2019178847-A1

Title: Rotor deflection monitoring system

Description:
RELATED APPLICATIONS 
     This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 15/247,168, filed 25 Aug. 2016, which is a continuation-in-part of U.S. patent application Ser. No. 14/819,131, filed 5 Aug. 2015, abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention is directed to rotor deflection probe systems, particularly systems for use with large rotating machinery. Known deflection monitoring sensors for large rotating machinery, eddy-current proximity displacement probes and spring-coil velocity transducers, are hampered with intrinsic errors lessening their effectiveness in providing diagnostic warning or data for balancing and accurate rotor deflection monitoring to determine approaching internal contact between rotating and stationary elements thus protecting against rotor damage during startups. For example, eddy-current proximity displacement probes may suffer from electrical run-out, magnetic run-out, surface irregularity (dents, scratches, and grooves) spiking, and ill-defined calibration. Spring-coil velocity transducers suffer poor low speed outputs, mechanical resonance, and difficulty with coupling to a rotating shaft without use of a contacting shaft rider which itself is spiked by surface irregularities. Further, the probes of prior art systems measure a small surface of the test object. As a result, surface anomalies impact the measurement data. 
     It the attempt to address the issues, prior art applications have employed Doppler probes. The Doppler Effect presumes the full waveform frequency is not altered. However, it has been found the properties of air are different at short distances. Such that the reflected waveform leading pressure pulse timing is altered. Specifically, where the distance between the probe and the test object is less than one foot, the reflected wave in a Doppler application does not have a sinus pattern. Instead, the distance between peak amplitudes at high frequency for the outgoing wave to the test object are not separated enough. As a result, on reflection of the wave from the test object, the sinus wave is irregular. Gains applied to adjust for the irregularity had to be very high. Which caused secondary noise to be at such a high level to make the Doppler measurement ineffective. 
     Further, prior art probes have employed analog signals. It has been shown that the amplifier gains of a Phase Lock Loop of an analog system to demodulate the Doppler Effect frequency shift would be so great as to pose undesirable thermal noise levels and poor Signal-to-Noise Ratio (SNR). Current electronic components are unable to improve the SNR to a level the application would require. 
     Further, the prior art seeks to identify a phenomena known as steam whirl instability. Steam-whirl instability in rotating machines can cause a very quick growth of the amplitude of the shaft vibrations that can reach high levels in a very short time. However, improvements in technology have reduced steam-whirl instability to a non-significant factor. As a result, the prior art is not testing the correct factor. The concern is the deflection of the rotor. Deflection normally occurs at the start-up of systems. The rotor experiences sag, or deflection, due to differential heating and expansion during shutdown. Upon start-up, the sag, or deflection, accentuates the natural resonance of the rotors. As a result, at least one of turbine rotor contact with stationary seals and rotating seal contact with stationary lands occurs. As a result, the rotating seals and stationary seals will be damaged. Due to the prior art focus on steam whirl instability, the prior art systems do not test rotor deflection to ensure the turbine rotor contact with stationary seals is minimized and rotating seal contact with stationary lands is minimized. Due to the in ability of the prior art to measure the required parameters, $1 million a year in damage to stationary seals and rotating seals due to the contact between the rotor and the seals. 
     Further, the prior art systems require target calibrations in regards to metallurgy in eddy current proximity probes. 
     Therefore, there exists a need for a monitoring system testing rotor deflection to ensure the turbine rotor contact with stationary seals is minimized and rotating seal contact with stationary lands is minimized. 
     There exists a need for a monitoring system testing rotor deflection which measures a large area of the test object minimizing the effect of surface anomalies. 
     There exists a need for a monitoring system testing rotor deflection system having a design which minimizes thermal noise levels and SNR. 
     There exists a need for a monitoring system testing rotor deflection system which is self-calibrating. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a system and method for measuring the rotor deflection of a test object, such as a machine shaft or other rotating equipment, and producing real-time deflection analysis. 
     The system for measuring rotor deflection of a rotor shaft may including: a first probe senor for measuring rotor deflection of the rotor shaft and a data manager; the first probe sensor having an ultrasonic speaker positioned in a first opening; the first probe sensor measuring an ultrasonic microphone positioned in a second opening; the first probe sensor may be in communication with a first digital circuit; the first digital circuit may have a rotor deflection data, wherein said first sensor and the first digital circuit measures the rotor deflection of the rotor shaft; and said first digital circuit in communication with said data manger; wherein pulsed measurement counts are at least one of measured and calculated by said first digital circuit, and communicated to said data manager. The probe sensor may further include a temperature and humidity sensor, wherein the temperature and humidity sensor provides for a self-calibration. The system may further including the system is a digital system. The system may further provide for an incident sound wave having at least one of at least substantially a 25 KHz frequency and at least substantially a 40 KHz frequency. The system may further provide for said incident sound wave having a frequency range from 25 KHz to 40 KHz. The system may further include the first digital circuit configured for measuring said rotor deflection and to perform a probe health diagnostics. The system wherein the first digital circuit is configured to transmit the rotor defection data and a probe health diagnostics data via a serial digital network. The system wherein the host data manager polls the rotor deflection data and the probe health diagnostics data. The system wherein the host data manager polls said rotor deflection data. The system wherein the host data manager performs a modal analysis. The system wherein the system having a zero-phase pulse. 
