OPTIMIZATION OF WAVEFORMER DETECTION

Abstract

A method implemented by a computer processor for configuring a vibration data collection device to acquire machine vibration data from a machine for use in generating a vibration spectrum with amplitude peaks at a variety of fault frequencies indicative of faults in the machine, wherein the machine includes components rotating at a rotational speed, and wherein the method comprises: (a) Determining a maximum frequency of data collection; (b1) Calculating a plurality of spectral error frequencies for several orders of rotational speed and different types of bearing error frequencies; (b2) Sorting the plurality of spectral error frequencies according to the order of frequency; (b3) Determining a minimum frequency separation within the plurality of error frequencies; (c) Determine, based on the maximum frequency and minimum frequency spacing, a number of resolution lines that will allow the identification of all amplitude peaks associated with each of the multitude of error frequencies that can be resolved, given the limitations of the vibration data acquisition device; and (d) Configure the vibration data collection device using the maximum frequency and the number of resolution lines.

Description

AREA

[0001] This invention relates to the field of machine vibration data analysis. More specifically, this invention relates to a system for optimizing the collection of machine vibration data to improve spectral waveform analysis. BACKGROUND

[0002] When collecting machine vibration data for spectral analysis, it is necessary to collect the data over a sufficient frequency range and with sufficient resolution to adequately distinguish between different spectral amplitude peaks, thus enabling the identification of peaks associated with potential machine faults. This requires defining the correct maximum frequency (F max ) and the correct number of resolution lines (N lines ) when configuring the vibration monitoring device that collects the data, such as the Emerson Model AMS 2140 Machinery Health Analyzer.

[0003] Therefore, a process for determining an F max -value and an N lines value is required to be used in configuring a vibration data collector to collect machine vibration data that will be sufficient for use in identifying spectral amplitude peaks associated with machine fault frequencies.

[0004] US 6,549,869 B1 discloses a hand-held device that collects and analyzes test data related to rotating electrical machines, wherein the test data is indicative of one or more operating characteristics of the mechanical equipment.

[0005] Ulrich Klein, Vibration Diagnostic Assessment of Machines and Systems, second edition, Düsseldorf: Stahleisen, 2000, Chapter 4, discloses methods for signal analysis in the acquisition and processing of condition data. SUMMARY

[0006] The above and other needs are met by a process that determines the optimal values ​​for the maximum frequency (F max ) and the number of resolution lines (N lines ) to be used in collecting machine vibration data, to sufficiently distinguish between spectral peaks for identifying faults in machine bearings. The process can be extended to other types of fault frequencies that a machine may exhibit, such as motor fault frequencies, pump / fan fault frequencies, and gear mesh fault frequencies. Embodiments of the process also ensure that the time required to acquire the waveform is optimized. This is particularly useful when collecting data using portable vibration monitoring devices.

[0007] Preferred embodiments provide a computer processor-implemented method for configuring a vibration data collection device to collect machine vibration data for use in generating a vibration spectrum. The vibration spectrum has amplitude peaks at a plurality of fault frequencies indicative of faults in the machine. In one embodiment, the method includes the following steps: (a) determining a maximum frequency of data collection; (b) determining a minimum frequency spacing within the plurality of error frequencies; (c) based on the maximum frequency and the minimum frequency spacing, determining a number of resolution lines that will enable identification of all amplitude peaks associated with each of the plurality of error frequencies that are resolvable given limitations of the vibration data collection device; and (d) Configure the vibration data collection device using the maximum frequency and the number of resolution lines.

[0008] In some embodiments, step (a) of the method includes specifying a number N of harmonics of the rotational speed and a number M of harmonics of the plurality of error frequencies to be included in the vibration spectrum, and determining the maximum frequency based at least in part on the number N.

[0009] In some embodiments, the method includes, prior to steps (a) and (b): - Calculating N number of rotational speed frequencies associated with the N number of harmonics of the rotational speed; and - Calculating M number of fault frequencies associated with the M number of harmonics of the plurality of fault frequencies.

[0010] In these embodiments, step (a) includes determining the maximum frequency based at least in part on a highest frequency of the N number of rotational speed frequencies and the M number of error frequencies, and step (b) includes determining the minimum frequency spacing within the N number of rotational speed frequencies and the M number of error frequencies.

[0011] In some embodiments, step (a) of the method includes: (a1) accessing from a storage device a list of discrete maximum frequency values ​​at which the vibration data collection device is operative; (a2) comparing one or more of the discrete maximum frequency values ​​with the highest frequency of the N number of rotational speed frequencies and the M number of error frequencies; (a3) based on the comparison of step (a2), determining a largest of the discrete maximum frequency values ​​that is less than or equal to the highest frequency of the N number of rotational speed frequencies and the M number of error frequencies; and (a4) Setting the maximum frequency to be equal to the largest of the discrete maximum frequency values ​​determined in step (a3).

