G e i s l i n g e r M o n i to r i n g
CO U P L I N G S A N D D A M P E R S . B U I LT TO L A S T.
Geislinger Monitoring Contents
page
Description 3
Miscellaneous 12
Applications 15
Examples 17
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Description
Introduction
The Geislinger Monitoring is an instrument designed to continuously monitor the torsional vibration
amplitudes. The system gives an alarm signal when safety limits are reached or exceeded. Additional the
Geislinger Monitoring indicates engine speed and operating hours. Measurements of torsional vibration
amplitudes and output of analyzed results to a PC can also be done.
Components
The Geislinger Monitoring consists of three main components:
• Digital Sensors
• Junction-box
• System Unit
Fig.1 General Arrangement of Components
System Unit
Digital Sensor elastic steel
spring blades
outer
part
Junction-box
inner
part
Section view of a Geislinger damper
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Description
Digital Sensors
The measurement is usually realized with digital sensors of inductive type which are mounted in a fixed
position and measure against rotating wheels with teeth. If no such wheels are available, the use of angle
encoders is also possible.
Junction-box
At the Junction-box the cables from the sensors are united to a single cable which leads to the System Unit.
The signals from the sensors are converted and transmitted to the System Unit.
System Unit
The System Unit contains a LCD-display, three alarm lamps, four push buttons and a printed circuit board
equipped with a microprocessor which calculates primarily the phase velocity of rotating elements. By means
of measurements taken on one or two torsionally vibrating elements, for instance on a coupling or damper, the
values of the static and dynamic twist between the elements and the vibratory angle of the elements are
calculated.
The calculated torsional vibration values and other parameters are shown on the LCD-display as a graph or
as FFT analyzed values.
The power supply for the Geislinger Monitoring and the alarm outputs (relay and analog outputs) for a Ship
Control System are at the back of the System Unit. A serial communication port RS232 for measurements and
programming is also included in the System Unit.
Cabling
The cable between System Unit and Junction-box can be supplied by Geislinger. The cable delivered by
Geislinger meets the requests of DIN 89159 and is approved for use in ship-building by many classification
societys (e.g. German Lloyd, Lloyd’s Register, ABS, BV, DNV).
All other cables have to be supplied by the customer. There are no special requirements for these cables. We
suggest to use cables with a square of minimum 0.75 mm2.
General arrangement of the components
The sensors are equipped only with short cables to avoid disturbances of the signal. Therefore the Junction-
box has to be placed close to the sensors (max. distance = 1.7m). The Junction-box can be mounted directly
to the Engine or Damper-housing by welding the mounting plate to the Engine or Damper housing and
screwing the Junction-box on the plate.
The System Unit is normally placed in the Engine Control room. For dimensions of installation openings and
fixing holes see ‘Technical Data’.
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Description
Advantages
• Optimal operation of the engine due to early detection of problems.
• Monitoring of a damper/coupling is very useful to determine the exact condition of the damper/coupling
before an engine overhaul or drydocking.
If the measurements show that the damper/coupling is working properly, it can be justified against the
classification society, that no overhaul is necessary. In the rare case of a spare part need, they can be
ordered in time.
• Reduced time during drydock or engine overhaul.
• Increased service life of the monitored installation.
• Longer inspection intervals.
• Reduction of maintenance costs.
• Geislinger after sales service.
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Description
Description of Display and Buttons
The System Unit has 4 push-buttons and 3 LED’s at the right side.
Fig.2 Front of System Unit
select
Push-button
up
cancel
down
LED’s
system
alarm
warning
rs 232
LCD-display area cover of serial
communication line
Fig.3 Display Description
monitoring range for
function no. 1 alarms
monitoring
function no. 2
range for
monitoring messages
function no. 3
engine speed operating hour counter
values in decimal format:
3.50 = 3 hours 30 minutes
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Description
Detailed Description of a Monitoring Function
Fig.4 Description of a Monitoring Function
number of name of
monitoring monitoring
function function
minimum bar graph maximum actual value
value value (unit is
for bar for bar milliradian)
indication indication
WARNING WARNING ALARM
LOW limit HIGH limit limit
(if defined)
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Description
Features
In the following section some features of the
Geislinger Monitoring Mark3 are described.
Waveform
Shows the torsional vibration signal for each
programmed application for one revolution.
Fig.5 Waveform Graphics
Fourier
Shows the amplitude of the different orders for
each application after a FFT (Fast Fourier
Transformation) analysis.
Fig. 6 Fourier Graphics
Infos Sub-menus
contain general information about the
programmed monitoring functions and current
serial communication line settings. The
programmed alarm curves are also shown in
graphical mode.