     A method for measuring a rotor deflection of a rotor shaft including: providing a first probe senor for measuring a rotor deflection of the rotor shaft and a data manager; transmitting an ultrasonic signal from a ultrasonic speaker housed within a first probe sensor first opening; reflecting the ultrasonic signal from the rotor shaft as a reflected ultrasonic signal to an ultrasonic microphone housed within a first probe sensor second opening; transmitting the reflected signal to a first digital circuit; said first digital circuit performing a deflection analysis, wherein said first digital circuit performing at least one of measuring and calculating deflection of said rotor shaft; and transmitting the deflection analysis to a data manager. Alternatively, the first digital circuit performing a deflection analysis, wherein the first probe sensor and the first digital circuit performing at least one of measuring and calculating deflection of the rotor shaft. The method may further include applying corrections from a temperature and humidity compensation sensor to the reflected ultrasonic signal, compensating for a gain. The method may further include the first digital circuit performing at least one of measuring and calculating the rotor deflection and a probe health diagnostics, which comprise the deflection analysis. The method may further include wherein the first digital circuit transmitting a rotor defection data and a probe health diagnostics data via a serial digital network. The method may further include said host data manager polling the rotor deflection data and the probe health diagnostics data. The method of may further include the host data manager polling the deflection analysis. The method may further including the host data manager performing a modal analysis. The method may further include comparing first and second modal deflections. The method may further include producing warnings for the rotor shaft proximity with at least one of stationary lands and stationary seals. The system includes a probe/input circuit assembly in communication with a Host Data Manager. The probe/input circuit assembly comprising a probe sensor and input circuit. The probe sensor having an ultrasonic speaker and an ultrasonic microphone. In use, the ultrasonic speaker transmits an ultrasonic signal toward the test object. The transmitted ultrasonic signal is reflected from the test object, and is detected by the ultrasonic microphone. The signal detected by the microphone is sent to an input circuit that processes the signal. It is observed, the probe targets a surface area of the test object wherein the target surface area of the test object is of a size to minimize effects of anomalies on the test object surface. The minimization of the effect of the anomalies on the test object surface results because the elastic properties of air smooth anomalies in the test object surface within ¼-inch of reflection. A microcomputer within said input circuit then performs deflection analysis. In a first preferred embodiment, the present system uses the reflection of an internally generated, continuous, 25 KHz frequency (ultrasound) incident sound wave to detect the deflection in the test object, rotor. In a second preferred embodiment, the present system uses the reflection of an internally generated, continuous, 40 KHz frequency (ultrasound) incident sound wave to detect the deflection in the test object, rotor. Alternatively, the present system may use the reflection of an internally generated, continuous, incident sound wave within the range of at least substantially 20 KHz to at least substantially 45 KHz frequency (ultrasound) to detect the deflection in the test object, rotor. The current system never disengages from a continuous signal, unlike other designs that routinely pulse a background calibration. Discontinuities in the disengaged signal of other designs can be falsely interpreted as vibration phenomena due to voltage step changes in signal output. 
     The input circuit comprises the speaker pulse shaper, a microphone pulse shaper, an XOR gate, a second grouping of digital gates, a clock generator, a counter, and a microcomputer. The combination of the speaker pulse shaper, the microphone pulse shaper, the XOR gate, the second grouping of digital gates, the clock generator, and the counter produce a sequence of immediate differential pulse width measurement counts. The pulse width measurement counts are proportional to the instantaneous distance to the test object, rotor. The differential pulse width measurement counts, counting displacement data, is transferred to the microcomputer. Firmware located in the microcomputer performs deflection analysis, and generates probe health diagnostics of the probe. 
     In addition, the microcomputer is in electrical connection with a bus. Wherein deflection data is communicated to the bus from the microcomputer. The bus, and in turn the input circuit, is in electrical communication with a communication interface module of the Host Data Manager through a serial digital interface network. The communication interface module of the Host Data Manager is in electrical communication with a touch screen PC, industrial computer, of the Host Data Manager through a communications interface module/touch screen PC communication. The serial communications network comprises at least one serial communications port in communication with an RS-485 connection, wherein each at least one serial communications port is in electrical communication with the RS-485 connection through a connection extension. Wherein the serial communications port receives queries from the Host DATA manager and transmits the deflection analysis requested to the Host Data Manager by way of at least one of the connection extension and the RS-485 connection. The data sets from all probes are combined by the communication interface module and sent to the touch screen PC, industrial computer, of the Host Data Manager. The touch screen PC, industrial computer, performs a modal analysis for each test object, rotor, using the deflection data sets of the test object, rotor. The touch screen PC, industrial computer, computes and combines 1st and 2nd modal element sets. The touch screen PC, industrial computer compares the combined 1st and 2nd modal element set of combined deflections to internal seal clearances of the test objects, rotors, at longitudinal locations of finite elements, and provides warning to operators when the deflections are impeding contact with turbine seals of the test object rotor, rotor, at the 100 finite element longitudinal locations along the test object length. Specifically, the system provides warnings to minimize rotor contact with stationary seals and rotating seal contact with stationary lands. 
     It is observed the system comprises at least one paired assembly. Each paired assembly comprises a primary assembly and a redundant assembly, wherein the primary and secondary assemblies are probe/input circuit assemblies. It is noted the primary assembly and the redundant assembly of each paired assembly is located substantially at the same location along a test object length, and positioned at a different radial location about a circumference of the test object, rotor. In the event that at least one of the probe and microcomputer of the primary assembly fails to respond to the Host Data Manager polling data query or receives a failure notice from the microcomputer, the redundant assembly of the paired assemblies is polled by the Data Host Manager for deflection data. 