[0012] In some embodiments, step (a) of the method also includes: (a5) accessing a storage device to determine a maximum device frequency value at which the vibration data collection device is operable; (a6) comparing the device maximum frequency value with the maximum frequency determined in step (a4); and (a7) if the maximum frequency set in step (a4) is greater than the device maximum frequency value, setting the maximum frequency to be equal to the device maximum frequency value.

[0013] In some embodiments, when the maximum frequency is set to be equal to the device maximum frequency value, the method includes: - determining a number of amplitude peaks associated with unresolved defect frequencies based on the maximum frequency and the number of resolution lines; and - Generate a list of amplitude peaks associated with unresolved error frequencies.

[0014] In some embodiments, step (c) of the method includes calculating Nlines=2×FmaxΔf, where N lines is a calculated number of resolution lines, F max is the maximum frequency and Δf is the minimum frequency spacing.

[0015] In some embodiments, step (c) of the method includes: (c1) accessing from a storage device a list of discrete resolution line count values ​​at which the vibration data collection device is operative; (c2) comparing one or more of the discrete resolution line count values ​​with the calculated number of resolution lines; (c3) based on the comparison of step (c2), determining a largest of the discrete resolution line number values ​​that is less than or equal to the calculated number of resolution lines; and (c4) Setting the number of resolution lines to be equal to the largest of the discrete resolution line number values ​​determined in step (c3).

[0016] In some embodiments, step (c) of the method includes: (c5) accessing a storage device to determine a value of the device's maximum number of resolution lines at which the vibration data collection device is operable; (c6) comparing the value of the device’s maximum number of resolution lines with the number of resolution lines determined in step (c4); and (c7) if the number of resolution lines set in step (c4) is greater than the value of the device maximum number of resolution lines, setting the number of resolution lines to be equal to the value of the device maximum number of resolution lines.

[0017] In some embodiments, when the number of resolution lines is set to be equal to the value of the device maximum number of resolution lines, the method includes: - determining a number of amplitude peaks associated with unresolved defect frequencies based on the maximum frequency and the number of resolution lines; and - Generate a list of amplitude peaks associated with unresolved error frequencies.

[0018] In some embodiments, the method includes determining a minimum waveform data acquisition time that is a shortest time during which the vibration data collection device can acquire vibration data without increasing a number of amplitude peaks associated with unresolved error frequencies.

[0019] In some embodiments, the minimum waveform data acquisition time is calculated according to Tacq=NlinesFmax, where T acq the minimum waveform data acquisition time is N lines is the number of resolution lines and F max is the maximum frequency.

[0020] In some embodiments, the minimum waveform data acquisition time is determined by: (e) Determine a value M lines according to Mlines=Nlines2, where N lines is the number of resolution lines; (f) based on the value M lines and the maximum frequency Determine a temporary value N tmp for the number of amplitude peaks associated with unresolved error frequencies N unres is connected; (g) if N tmp greater than N unres is, then - Setting N lines equal to 2 × M lines and - Determine the minimum waveform data acquisition time T acq according to Tacq=NlinesFmaxand if N tmp not greater than N unres is, then - Setting N lines equal to N lines and - Repeat steps (f) and (g) until N tmp greater than N unres is; and (h) Configure the data collection device using the minimum waveform data acquisition time.

[0021] In some embodiments, the method includes: - Calculate N number of rotational speed frequencies associated with N number of harmonics of the rotational speed; - and calculating M number of error frequencies associated with the M number of harmonics of the plurality of error frequencies; and - Generate a graphical display of the N number of rotational speed frequencies and the M number of error frequencies.

[0022] In some embodiments, the method is performed by a computer processor that is a component of the data collection device.