Fig. 7 Programmed Alarmcurves
Serial communication line RS232 for connecting the Geislinger
Monitoring to a PC
The Geislinger Monitoring is equipped with a standard RS232 communication interface. Therefore it is
possible to transmit measured and analyzed values to a PC for further calculations. At the PC the values can
be recorded with a simple terminal program which is for example included in Microsoft Windows. The
evaluation of the recorded values can be done by a standard spreadsheet like Microsoft Excel.
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Description
Normal Operation
The Geislinger Monitoring is starting up automatically after electrical power is connected. During operation the
readings are taken from the sensors and processed simultaneously. The computed values of the monitoring
functions are shown both as numbers and graphically in a bar graph on the display.
Depending on the engine speed the system reads the appropriate limits from the memory and compares
these values with the computed values for exceedings of limits. The limiting values are also shown within the
bar graph. If a value is over a warning or alarm limit the following happens:
• You can see a message at the right side of the display at which monitoring function the warning
respectively alarm occured.
• The corresponding relay output is opened.
• The corresponding LED is shining.
For further details concerning alarm definition see ‘Alarm Definition’.
Standard Monitoring Functions
Free end total
This monitoring function shows the synthesis of the vibratory angle at the free end of the crankshaft. This
indicates how balanced the engine is running. Reduced power or breakdown of a cylinder or misfiring of a
cylinder increases the vibratory angle at the free end of the crankshaft. For this monitoring function the sensor
signal directly from the crankshaft resp. damper inner part is used (damper inner part is bolted to the
crankshaft).
Free end filtered
This application calculates the vibratory angle of a single order or a range of orders out of the synthesis of the
vibratory angle at the free end of the crankshaft. In many propulsion systems only a specific order, or a range
of orders is responsible for critical shaft, crankshaft or intermediate shaft stresses caused by torsional
vibrations. Monitoring the amplitude of this order is a proper method for detection of dangerous operating
conditions. For this monitoring function the same sensor signal as in monitoring function ‘Free end total’ is
used.
Damper twist
Shows the vibratory twist angle between damper inner part and damper outer part. This application controls
the damper load. A broken oil supply or heavy wear of the damper springs leads to an increased vibratory
twist. This will activate an alarm on the Geislinger Monitoring. A blocked damper with no vibratory twist causes
also an alarm, because other parts of the propulsion system (eg. crankshaft, intermediate shaft) are
overloaded if the damper does not work.
Monitoring of the damper is also very useful to determine the exact condition of the damper before an engine
overhaul or drydocking. If the measurements show that the damper is working properly, it can be justified
against the classification society, that no damper overhaul is necessary. In the rare case of a spare part need,
they can be ordered in time.
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Description
Alarm Definition
After the CPU has calculated the vibratory angle or vibratory twist, the results are evaluated against limit
curves. Limit curves are defined as continuous lines with a maximum of 20 supporting points. Each point is
defined by its coordinates. The unit of the x-coordinate is rpm (or the static twist in case of coupling
monitoring), the unit of the the y-coordinate unit is milliradian.
It is possible to monitor only a part of the speed range. The WARNING LOW curve is normally only defined for
monitoring of damper- or coupling-twist. To avoid short term alarms the required number of successively
alarms can be defined before an alarm is really activated. If an alarm is activated, usually a message appears
on the display, a LED on the display is shining and an alarm relay is activated.
For special applications the Geislinger Monitoring can be programmed in a way that warnings or alarms from
certain monitoring functions are not connected to the relay output. Exceedings of the WARNING levels can
occur sometimes due to abnormal engine handling, but should not be the normal condition. Exceeding of
ALARM levels must be strictly avoided.
Fig.8 Alarm Definition
vibratory angle actual limit
or
ALARM curve
for ALARM
vibratory twist
[mrad] WARNING HIGH
actual limit
curve
for WARNING
10
9
8 calculated
7 value
6
5
4 normal operating graph
3
WARNING LOW curve
2
1
speed
[rpm]
30 40 50 60 70 80 90 100 110 120
permissible operating range
not monitored speed range
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Description
Technical Data
Permissible ambient temperature
System Unit 65 °Celsius
Inductive Sensors 100 °Celsius
Power supply
Voltage: 24V DC ± 20%
Maximal current consumption: 1 Ampere
Fuse at back of System Unit 1 Ampere (slow blow)
Electrical protection class IP54
Outputs 4 Relay outputs (max. 24 VDC, 1 Ampere)
2 Analog outputs (0 .. 20 mAmp.)
1 serial communication line RS232
Dimensions and Weights
System Unit: 236 x 165 mm,
approx. 120mm deep (including space for cables at back)
weight: 2.3 kg
Junction-box: 130 x 130 mm (including space for cable glands)
60 mm high
weight: 0.6 kg
Cable between System Unit and Junction-box:
Outer diameter: 12.3 - 14.8 mm
weight: 0.29 kg/metre
Assembly opening for System Unit
Fig. 9 Sytem Unit
assembly opening:
151
218 x 147 mm
222
M4
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Miscellaneous
What are torsional Vibrations?