     The touch screen PC, industrial computer, outputs a condensed serial data stream for each probe/input circuit assembly to the Communications Interface Module of the Host Data Manager which maintains a data update with a plant computer or Distributed Control System (DCS) to inform operators. 
     Further, in each probe/input circuit assembly, the ultrasonic speaker and ultrasonic microphone are located within a housing at a fixed alignment. The present design preferably positions the ultrasonic microphone in exact coincidence with the opposite direction of the reflected ultrasonic waves, usually employing a fixed degree incidence and 30 degree reflection positioning of the ultrasonic speaker (source) and the ultrasonic microphone (receiver). In addition, a buffered, zero-phase pulse provides a timing reference for all time-dependent vibration analysis data such as running speed and half running speed. 
     As will be discussed, a system according to the present invention further preferably includes a temperature and humidity compensation sensor and an extension tube support, with all components positioned at a fixed distance from a target rotating shaft. The temperature and relative humidity sensor detects and signals the system to compensate for variations in the ambient temperature and relative humidity of the test application. The ambient temperature and relative humidity of the application, for example a turbine monitoring atmosphere, affects the speed of sound by up to 25%. Such changes in the speed of sound directly impact the positional measurements. This arrangement provides for highly accurate gain corrections to the signal from changes in temperature and relative humidity, keeping the sensor system in acceptable calibration at all times. In a first preferred embodiment, the present design preferably utilizes a 25 KHz (+/−200 Hz) incidence wave frequency. In a second preferred embodiment, the present design preferably utilizes a 40 KHz (+/−200 Hz) incidence wave frequency. Alternatively, the present system may utilize an incidence wave frequency ranging from 20 KHz (+/−200 Hz) to 45 KHz (+/−200 Hz). 
     The microcomputer further generates diagnostic data. Said diagnostic data is sent to the Data Host manager prior to any deflection data to prevent the Data Host Manager from interpreting these events as deflection phenomena in the industrial machine being monitored. 
     Further configuration can be performed by manually toggling a pair of eight-position Dual in-line Package (DIP) switches which connect to two eight-bit microcomputer ports. 
     An intended benefit of the present invention is a monitoring system testing rotor deflection to ensure the turbine rotor contact with stationary seals is minimized and rotating seal contact with stationary lands is minimized. 
     An intended benefit of the present invention is a monitoring system testing rotor deflection which measures a large area of the test object minimizing the effect of surface anomalies. 
     An intended benefit of the present invention is a monitoring system testing rotor deflection system having a design which minimizes thermal noise levels. 
     An intended benefit of the present invention is a monitoring system testing rotor deflection system which is self-calibrating. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a view illustrating a sensor and input circuit of a system according to the present invention, the sensor positioned to measure deflections of a test object. 
         FIG. 2  is a perspective view of the sensor illustrated in  FIG. 1 . 
         FIG. 3  is a top planar view of the sensor illustrated in  FIGS. 1 and 2 . 
         FIG. 4  is an end view of the sensor illustrated in  FIGS. 1-3 . 
         FIG. 5  is a partial cut away and cross sectional view of the sensor illustrated in  FIGS. 1-4 , taken along lines  5 - 5  of  FIG. 2 , and showing an ultrasonic speaker and an ultrasonic microphone. 
         FIG. 6  is a view similar to that of  FIG. 5 , but showing the sensor positioned to measure the deflections of the test object. 
         FIG. 7  is a view similar to that of  FIG. 6 , but showing the sensor measuring the deflections of the test object. 
         FIG. 8  is a block diagram of an input circuit of the system according to the present invention. 
         FIG. 9A  is a graphical illustration of a phase offset between a reflected waveform and an incidence waveform, illustrating at least substantially minimal deflection in the test object. 
         FIG. 9B  is a graphical illustration of a phase offset between a reflected waveform and an incidence waveform illustrating deflection in the test object in a direction of the sensor. 
         FIG. 9C  is a graphical illustration of a phase offset between a reflected waveform and an incidence waveform illustrating deflection in the test object in a direction opposite the sensor. 
         FIG. 10  is a diagram of the system of the present invention applying multiple sensors used in a network for rotor deflection detection. 
         FIG. 11  is a polar vector graphical display identifying a 1 st  Mode deflection and a 2 nd  Mode deflection of the test object. 
         FIG. 12  is a graphical illustration of the 1 st  Mode deflection of the test object. 
         FIG. 13  is a graphical illustration of the 2 nd  Mode deflection of the test object. 
         FIG. 14  is a graphical illustration of a comparison of combined 1 st  and 2 nd  Mode deflections of the test object to internal seal clearances of the test object. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 
     With reference to  FIGS. 1, 2 and 10 , a system  2  having at least one probe/input circuit assembly  10 , Host Data Manager  110  according to the present invention may be seen. As shown in  FIG. 10 , the system  2  provides a device and method adapted to measure the deflection of a test object, rotor,  14 , such as a machine shaft or other rotating object. 
     As seen in  FIGS. 1 and 2 , the probe/input circuit assembly  10  includes a probe sensor  12  having a housing  16 , an extension tube support  18 , and a input circuit  20 . As seen in  FIG. 2 , a probe sensor  12  for use with the probe/input circuit assembly  10  preferably includes an ultrasonic speaker  22  and an ultrasonic microphone  24 . The probe sensor  12  may further include a temperature and relative humidity sensor  26 , as will be discussed (see  FIG. 5 ).  FIGS. 3 and 4  illustrate top and end views, respectively, of the probe sensor  12  shown in  FIGS. 1 and 2 . 