[0023] In another aspect, the invention provides a computer processor-implemented method for configuring a vibration data collection device to collect machine vibration data from a machine for use in generating a vibration spectrum. A preferred embodiment of the method includes the following steps: (a) determining a maximum frequency of data collection; (b) determining a minimum frequency separation within a plurality of error frequencies; (c) on the basis of the maximum frequency and the minimum frequency spacing, determining a number of resolution lines of the data collection according to Nlines=2×FmaxΔf, where N lines is a calculated number of resolution lines, F max is the maximum frequency and Δf is the minimum frequency spacing; (d) Configuring the vibration data collection device using the maximum frequency and the number of resolution lines; (e) Determining a minimum waveform data acquisition time T acq according to Tacq=NlinesFmax;and (f) Configure the vibration data collection device using the maximum frequency, the number of resolution lines and the minimum waveform data collection time. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Other embodiments of the invention will become apparent upon reference to the detailed description taken in conjunction with the figures, wherein elements are not to scale to more clearly show detail, wherein like reference numerals indicate like elements throughout the several views, and wherein: Fig. 1 illustrates a vibration data collection and analysis system according to an embodiment of the invention; Fig. 2 is a graphical representation of frequencies associated with the rotational speed of a machine and several types of bearing errors, according to one embodiment of the invention; Fig. 3 illustrates a table of non-resolvable peaks and peak frequencies associated with the rotational speed of a machine and several types of bearing errors, according to one embodiment of the invention; Fig. 4 and 5A - 5D a preferred embodiment of a process for determining F max - and N lines -Display settings for optimized acquisition of machine vibration waveform data to be used in detecting bearing faults; Fig. 6A and Fig. 6B illustrates a first example showing differences in the identification of error frequency peaks when using an optimized method of determining F max and N linescompared to using a “rule of thumb” method; Fig. 7A and Fig. 7B illustrates a second example showing differences in the identification of error frequency peaks when using an optimized method of determining F max and N lines compared to using a “rule of thumb” method; Fig. 8A and Fig. 8B illustrates a third example showing differences in the identification of error frequency peaks when using an optimized method of determining F max and N lines compared to using a “rule of thumb” method; DETAILED DESCRIPTION

[0025] As in Fig. 1, a vibration data collection and analysis system 10 includes vibration sensors 16 mounted on a machine 12. The machine 12 includes at least one rotating component 14, such as a shaft supported by bearings B1, B2, and B3. The vibration sensors 16 generate vibration signals representative of the vibration of the machine 12, including vibration components associated with the bearings B1, B2, and B3. The vibration signals are received, conditioned, and converted into digital time waveform data by one or more vibration data collectors, such as a portable vibration analyzer 18 or a continuous online vibration monitoring system 20.The vibration data collectors 18 and 20 include signal conditioning circuitry and analog-to-digital conversion circuitry for conditioning the vibration signals from the sensors 16 and generating the digital time waveform vibration data based thereon.

[0026] In preferred embodiments, the portable vibration analyzer 18 or the continuous online vibration monitoring system 20 includes a processor that performs a Fast Fourier Transform (FFT) on the vibration time waveform data to generate vibration spectral data. The vibration time waveform data and vibration spectral data are preferably stored in a vibration database 22, from which the data is available for analysis by software routines executing on a vibration analysis computer 24. The system 10 preferably includes an instrument parameter library 26 in which lookup tables of instrument setup parameters for various types of vibration data collection devices are stored, such as the maximum values ​​of F max and N lines. In preferred embodiments, the system 10 includes a user interface 28, such as a touchscreen, that allows a user to view measurement results, select specific measurement parameters, and provide other inputs as described herein.

[0027] Prior to collecting vibration data using system 10, a preferred embodiment implements a process that determines optimal values ​​for certain data collection parameters used in configuring vibration data collectors 18 and 20. The process may be performed by a processor comprising a component of the data collection device (such as 18 or 20 in Fig. 1) or which is a component of vibration analysis computer 24. A preferred embodiment of the process first calculates potential bearing fault frequency peaks by specifying the number of harmonics for each type of bearing fault frequency that could be exhibited and setting a maximum frequency based thereon. The process then determines the minimum frequency gap between two peaks. These two pieces of information are used to determine values ​​for the maximum frequency (F max ) and the number of resolution lines (N lines ) as described in more detail below. Once F max and N lines were determined, the frequency resolution of the vibration spectrum is given by Δf=Fmax / Nlines, and the data acquisition time is given by Tacq=Nlines / Fmax.

[0028] To determine F max and N linesA first step is to determine the number of orders for each potential type of bearing failure frequency (rotational speed, inner race roll frequency (BPFI), outer race roll frequency (BPFO), ball spin frequency (BSF), cage frequency (FTF)). The number of orders is typically ten for the rotational speed and seven for the bearing failure frequencies. This determines the maximum frequency required in the spectra, of which F max derived from a set of discrete values. Fig. Figure 2 graphically illustrates the different fault frequencies associated with bearing faults.

[0029] Referring to Fig. 2, the next step is to determine the minimum frequency separation (Δf) between all defect frequencies, except for the case of coincidence of two defect frequencies. The number of spectral resolution lines N calc is then calculated, assuming at least one spectral bin between peaks. N calc is then used to determine the number of resolution lines N lines from a set of discrete values.