Torsional vibrations are the result of the pulsing torque of a reciprocating combustion engine and the torsional
elasticity of the shaftline.
All system components like crankshaft, intermediate shaft, propeller shaft and optional couplings and gears
have to transmit the static torque and the additional vibratory torque.
The Geislinger Monitoring monitors the torsional vibrations.
Some torsional Vibration Terms
order ... vibration frequency divided by speed
synthesis ... summary of single orders
FFT ... Fast Fourier Transformation - frequency analyzed vibration
Description of Signal Processing
The sensor which is mounted on a fixed position measures against a rotating toothed wheel, or an angle
encoder mounted on the front end of a wheel or shaft, is supplying a digital signal.
This signal switches from low output to high output when a tooth passes the sensorhead. The measured
signal is the elapsed time (pulse duration) between a tooth and the next tooth (see 10). The measured pulse
duration is proportional to the angular velocity. A microprocessor records the signal of the last ten revolutions.
On demand this sample of ten revolutions is used for further signal processing.
Fig.10 Signal Processing
sensor sensor signal
high
low
t1 t2 t3 t4 t5 t...
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Miscellaneous
A plot of the time over the angle gives a graph as shown in Fig.11. The mean time between two teeth
(constant angular velocity or rpm) can be subtracted.
time Fig.11 Plot of sensor signal
mean time
between
two teeth
t1 t2 t3 t4 t5 t6 t7 t8 t9
angle
To obtain the peaks of the signal, it is necessary to do oversampling (insert additional generic points). Another
necessary step is to calculate from time differences to angle differences by use of the angular velocity.
Fig.12 Signal oversampling
vibratory
angle
generic points
t5’ t6’ t7’ t8’ t9’
angle
t1’ t2’ t3’ t4’
After these calculation steps (result is shown in Fig.12) the signal passes through a bandpass-filter (Fig.13).
The purpose of the bandpass filter is to remove accelerations (caused by the engine speed control system) by
removing low orders (below the first order in case of 2-stroke engines, below the 0.5th order in case of 4-
stroke engines) and to smooth the signal by interpreting the additional inserted points as high frequent
interferences (this is necessary to obtain the exact amplitude of the vibratory angle).
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Miscellaneous
Fig.13 Results of Signal Filtering
Bandpass-filter
order
vibratory
angle
amplitude = (max -min) / 2
max
angle
min
The result of the filtered values is the ±vibratory angle of the synthesis of a specified range of orders (Fig.13)
depending on the filtersettings. The quality of the used filters allows filtering of just one order or half orders.
The last step is to calculate the amplitude by the (maximum-minimum)/2 of the vibratory (twist) angle and
check this value against safety limits. These limits are depending on the engine speed (rpm). For explanation
of Alarm limits see capture Alarm Definition.
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Applications
In the following catalog section the various possible Monitoring applications are described.
Monitoring of Free End
This function calculates from a sensor signal the synthesis of Fig.14 Free end monitoring
all orders of the absolute vibratory angle of a rotating part. Also
a range of orders or a single order can be filtered out. For this
monitoring function only one sensor (inductive sensor or angle
encoder) is used.
Monitoring of free end is used for:
Misfiring Detector
The synthesis of the vibratory angle at the free end of the
crankshaft indicates how balanced the engine is running.
Misfiring of one or more cylinders of a combustion engine will
cause an increase in loads due to torsional vibrations
(increased amplitude of the synthesis of the vibratory angle)
and may result in a damage of certain components.
Shaft, crankshaft stress or
intermediate shaft stress monitoring
In many propulsion systems only a specific order is responsible
for critical shaft, crankshaft or intermediate shaft stresses
caused by torsional vibrations. Monitoring of the amplitude of this order is a proper method for detection of
dangerous operating conditions.
Fig.15 Damper monitoring
Damper Monitoring
Monitoring of the synthesis of the vibratory twist angle
between two rotating parts. The two rotating parts are
combined elastically. For this monitoring function two
sensors are necessary.
From the signal of each sensor the synthesis of all orders
of the absolute vibratory angle is calculated. The
synthesis of the amplitude of the difference between
these values is monitored.