     With attention now to the cross sectional view of  FIG. 5 , the sensor  12  with the ultrasonic speaker  22  and ultrasonic microphone  24  are seen as preferably fitted into the housing  16 . The housing is a molded housing  15 . The housing  16  includes cradle openings  28  and foam isolation jackets  30  to attenuate the incident frequency conduction in the housing  16 . An extension tube  18  channels component wiring  32  to an input circuit  20  (see  FIG. 8 ), as will be discussed. The extension tube  18  may be of any length necessary for the specific application, and is determined by the particular requirements of the housing  16  and test object, rotor,  14  (see  FIG. 6 ). As shown, the probe/input circuit assembly  10  uses a fixed alignment ultrasonic speaker  22  and ultrasonic microphone  24 , each placed at a fixed distance D 2  ( 31 ) (see  FIG. 6 ) from the test object  14 . 
     As mentioned, the sensor  12  preferably includes a temperature and relative humidity sensor  26 . The temperature and relative humidity sensor  26  detects and compensates for temperature and relative humidity in the volume of air  29  along the distance D 1  ( 27 ), since the ambient temperature and relative humidity in the volume of air along the distance D 1  ( 27 ) affects the speed of sound by up to 25% in the application (e.g. turbine monitoring) atmosphere. It is noted, the distance D 1  ( 27 ) is a distance from at least one of an ultrasonic speaker face  111  and an ultrasonic microphone face  115 . Wherein at least one of the ultrasonic speaker face  111  and the ultrasonic microphone face  115  is positioned at least one of towards the test object, rotor,  14  and in a test object direction  117  allowing for transmission of continuous ultrasonic acoustical carrier signal  38  from the ultrasonic speaker  22  and receipt of the reflected wave  36  by the ultrasonic speaker  24 . Since detection is through timing, the measurements of temperature and relative humidity correct the timing counts of the probe/input circuit assembly  10 . Further since detection is through timing only and the measurements of temperature and relative humidity correct the timing counts of the probe/input circuit assembly  10 , calibration of the probe/input circuit assembly  10  as to the metallurgy is not required as in eddy current proximity probes. 
     As seen particularly in  FIGS. 6 and 7 , the ultrasonic microphone  24  of the probe/input circuit assembly  10  is preferably positioned in exact coincidence with the opposite direction of the reflected ultrasonic waves  36 . As shown in  FIG. 6 , a preferred position is a fixed 30 degree incidence and 30 degree reflection positioning of the ultrasonic speaker  22  and ultrasonic microphone  24 . The probe  12  is further preferably positioned a predetermined distance D 2  ( 31 ), from the target test object  14 . As illustrated in  FIG. 7 , the distance D 2  ( 31 ) of the probe  12  to the test object  14 , provides for the distance D 1  ( 27 ) from the ultrasonic speaker  22  to test object  14  and the distance D 1  ( 27 ) from ultrasonic microphone  24  to the test object  14 . Preferably, distance D 1  ( 27 ) equates to a distance from ⅞ of an inch up to and including 1⅜ inches. Alternatively, the distance D 1  ( 27 ) equates less than ⅞ of an inch. Alternatively, the distance D 1  ( 27 ) equates to more than 1⅜ inches. Further, the probe  12  targets a surface area (not illustrated in the figures) of the test object, rotor,  14  wherein the target surface area (not illustrated in the figures) of the test object is of a size (not illustrated in the figures) to minimize effects of anomalies on the test object surface  149 . The probe  12  preferably targets a surface area (not illustrated in the figures) of the test object, rotor,  14  wherein the target surface area (not illustrated in the figures) of the test object is at least substantially a 1-inch diameter circle. Alternatively, the probe  12  preferably targets a surface area (not illustrated in the figures) of the test object, rotor,  14  wherein the target surface area (not illustrated in the figures) of the test object is less than a 1-inch diameter circle. Alternatively, the probe  12  preferably targets a surface area (not illustrated in the figures) of the test object, rotor,  14  wherein the target surface area (not illustrated in the figures) of the test object is greater than a 1-inch diameter circle. The minimization of the effect of the anomalies on the test object surface  149  results because the elastic properties of air smooth anomalies in the test object surface  149  within ¼-inch of reflection. 
     In use, and as shown in  FIG. 7 , the ultrasonic speaker  22  transmits a continuous ultrasonic acoustical carrier signal  38 , an incidence wave  35 , in a first preferred embodiment preferably a 25.000 KHz (+/−200 Hz) incidence wave frequency, toward the test object  14  in the direction A ( 39 ). The ultrasonic speaker  22  transmits a continuous ultrasonic acoustical carrier signal  38 , an incidence wave  35 , in a second preferred embodiment preferably a 40.000 KHz (+/−200 Hz) incidence wave frequency, toward the test object  14  in the direction A ( 39 ). Alternatively, the ultrasonic speaker  22  transmits a continuous ultrasonic acoustical carrier signal  38 , an incidence wave  35 , in a incidence wave frequency range from 20.000 KHz (+/−200 Hz) to 45.000 KHz (+/−200 Hz), toward the test object  14  in the direction A ( 39 ). Prior art devices for measuring blood flow apply a high incidence wave frequency, in the range of 200.000 KHz. A 200.000 KHz incidence wave frequency would cause the distance D 1  ( 27 ) to be reduced in dimension such that an operator could not adjust the distance D 1  ( 27 ) accurately. The ultrasonic speaker  22  transmits a continuous ultrasonic acoustical carrier signal  38 , incidence wave  35 . The continuous ultrasonic acoustical carrier signal  38 , incidence wave  35 , strikes the test object, rotor,  14 . The incidence wave  35  is reflected off the test object, rotor,  14  and travels in the direction B ( 43 ) towards the ultrasonic microphone  24 . The reflected wave  36  is received by the ultrasonic microphone  24 . 