[0030] It is understood that the number of bins between spectral peaks can be increased, for example, to account for Hanning window effects.

[0031] Da N lines and F max discrete values ​​that have limited ranges, certain error frequencies that cannot be resolved may be present. Examples of such frequencies are shown in the table of Fig. 3. listed.

[0032] As noted above, the waveform data acquisition time (T acq ) can then be calculated as Tacq=Nlines / Fmax.

[0033] The time T acq can be optimized to minimize data acquisition time without increasing the number of unresolved error frequencies. Optimizing F max

[0034] In the Fig. 2, only a few of the harmonic BPFI and BPFO peaks would be lost if F max is reduced by half. If N lines remains unchanged, reducing F max by half the frequency resolution by a factor of two (i.e., half of Δf). The consequence of this is a doubling of the acquisition time T acq , although more peaks are likely to be resolved due to the smaller Δf.

[0035] Increasing F max , while N linesis kept constant, but reduces the frequency resolution and reduces T acq , in which case fewer peaks may be resolvable. Optimizing N lines

[0036] Increasing N lines , while F max is kept constant, increases the frequency resolution (ie reduces Δf), in which case more peaks can be resolved. However, T acq be increased.

[0037] Reducing N lines , while F max is kept constant, reduces the frequency resolution (ie increases Δf), in which case fewer peaks may be resolvable and T acq is reduced. Optimizing T acq

[0038] Optimizing T acq is important for route-based portable vibration data collectors to optimize total route time. However, it is also important that T acqlong enough to collect usable data for machine diagnostics.

[0039] As shown by the above discussion on optimizing F max and N lines specified, T acq depends on these two values. By setting F max and N lines , can T acq be optimized to produce a route with a total route time that is practical while ensuring that most spectral peaks of interest are resolvable.

[0040] Situations may arise for some machines - especially slow-rotating machines - in which the optimal T acqis too long for route-based portable vibration data collectors, and therefore lower-resolution data is collected. In these situations, higher-resolution data must be collected as soon as there is an indication that a fault may be developing. This is typically not a problem for continuous online vibration data monitoring systems. Rule of thumb method for determining F max and N lines

[0041] A well-known “rule of thumb” method for estimating F max and N lines is defined as follows: - The cage frequency (FTF) of the bearing is estimated as 0.4 × TS, where TS is the rotational speed in Hz. - The spectral frequency resolution Δf is set to FTF6. - F max is set to 70 × TS - Nlines=FmaxΔf - Tacq=NlinesFmax

[0042] For example, if TS = 60 Hz (3600 rpm), then - FTF = 0.4 × TS = 0.4 × 60 Hz = 24 Hz - Δf=FTF6=24Hz6=4Hz - F max = 70 × TS = 70 × 60 = 4200 Hz (fixed to discrete device setting of 4500 Hz) - Nlines=FmaxΔf=4200Hz4Hz=1050 (set to discrete device setting of 1600) - Tacq=NlinesFmax=16004500Hz=0.36seconds

[0043] In Fig. 6A, Fig. 6B, Fig. 7A, Fig. 7B, Fig. 8A and Fig. Examples shown in Figure 8B illustrate differences between the optimized method of determining F max and N lines compared to the “rule of thumb” method. When comparing Fig. 6A with Fig. 6B and Fig. 7A with FIG. B, it should be noted that fewer unresolved peaks result from the optimized approach. When comparing Fig. 8A and Fig. 8B it should be noted that a reduced T acq resulting from the optimized approach. Optimized method for determining F max and N lines

[0044] Fig. Figure 4 illustrates one embodiment of a process for determining F max - and N lines Settings for optimized acquisition of machine vibration waveform data to be used in detecting bearing faults. The initial configuration of the data acquisition device requires setting the bearing fault frequencies (step 102) and the machine reference rotational speed (TS) (step 104). It should be understood that an exact rotational speed is not necessary for this process, as all fault frequencies are proportional to the machine rotational speed.

[0045] The number of orders (harmonics) N to be resolved for the rotational speed and the number of orders (harmonics) M to be resolved for each type of bearing error frequency (BPFI, BPFO, BSF, FTF) are specified (step 106). The number of orders N for the rotational speed is typically set to ten, and the number of orders M for the bearing error frequencies is typically set to seven.