Damper monitoring is manly used for:
Geislinger Damper Monitoring
Monitoring of the vibratory twist angle between damper
inner part and damper outer part is necessary to control
the damper load. A broken oil supply or heavy wear of the damper springs leads to an increased vibratory
twist. This will activate an alarm on Geislinger Monitoring.
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Applications
A blocked damper with no vibratory twist causes also an alarm, because other parts of the propulsion system
(eg. crankshaft, intermediate shaft) are overloaded.
Monitoring of the damper is also very useful to determine the exact condition of the damper before an engine
overhaul or drydocking. If the measurements show that the damper is working properly, it can be justified
against the classification society, that no damper overhaul is necessary. In the rare case of a spare part need,
they can be ordered in time.
Fig.16 Coupling monitoring
Coupling Monitoring
Monitoring of the synthesis of the vibratory
twist angle between two rotating parts with
a static offset (caused by torque) in relation
to this static offset. Based on the measured
static twist, computing of the transmitted
torque and power is possible.
The two rotating parts are combined
elastically. For this monitoring function two
sensors are necessary. Both rotating parts
must have a reference mark (a longer gap
or tooth), which is used to recognize the
static offset. The torsional stiffness of the
monitored part can be entered as a cubic
polynom and is used to caclulate torque
and transmitted power.
Coupling monitoring is manly used for:
Geislinger coupling monitoring
One sensor is mounted on the power input side, the other on the power output side of the coupling. The
Geislinger coupling is equipped with elastically steel spring blades.
Monitoring of the vibratory twist angle between coupling inner part and coupling outer part is necessary to
control the coupling load. A broken oil supply or heavy wear of the coupling springs due to overload leads to
an increased vibratory twist. This will activate an alarm on the Geislinger Monitoring.
A blocked coupling with no vibratory twist causes also an alarm, because other parts of the propulsion system
are overloaded. Monitoring of the coupling is also very useful to determine the exact condition of the coupling
before an engine overhaul or drydocking. If the measurements show that the coupling is working properly, it
can be justified against the classification society, that no coupling overhaul is necessary. In the rare case of a
spare part need, they can be ordered in time.
Shaft Monitoring
Shaft monitoring is similar to coupling monitoring. The only difference is, that the
stiffness of the springs is substituted by the stiffness of the shaft. The accuracy
of the measured torque increases with the distance between the sensors (=length of shaft).
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Examples
Geislinger Monitoring used for Damper Monitoring
Damper type: D 260/17 + Geislinger Monitoring
Damper outer diameter: 2600 mm
Nominal damper twist: 3.5 mrad
Engine type: B&W 12K90MC-C
Engine power: 49 320 kW, 104 rpm
Ship: HYUNDAI ADMIRAL
Yard: Hyundai Heavy Industries, Republic of Korea
This damper is designed to protect the crankshaft and therefore an important part of the Main Engine.
Fig. 17 Example for Damper monitoring
Sensor 2
Sensor 1
damper
inner
part
damper
outer
part
Sensor 1 is mounted near the damper inner part, sensor 2 is mounted near the damper outer part.
This installation is an example for the high accuracy of the Geislinger Monitoring, because the vibratory angles
are very low (damper twist: 3.5 mrad, free end filtered (9th order): 1.75 mrad).
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
Geislinger Monitoring Examples
Geislinger Monitoring used for Coupling Monitoring
Coupling type: BE180/22.5/126U + GFL S112 F8 + Geislinger Monitoring
Coupling outer diameter: 1800 mm
Performance data: 13 000 kW, 308 rpm, torque: 403 kNm
Ships: FENNICA and NORDICA, Multipurpose Icebreakers
Yard: Aker Finnyards, Finnland
The combination of Geislinger Flexlink and Geislinger Coupling is mounted between the electric engine and the
aquamaster. The system is designed to protect the aquamaster unit and to compensate for misalignments
between engine and aquamaster.
Fig. 18 Example for Coupling monitoring
Sensor 2
Sensor 1
Torque-flow
Flange hub Geislinger Flexlink Geislinger Coupling Flange
hub Sensor 2
View A
(View without flange hub)
Geislinger Geislinger
Flexlink Coupling
Sensor 1
Sensor 2 is mounted near the outer part of the Geislinger coupling (input of torque), sensor 1 is mounted near the
inner part of the Geislinger Fexlink coupling (output of torque). Through this arrangement of the sensors both
couplings are monitored.
Geislinger GmbH, A-5300 Hallwang / Salzburg, Austria Monitoring July 2000
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