     As shown in  FIGS. 7 and 8 , the continuous ultrasonic acoustical carrier signal  38  is internally generated at an adjustable rate from an output capture pin  48  on the microcomputer  56 . The carrier signal generated by the output capture pin  48  is converted to a sine wave by a pulse shaper circuit  50  before speaker output  76  transmission through the ultrasonic speaker  22 . As previously mentioned, the probe/input circuit assembly  10 , and the system  2  as a whole, uses in a first preferred embodiment the reflection of the continuous 25.000 KHz frequency (ultrasound) ultrasonic acoustical carrier signal  38 , incidence wave  35 , to detect immediate displacement, deflection C ( 45 ) of the test object, rotor,  14 . As previously mentioned, the probe/input circuit assembly  10 , and the system  2  as a whole, uses in a second preferred embodiment the reflection of the continuous 40.000 KHz frequency (ultrasound) ultrasonic acoustical carrier signal  38 , incidence wave  35 , to detect immediate displacement, deflection C ( 45 ) of the test object, rotor,  14 . As previously mentioned, the probe/input circuit assembly  10 , and the system  2  as a whole, uses in an alternative embodiment, the reflection of the continuous ultrasonic acoustical carrier signal  38 , incidence wave  35 , in the range of 20.000 KHz to 45.000 KHz frequency (ultrasound) to detect immediate displacement, deflection C ( 45 ) of the test object, rotor,  14 . The transmitted continuous ultrasonic acoustical carrier signal  38 , incidence wave  35 , is reflected from the test object, rotor,  14  as reflected waves  36  in the direction B ( 43 ), and is detected by the ultrasonic microphone  24 . 
     As shown in  FIGS. 9A, 9B and 9C , at any fixed probe distance D 2  ( 32 ) of the probe sensor  12  from the test object, rotor,  14 , the reflected wave  36 , received by the ultrasonic microphone  24 , will have a reflected waveform  47  at a fixed phase offset  51  from the incidence waveform  53  of the continuous ultrasonic acoustical carrier signal  38 , incidence wave  35 . The phase offset  51  is the difference  59  between the pulsed time width of the incidence wave form  55 , and the pulsed time width of the reflected wave form  57 . An immediate displacement C ( 45 ) in the rotating test object, rotor,  14  due to rotor deflection will cause the difference  59  between the pulsed time width of the incidence wave form  55 , and the pulsed time width of the reflected wave form  57  to increase and decrease. As illustrated in  FIG. 9A , where substantially minimal deflection in the test object, rotor,  14  exists at the probe sensor  12 , a steady state phase offset  63  exists. As illustrated in  FIG. 9B , a deflection in the test object, rotor,  14  away from the probe sensor  12  will result in a waveform differential increase  119  in the difference  59  between the pulsed time width of the incidence wave form  55  and the pulsed time width of the reflected wave form  57  to a second difference  123 . As illustrated in  FIG. 9C , a deflection in the test object, rotor,  14  towards the probe sensor  12  will result in a waveform differential decrease  121  in the difference  59  between the pulsed time width of the incidence wave form  55  and the pulsed time width of the reflected wave form  57  to a third difference  125 . 
     As shown in  FIG. 8 , an output signal from the ultrasonic microphone  24  is then transmitted to an input circuit  20  by way of wiring  32  or other conventional means through microphone input  40 . The input circuit  20  is powered by power supply  74 . A microcomputer  56  receives temperature and humidity input corrections  25  via a Serial Peripheral Interface link  44  and digitally, within its code, applies the input corrections  25 . This retains the system  2  (see  FIG. 7 ) in acceptable calibration at all times, by self-calibration. Due to the application of a digital system noise issues are minimized. Mechanical acoustical isolation, such as the jackets  30  shown (see  FIG. 5 ), are present to reduce any system noise. In regards to self-calibration, any changes in the distance D 1  ( 27 ) affect only the steady state phase offset  63 . Further, the changes are subtracted in real time analysis from the actual deflection of the test object, rotor,  14 , 
     Measurements counts from the microphone input  40  are sent to the input circuit  20 . The input circuit  20  comprises the speaker pulse shaper  50 , a microphone pulse shaper  65 , an XOR gate  69 , a second grouping of digital gates  71 , a clock generator  73 , a counter  75 , and a microcomputer  56 . The combination of the speaker pulse shaper  50 , the microphone pulse shaper  65 , the XOR gate  69 , the second grouping of digital gates  71 , the clock generator  73 , and the counter  75  produce a sequence of immediate differential pulse width measurement counts. The pulse width measurement counts are proportional to the instantaneous distance D 1  ( 27 ) to the test object, rotor,  14 . Preferably, the pulse width measurement counts are proportional to the instantaneous distance D 1  ( 27 ) to the rotor with an accuracy of at least +/−0.0001 inch (+/−0.0001 inch and greater accuracy than +/−0.0001 inch). Alternatively, the pulse width measurement counts may be proportional to the instantaneous distance D 1  ( 27 ) to the rotor with an accuracy of less than +/−0.0001 inch. 