[0046] A maximum value of F max and a value for N lines for data acquisition are then determined for the vibration data collection device (step 108). For F max This first involves executing steps 202-210 of process 200, shown in Fig. 5A, to calculate the spectral error frequencies for only the maximum order (largest values ​​of N and M) of the rotational speed (F TS ) and the different types of bearing error frequencies (F BPFI , F BPFI_­Low , F BPFI_High , FBPFO , F FTF , F BSF , F BSF_Low and F BSF_High ) (step 110) as follows: FTS=N×TS FBPFI=M×TS×BPFI FBPFI_Low=FBPFI−TS FBPFI_High=FBPFI+TS FBPFO=M×TS×BPFO FFTF=M×TS×FTF FBSF=M×TS×BSF FBSF_Low=FBSF−FTF FBSF_High=FBSF+FTF

[0047] The value of F max is originally set to the highest of these calculated error frequencies.

[0048] In step 112 in Fig. 4, a process 400 (shown in Fig. 5C) which has the highest of the calculated values ​​of F max used to determine a discrete value for F max that is compatible with the vibration data collector. As described in Fig. 5C, a lookup table, such as from the device parameter library 26, is accessed, which contains discrete device-compatible values ​​for F maxFor example, the lookup table can list discrete values ​​F dis in the range from a maximum of 80 kHz to a minimum of 10 Hz. In a preferred embodiment, the discrete values ​​F dis sorted in the lookup table in descending order (step 402). The first (highest) F dis -value from the lookup table is selected (step 404) and compared with the highest of the calculated values ​​of F max compared (step 406).

[0049] If the highest of the calculated F max - Values ​​not greater than or equal to the F dis value from the lookup table in step 406, then the next F dis -value is selected from the lookup table (step 408) and compared with the highest of the calculated values ​​of F max compared (step 406). Steps 408 and 406 are repeated until the highest of the calculated F max-Values ​​greater than or equal to the selected F dis value from the lookup table.

[0050] If the highest of the calculated F max - Values ​​greater than or equal to the F dis value from the lookup table in step 406, then F max equal to the selected F dis -value from the lookup table (step 410). F max is then compared with the highest discrete maximum frequency value at which the vibration data collection device can operate (step 412). In a preferred embodiment, this highest discrete maximum frequency value can be accessed from the device parameter library 26. If F max less than or equal to the highest discrete maximum frequency value at which the vibration data collector can operate, then the process returns to step 114 in Fig. 4 (step 416). If F maxgreater than the highest discrete maximum frequency value at which the vibration data collector can operate, then F max set to this highest discrete maximum operating frequency value (step 414) and the process returns to step 114 in Fig. 4 (step 416). The final selected value of F max , as determined by process 400, is used in configuring the vibration data collector.

[0051] Continuing in step 114 in Fig. 4, the spectral error frequencies for several orders of rotational speed and the various types of bearing error frequencies are determined by executing steps 202-210 of the process 200 shown in Fig. 5A, and the error frequency peaks are sorted in ascending order from the lowest to the highest frequency (step 116).

[0052] The minimum frequency separation Δf is then determined between all error frequencies, except when two error frequencies coincide (step 118). The value of Δf is then used to determine an initial N lines -value to be calculated according to Nlines=2×FmaxΔf(step 120).

[0053] In step 122 in Fig. 4, a process 500 (shown in Fig. 5D), which is the N lines value calculated in step 120 is used to obtain a discrete value for N lines that is compatible with the vibration data collector. As described in Fig. 5D, a lookup table, such as from the device parameter library 26, is accessed, which contains discrete device-compatible values ​​for N lines For example, the lookup table can list discrete values ​​N disin the range of a maximum value of 102400 and a minimum value of 100. In a preferred embodiment, the discrete values ​​N dis sorted in the lookup table in descending order (step 502). The first (highest) N dis -value from the lookup table is selected (step 504) and compared with the N lines value calculated in step 120 (step 506).

[0054] If the N lines -value calculated in step 120 is not greater than or equal to the N dis value from the lookup table in step 506, then the next N dis - Value selected from the lookup table (step 508) and with the N lines - value calculated in step 120 (step 506). Steps 508 and 506 are repeated until the N lines -value calculated in step 120 is greater than or equal to the selected N disvalue from the lookup table.

[0055] If the N lines -value calculated in step 120 is greater than or equal to the N dis value from the lookup table in step 506, then N lines equal to the selected N dis -value from the lookup table (step 510). N lines is then calculated with the highest discrete N lines -value at which the vibration data collector can operate (step 512). In a preferred embodiment, this highest discrete N lines -value can be accessed from the device parameter library 26. If N lines less than or equal to the highest discrete N lines value at which the vibration data collector can operate, then the process returns to step 124 in Fig. 4 (step 516). If N lines greater than the highest discrete N lines-value at which the vibration data collector can operate, then N lines to this highest discrete operating N lines value is set (step 514) and the process returns to step 124 in Fig. 4 (step 516). The final selected value of N lines , as determined by process 500, is used in configuring the vibration data collector.

[0056] Da N lines and F max have limited ranges due to data collection device limitations, certain error frequency peaks that cannot be resolved exist. The number of these unresolved spectral error frequency peaks (N unres) is determined (step 124), and their frequencies are listed in a table along with the frequencies of the resolved spectral error frequency peaks (step 128). Unresolved peaks are any pair of peaks that do not have at least one resolution line between them.

[0057] By executing steps 302-312 of process 300 shown in Fig. 5B, a minimum value of N lines which determines the waveform acquisition time T acq minimized without increasing the number of unresolvable spectral peaks (step 126). As in Fig. 5B, an integer value M lines determined according to Mlines=Nlines2(step 302).

[0058] A temporary value for the number of unresolved peaks (Nt mp ) is based on F max and M lines determined (step 304). If N tmp greater than N unresin step 306, then Nlines=2×Mlines(Step 310) and Tacq=NlinesFmax(step 312).

[0059] If N tmp not greater than N unres in step 306, then a new value of N lines on Nlines2 set (step 308) and the process loops back to step 304.

[0060] The final value of T acq , calculated in step 312, is then used in configuring the vibration data collection device.

[0061] The foregoing description of preferred embodiments of this invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described in an effort to provide the best illustrations of the principles of the invention and their practical application, and thereby to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the extent to which they are fairly, legally and equitably entitled.