     The speaker output  76  is electrically connected to the speaker pulse shaper  50  via a speaker output/speaker pulse shaper connection  85 . The speaker pulse shaper  50  is electrically connected to the XOR gate  69  through a speaker pulse shaper/XOR gate connection  79 . The microphone input  40  is electrically connected to the microphone pulse shaper  65  through the microphone input/microphone pule shaper connection  87 . The microphone pulse shaper  65  is electrically connected to the XOR gate  69  through a microphone pulse shaper/XOR gate connection  77 . The microphone pulse shaper/XOR gate connection and the speaker pulse shaper/XOR gate connection  79  provide the two inputs required for the XOR gate  69 . An XOR gate/logic gate connection  89  electrically connects the XOR gate  69  to an AND 1  gate  72  of the second grouping of digital gates  71 . The XOR gate/logic gate connection  89  is an output for the XOR gate and a subsequent input for the AND 1  gate  72 . Wherein the XOR output is combined with a microcomputer port control. Speaker pulse shaper/XOR gate connection  79  is in electrical communication with a first intermediate connection  83  at a first connection junction  81 . The first junction  81  and an AND 2  gate  91  are in electrical connection through the first intermediate connection  83 . At a second connection junction  90 , along a first intermediate connection length  93  of the first intermediate connection  83 , a first NOT gate connection  94  electrically connects the first intermediate connection  83  and a NOT gate  95 . The AND 2  gate  91  and the microcomputer  56  are electrically connected through the AND 2  gate/microcomputer connection  96 . The AND 2  gate/microcomputer connection  96  and the first intermediate connection  83  provide the input connections to the AND 2  gate  91 . 
     The AND 2  gate  91  and the clock generator  73  are electrically connected through the AND 2  gate/clock generator connection  97 . The AND 2  gate/clock generator connection  97  provides for the output from the AND 2  gate  91  and an input to the clock generator  73  to enable the clock generator  73 . 
     A microcomputer/AND 1  gate connection  98  provides electrical communication between the microcomputer  56  and the AND 1  gate  72 . A second NOT gate connection  99  provides for electrical communication between the NOT gate  95  and the AND 2  gate/clock generator connection  97 , wherein the second NOT gate connection  99  provides for an output from the NOT gate  95 . The second NOT gate connection  99  contacts the microcomputer/AND 1  gate connection  98  at a third connection junction  100 . The microcomputer/AND 1  gate connection  98  and the XOR gate/logic gate connection  89  provide the input connections to the AND 1  gate  72 . 
     The AND 1  gate  72  is in electrical communication with an AND 3  gate  104  through an AND 1  gate/AND 3  gate connection  102 . The clock, generator  73  is in electrical communication with the AND 3  gate  104  through a clock generator/AND 3  gate connection  101 . The AND 1  gate/AND 3  gate connection  102  and the clock generator/AND 3  gate connection  101  provide the inputs into the AND 3  gate  104 . Wherein the XOR output is combined with a high speed clock, signal from the clock, generator  73 . The high speed clock signal is preferably at least substantially 170 MHz. Alternatively, the high speed clock signal may be less than substantially 170 MHz. Alternatively, the high speed clock signal may be more than substantially 170 MHz. The AND 3  gate  104  is in electrical communication with the counter  75  through an AND 3  gate/counter connection  105 . The AND 3  gate/counter connection  105  provides for an output from the AND 3  gate and an input into the counter  75 . The counter  75  is preferably a 12-bit counter (4096 count). Alternatively, the counter  75  may be greater than a 12-bit counter. Alternatively, the counter  75  may be less than a 12-bit counter. The counter  75  measures the pulse width of the differences in the real time waveform of the incidence waveform  53  and the reflected waveform  47 . The counter  75  and the microcomputer  56  are in electrical connection the counter/microcomputer connection  106 . Where the counter/microcomputer connection  106  provides for transfer of counting displacement date to the microcomputer  56 . The counter/microcomputer connection  106  connect to microcomputer input ports  147  for parallel data reads. Internal timing features of the microcomputer adjust a counter sampling rate to each one-degree of shaft turn. Over sampling of five test object, rotor,  14  turns is performed and stored in a memory. The oversampling data is corrected to a bipolar signal by subtracting the DC component from the difference  59 . 
     It is observed alternative embodiments of the second grouping of digital gates  71  may comprise at least one of an AND gate, an OR gate, a NAND gate, a NOR gate, an XOR gate, a XNOR gate, and a NOT gate to perform the at least one function of the second grouping of digital gates  71  as described in this application. 
     Firmware located in the microcomputer  56  performs deflection analysis. The firmware operates on the bipolar deflection signal using a demodulation technique to resolve a data set of the running speed frequency (Hz), (1×) peak-to-peak deflection amplitude and phase, the half running speed frequency (½×) peak-to-peak deflection amplitude, the twice running speed frequency (2×) peak-to-peak deflection amplitude. The microcomputer  56  uses a buffered, zero-phase pulse  54  transmitted from zero phase probe  84  as a once-per-shaft revolution timing signal reference to generate time-dependent vibration analysis data. 
     As illustrated in  FIGS. 8 and 10 , the microcomputer  56  is in electrical connection with a bus  107  through a microcomputer/bus communication  108 . Wherein deflection data is communicated to the bus  107  from the microcomputer  56 . The bus  107 , and in turn the input circuit  20 , is in electrical communication with a communication interface module  140  of the Host Data Manager  110  through a serial digital interface network  109 . The communication interface module  140  of the Host Data Manager  110  is in electrical communication with a touch screen PC, industrial computer,  70  of the Host Data Manager  110  through a communications interface module/touch screen PC communication  143 . 
     Upon query from the Host Data Manager  110 , any or all of this deflection data is delivered via the serial digital network  109  to the Host Data Manager  110 . The serial communications network  109  comprises at least one serial communications port  60  in communication with an RS-485 connection  78 , wherein each at least one serial communications port  60  is in electrical communication with the RS-485 connection  78  through a connection extension  145 , wherein the extension connection  145  is a continuation of the RS-485 connection  78 . The at least one serial communications port  60  is buffered with a transceiver chip. The serial communications port  60  is in electrical communication with the bus  107 . Wherein the serial communications port  60  receives queries from the Host Data manager  110  and transmits the deflection analysis requested to the Host Data Manager  110  by way of at least one of the connection extension  145  and the RS-485 connection  78 . The Host Data Manager  110  automatically polls the deflection data from each probe sensor  20  in less than 0.0417 seconds, and stacks the deflection data from multiple probe sensors  20  into one message that is provided to the touch screen PC, industrial computer,  70  at a rate of once per second. The touch screen PC, industrial computer,  70  is equipped with software to provide graphical data displays, diagnostics, and alarms. The data sets from all probes are combined by the communication interface module  140  and sent to the touch screen PC, industrial computer,  70 . 
     As best shown in  FIG. 10 , multiple probe/input circuit assemblies  10 , the probe sensor  12  and the input circuit  20 , can be used together in a network to provide vibration analysis at a variety of locations along a large test object, rotor,  14 , such as a large tandem compound turbine-generator. Zero-phase probe  84  provides a timing reference for deflection analysis performed by the input circuit  20 . The wiring connection between the probe sensor  12  and input circuit  20  is preferably protected by flexible, armored cable  82  to provide strain relief and adjustable probe sensor  12  placement. Each probe sensor  12  and input circuit  20  of each probe/input circuit assembly  10  is paired with a redundant assembly  112 . Wherein there is a primary assembly  116  and a redundant assembly  112  in a paired assembly  114 . There is at least one paired assemblies  114  measuring the test object, rotor,  14 . It is noted the primary assembly  116  and the redundant assembly  112  of the paired assemblies  114  are located substantially at the same location along a test object length  118 , and positioned at a different radial location about a circumference  120  of the test object, rotor,  14 . Wherein the primary assembly  116  is located at a first radial location  122  about the circumference  120  and the redundant assembly  112  is located at a second radial location  124  about the circumference  120 . It is noted the components of the primary assembly  116  and the redundant assembly  112  incorporate the elements as described in the probe/input circuit assembly  10 , which include the probe sensor  12 , input circuit  20 , and elements of the probe sensor  12  and elements of the input circuit  20 . 
     The input circuit  20  of at least one of the primary assembly  116  and the redundant assembly  112  of each paired assemblies  114  communicates with communication interface module  140  of the Host Data Manager  110  via the RS-485 connection  78 . The communication interface module  140  of the Data Host manager  110  requests and reads polling data much faster than a typical computer USB port. So the use of the communication interface module  140 , which stacks all data into one, once per second message, as an intermediary between the input circuits  20  and the touch screen PC, industrial computer,  70 , allows up to  32  probes to be used in a single network. Communication interface modules  140  may be employed to raise probe counts of a system in quantities of thirty-two each. The high volume of probe sensors and deflection data gives the user an incredibly accurate sampling of deflection phenomena. 
     In the event that at least one of the probe  20  and microcomputer  56  of the primary assembly  116  fails to respond to the Host Data Manager  110  polling data query or receives a failure notice from the microcomputer  56 , the redundant assembly  112  of the paired assemblies  114  is polled by the Data Host Manager  110  for deflection data. This eliminates loss of function for a single probe or analyzer failure. 
     As illustrated in  FIG. 10 , the probe sensors  12  of the primary assembly  116  and the redundant assembly  112  are rigidly mounted and located along the test object length  118  in order to maximize model deflection. Thus the probe sensors  12  of the primary assembly  116  and the redundant assembly  112  are distant from the support bearings  153  along the test object length  118 . 
     As illustrated in  FIGS. 10, 11, 12 and 13 , the deflection data gathered by the communication interface module  140  of the Host Data Manager  110  is sent to the touch screen PC, industrial computer,  70  through the communications interface module/touch screen PC communication  143 . The touch screen PC, industrial computer,  70  performs a modal analysis for each test object, rotor,  14  using the deflection data sets of the test object, rotor,  14 . Each rotor end pair of probe data (or redundant spares) is used for the rotor deflection analysis. 
     As illustrated in  FIG. 11 , the modal analysis proceeds as follows. The running speed amplitude and phase vectors (combined as  126 ) from the primary assembly  116  and redundant assembly  112  of each paired assembly  114  are summed to yield the Static Resultant  128 . The original running speed amplitude and phase vectors (combined as  126 ) have one-half of the Static Resultant  128  magnitudes subtracted, opposite a Static Resultant phase  133 , from running speed amplitude and phase vectors (combined as  126 ) to establish dynamic resultants, DR 1  and DR 2 ,  132 . 