Claims

[1] A computer processor-implemented method for configuring a vibration data collection device to collect machine vibration data from a machine for use in generating a vibration spectrum having amplitude peaks at a plurality of fault frequencies indicative of faults in the machine, the machine including components rotating at a rotational speed, the method comprising: (a) determining a maximum frequency of data collection; (b1) calculating a plurality of spectral error frequencies for several orders of rotational speed and different types of bearing error frequencies; (b2) sorting the plurality of spectral error frequencies according to the order of frequency; (b3) determining a minimum frequency spacing within the plurality of error frequencies; (c) based on the maximum frequency and the minimum frequency spacing, determining a number of resolution lines that will enable identification of all amplitude peaks associated with each of the plurality of error frequencies that are resolvable given limitations of the vibration data collection device; and (d) Configure the vibration data collection device using the maximum frequency and the number of resolution lines. [2] The method of claim 1, further comprising before steps (a) and (b1): - Calculating N number of rotational speed frequencies associated with the N number of harmonics of the rotational speed; and - Calculating M number of error frequencies associated with the M number of harmonics of the plurality of error frequencies, where Step (a) comprises determining the maximum frequency based at least in part on a highest frequency of the N number of rotational speed frequencies and the M number of error frequencies; and Step (b) comprises determining the minimum frequency separation within the N number of rotational speed frequencies and the M number of error frequencies. [3] The method of claim 2, wherein step (a) further comprises: (a1) accessing from a storage device a list of discrete maximum frequency values ​​at which the vibration data collection device is operative; (a2) comparing one or more of the discrete maximum frequency values ​​with the highest frequency of the N number of rotational speed frequencies and the M number of error frequencies; (a3) based on the comparison of step (a2), determining a largest of the discrete maximum frequency values ​​that is less than or equal to the highest frequency of the N number of rotational speed frequencies and the M number of error frequencies; and (a4) Setting the maximum frequency to be equal to the largest of the discrete maximum frequency values ​​determined in step (a3). [4] The method of claim 3, wherein step (a) further comprises: (a5) accessing a storage device to determine a maximum device frequency value at which the vibration data collection device is operable; (a6) comparing the device maximum frequency value with the maximum frequency determined in step (a4); and (a7) if the maximum frequency set in step (a4) is greater than the device maximum frequency value, setting the maximum frequency to be equal to the device maximum frequency value. [5] The method of claim 4, wherein when the maximum frequency is set to be equal to the device maximum frequency value, the method includes: - determining a number of amplitude peaks associated with unresolved defect frequencies based on the maximum frequency and the number of resolution lines; and - Generate a list of amplitude peaks associated with unresolved error frequencies. [6] The method of claim 1, wherein step (c) comprises calculating Nlines=2×FmaxΔf comprises, where N lines is a calculated number of resolution lines, F max is the maximum frequency and Δf is the minimum frequency spacing. [7] The method of claim 6, wherein step (c) further comprises: (c1) accessing from a storage device a list of discrete resolution line count values ​​at which the vibration data collection device is operative; (c2) comparing one or more of the discrete resolution line count values ​​with the calculated number of resolution lines; (c3) based on the comparison of step (c2), determining a largest of the discrete resolution line number values ​​that is less than or equal to the calculated number of resolution lines; and (c4) Setting the number of resolution lines to be equal to the largest of the discrete resolution line number values ​​determined in step (c3). [8] The method of claim 7, wherein step (c) further comprises: (c5) accessing a storage device to determine a value of the device's maximum number of resolution lines at which the vibration data collection device is operable; (c6) comparing the value of the device’s maximum number of resolution lines with the number of resolution lines determined in step (c4); and (c7) if the number of resolution lines set in step (c4) is greater than the value of the device maximum number of resolution lines, setting the number of resolution lines to be equal to the value of the device maximum number of resolution lines. [9] The method of claim 8, wherein when the number of resolution lines is set to be equal to the value of the device maximum number of resolution lines, the method includes: - determining a number of amplitude peaks associated with unresolved defect frequencies based on the maximum frequency and the number of resolution lines; and - Generate a list of amplitude peaks associated with unresolved error frequencies. [10] The method of claim 1, further comprising determining a minimum waveform data acquisition time that is a shortest time during which the vibration data collection device can acquire vibration data without increasing a number of amplitude peaks associated with unresolved error frequencies. [11] The method of claim 10, wherein the minimum waveform data acquisition time is calculated according to Tacq=NlinesFmax, where T acq the minimum waveform data acquisition time is N lines is the number of resolution lines and F max is the maximum frequency. [12] The method of claim 10, wherein the minimum waveform data acquisition time is determined by: (e) Determine a value M lines according to Mlines=Nlines2, where N lines is the number of resolution lines; (f) based on the value M linesand the maximum frequency Determine a temporary value N tmp for the number of amplitude peaks associated with unresolved error frequencies N unres is connected; (g) if N tmp greater than N unres is, then - Setting N lines equal to 2 × M lines and - Determine the minimum waveform data acquisition time T acq according to Tacq=NlinesFmaxand if N tmp not greater than N unres is, then - Setting N lines even Nlines2 and - Repeat steps (f) and (g) until N tmp greater than N unres is; and (h) Configure the data collection device using the minimum waveform data acquisition time. [13] The method of claim 1, further comprising: - Calculate N number of rotational speed frequencies associated with N number of harmonics of the rotational speed; - and calculating M number of error frequencies associated with the M number of harmonics of the plurality of error frequencies; and - Generate a graphical display of the N number of rotational speed frequencies and the M number of error frequencies. [14] The method of claim 1, wherein the computer processor is a component of the data collection device. [15] A computer processor-implemented method for configuring a vibration data collection device to collect machine vibration data from a machine for use in generating a vibration spectrum having amplitude peaks at a plurality of fault frequencies indicative of faults in the machine, the machine including components rotating at a rotational speed, the method comprising: (a) determining a maximum frequency of data collection; (b1) calculating a plurality of spectral error frequencies for several orders of rotational speed and different types of bearing error frequencies; (b2) sorting the plurality of spectral error frequencies according to the order of frequency; (b3) determining a non-zero minimum frequency separation between any two of the sorted error frequencies; (b) on the basis of the maximum frequency and the minimum frequency