     The Static Resultant  128  identifies a 1 st  Mode Magnitude and Phase  127  at the probe sensor  12  finite elements (not illustrated in the figures). A 1st Mode full rotor span deflection is calculated using extrapolation of the rotor end probe sensor  12  longitudinal locations  134  along the test object length  118  and amplitudes to a full set of 100 finite elements between the rotor support bearing  153  centerlines utilizing a 1st Mode deflection curve  135  established based upon the particular rotor bearing span and stiffness. The curve is a 3rd-order polynomial.  FIG. 12  illustrates a typical 1st Mode plot. 
     The Dynamic Resultants  132  identify a 2 nd  Mode Magnitude and Phase  129  at the probe sensor  12  finite elements (not illustrated in the figures). A 2 nd  Mode full rotor span deflection is calculated using extrapolation of the rotor end probe sensor  12  longitudinal locations  134  along the test object length  118  and amplitudes to a full set of 100 finite elements between the rotor support bearing  153  centerlines utilizing a 2nd Mode deflection curve  137  established based upon the particular rotor bearing span and stiffness. The curve is also a 3rd-order polynomial.  FIG. 13  illustrates a typical 2nd Mode plot. 
     A combined 1st Mode and 2nd Mode rotor deflection curve  139  (see  FIG. 14 ) is calculated by one-half the vector sum of the 1st Mode deflection curve  135  and the 2nd Mode deflection curve  137  at each of the 100 finite elements. 
     A seal clearance array of values at the same finite element rotor end probe sensor  12  longitudinal locations  134  along the test object length  118  used for the deflection curve generation is pre-assigned to touch screen PC, industrial computer,  70  memory. The source of the seal clearance array of values is the seal clearances measured at a last turbine overhaul inspection. 
     Due to the 0.0001 inch vector accuracy of the deflection data, the system may also calculate optimum balance weight installations in test objects, rotors,  14  to minimize operation test object, rotor,  14  deflection. 
     As previously noted, the touch screen PC, industrial computer,  70  computes 1 st , as illustrated by the 1st Mode deflection curve  135 , and 2 nd  modal deflection phases and magnitudes, as illustrated by the 2nd Mode deflection curve  137 , of the test objects, rotors,  14 . The touch screen PC, industrial computer,  70  further computes the 1 st  and 2 nd  modal deflection over a set of finite elements over the test object length  128  between support bearings  153 , as illustrated by the combined 1st Mode and 2nd Mode rotor deflection curve  139 . 
     As illustrated in  FIG. 14 , the touch screen PC, industrial computer,  70  compares the combined 1 st  and 2 nd  modal element set of combined deflections, as illustrated by the combined 1st Mode and 2nd Mode rotor deflection curve  139 , to internal seal clearances of the test objects, rotors,  14  at the longitudinal locations  134  of the finite elements, and provides warning to operators when the deflection is impeding contact with the turbine seals of the test object, rotor,  14  at the 100 finite element longitudinal locations along the test object length  128 . If the deflection  138  has consumed 75% of the clearance distance  136  to a clearance limit value  155  at any elements an advisory alarm is generated to caution operators. A second notice is produced if the deflection  138  has consumed 90% of the clearance distance  136  the clearance limit value  155  at any elements. Specifically, the system  2  provides warnings to minimize test object, rotor,  14  contact with stationary seals and rotating seal contact with stationary lands. 
     As illustrated in  FIG. 10 , the touch screen PC, industrial computer,  70  outputs a condensed serial data stream for each probe/input circuit assembly  10  to the Communications Interface Module  140  of the Host Data Manager  110  which maintains a data update with a plant computer or Distributed Control System (DCS)  88  through a Plant computer/Data host manager interface  80  to inform operators. Notices, as described, are displayed on the touch screen PC, industrial computer,  70  and are used by operators to avoid a continuing startup of the turbines through the rotor critical speeds which maximize rotor deflection, by slow rolling the test object, rotors,  14  to reduce deflection. 
     The microcomputer  56  also generates diagnostic data such as probe signal loss, carrier frequency loss, and demodulator power loss. Said diagnostic data is sent to the Data Host manager  110  prior to any deflection data to prevent the Data Host Manager  110  from interpreting these events as deflection phenomena in the industrial machine being monitored. This prevents false emergency shutdowns of the monitored machine. Said diagnostic data is delivered via the same serial digital network  109  as said deflection data. By utilizing a polled digital serial data stream, the present system prevents the possibility of introducing transmission noise prior to deflection analysis. 
     As shown in  FIG. 8 , further configuration can be performed by manually toggling a pair of eight-position Dual in-line Package (DIP) switches  64  and  66  which connect to two eight-bit microcomputer ports  68 . DIP switches  64  and  66  provide direct manual configuration of the microcomputer  56  by the user. DIP switch  64  provides manual assignment of the engineering units desired for the deflection data output and also provides manual assignment of the direction of shaft rotation. The second DIP switch  66  provides manual input of the serial network drop code and transceiver drop code. 
     An intended benefit of the present invention is a monitoring system testing rotor deflection to ensure the turbine rotor contact with stationary seals is minimized and rotating seal contact with stationary lands is minimized. 
     An intended benefit of the present invention is a monitoring system testing rotor deflection which measures a large area of the test object minimizing the effect of surface anomalies. 
     An intended benefit of the present invention is a monitoring system testing rotor deflection system having a design which minimizes thermal noise levels. 
     An intended benefit of the present invention is a monitoring system testing rotor deflection system which is self-calibrating. 
     The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.