spacing, determining a number of resolution lines of the data collection according to Nlines=2×FmaxΔf, where N lines is a calculated number of resolution lines, F max is the maximum frequency and Δf is the minimum frequency spacing; (c) Configuring the vibration data collection device using the maximum frequency and the number of resolution lines; (d) Determining a minimum waveform data acquisition time T acq according to Tacq=NlinesFmax;and (e) Configure the vibration data collection device using the maximum frequency, the number of resolution lines and the minimum waveform data collection time. [16] A computer processor-implemented method for configuring a vibration data collection device to collect machine vibration data from a machine for use in generating a vibration spectrum having amplitude peaks at a plurality of fault frequencies indicative of faults in the machine, the machine including components rotating at a rotational speed, the method comprising: Calculate N number of rotational speed frequencies associated with N number of harmonics of the rotational speed; Calculating M number of error frequencies associated with the M number of harmonics of the plurality of error frequencies, (a) Determining a maximum frequency based on a highest frequency of the N number of rotational speed frequencies and the M number of error frequencies by (a1) accessing from a storage device a list of discrete maximum frequency values ​​at which the vibration data collection device is operative; (a2) comparing one or more of the discrete maximum frequency values ​​with the highest frequency of the N number of rotational speed frequencies and the M number of error frequencies; (a3) based on the comparison of step (a2), determining a largest of the discrete frequency values ​​that is less than or equal to the highest frequency of the N number of rotational speed frequencies of the M number of error frequencies; (a4) setting the maximum frequency to be equal to the largest of the discrete maximum frequency values ​​determined in step (a3); (a5) accessing a storage device to determine a maximum device frequency value at which the vibration data collection device is operable; (a6) comparing the device maximum frequency value with the maximum frequency determined in step (a4); and (a7) if the maximum frequency set in step (a4) is greater than the device maximum frequency value, setting the maximum frequency to be equal to the device maximum frequency value; (b) determining a minimum frequency separation within the N number of rotational speed frequencies and the M number of error frequencies; (c) determining, based on the maximum frequency and the minimum frequency level, a number of resolution lines that will enable identification of all amplitude peaks associated with each of the plurality of error frequencies that are resolvable given limitations of the vibration data collection device; (d) Configuring the vibration data collection device using the maximum frequency and the number of resolution lines; (e) determining a number of amplitude peaks associated with unresolved defect frequencies based on the maximum frequency and the number of resolution lines; and (f) Generate a list of amplitude peaks associated with unresolved error frequencies. [17] A computer processor-implemented method for configuring a vibration data collection device to collect machine vibration data from a machine for use in generating a vibration spectrum having amplitude peaks at a plurality of fault frequencies indicative of faults in the machine, the machine including components rotating at a rotational speed, the method comprising: (a) determining a maximum frequency of data collection; (b) determining a minimum frequency spacing within the plurality of error frequencies; based on the maximum frequency and the minimum frequency spacing, determining a number of resolution lines that will enable identification of all amplitude peaks associated with each of the plurality of error frequencies that are resolvable given limitations of the vibration data collection device; and in step (c) calculating Nlines=2×FmaxΔf comprises; where N lines is a calculated number of resolution lines, F max is the maximum frequency and Δf is the minimum frequency spacing and further containing: (c1) accessing from a storage device a list of discrete resolution line count values ​​at which the vibration data collection device is operative; (c2) comparing one or more of the discrete resolution line count values ​​with the calculated number of resolution lines; (c3) based on the comparison of step (c2), determining a largest of the discrete resolution line number values ​​that is less than or equal to the calculated number of resolution lines; and (c4) Setting the number of resolution lines to be equal to the largest of the discrete resolution line number values ​​determined in step (c3). (c5) accessing a storage device to determine a value of the device's maximum number of resolution lines at which the vibration data collection device is operable; (c6) comparing the value of the device’s maximum number of resolution lines with the number of resolution lines determined in step (c4); and (c7) if the number of resolution lines set in step (c4) is greater than the value of the device maximum number of resolution lines, setting the number of resolution lines so that it is equal to the value of the device maximum number of resolution lines; and (d) Configuring the vibration data collection device using the maximum frequency and the number of resolution lines; (e) determining a number of amplitude peaks associated with unresolved defect frequencies based on the maximum frequency and the number of resolution lines; and (f) Generate a list of amplitude peaks associated with unresolved error frequencies. [18] The method of claim 17, further comprising determining a minimum waveform data acquisition time that is a shortest time during which the vibration data collection device can acquire vibration data without increasing a number of amplitude peaks associated with unresolved error frequencies. [19] A method implemented by a computer processor for configuring a vibration data collection device to collect machine vibration data from a machine for use in generating a vibration spectrum having amplitude peaks at a plurality of fault frequencies indicative of faults in the machine, the machine including components rotating at a rotational speed, the method comprising: (a) determining a maximum frequency of data collection; (b) determining a minimum frequency spacing within the plurality of error frequencies; (c) based on the maximum frequency and the minimum frequency spacing, determining a number of resolution lines that will enable identification of all amplitude peaks associated with each of the plurality of error frequencies that are resolvable given limitations of the vibration data collection device; and (d) Configuring the vibration data collection device using the maximum frequency and the number of resolution lines; (e) determining a minimum waveform data acquisition time, which is a shortest time during which the vibration data acquisition device can acquire vibration data without increasing a number of amplitude peaks associated with unresolved error frequencies, the minimum waveform data acquisition time being determined by: (e1) Determine a value M lines according to Mlines=Nlines2, where N lines is the number of resolution lines; (e2) based on the value M lines and the maximum frequency Determine a temporary value N tmp for the number of amplitude peaks associated with unresolved error frequencies N unres is connected; (e3) if N tmp greater than N unres is, then - Setting N lines equal to 2 × M lines and - Determine the minimum waveform data acquisition time T acq according to Tacq=NlinesFmaxand if N tmp not greater than N unres is, then - Setting N lines even Nlines2 and - Repeat steps (f) and (g) until N tmp greater than N unres and (e4) configuring the data collection device using the minimum waveform data acquisition time.

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