S4B P2

REM 2011
27.09.2011
REM2011
12th International Workshop on Research and Education in Mechatronics
September 15th 16th 2011, Kocaeli, Turkey
Outline of the presentation
VIBRATION ANALYSIS BASED LOCALIZED

BEARING FAULT DIAGNOSIS
UNDER DIFFERENT LOAD CONDITIONS
H.Metin Ertun
Hasan Ocak
Muhammet Merdolu
Samet Bayram
Mesut avu
Kocaeli University
Mechatronics Engineering Department
Sensor Laboratory
Kocaeli, Trkiye
September 16, 2011
Bearings
Motivation
Predictive maintenance, condition monitoring
Theoretical information
Experimental setup
Experimental results
Conclusions
H.M.Ertun
Kocaeli Mechatronics
REM2011
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Bearing
Motivation
Bearing allows the motion of the shafts at the desired direction
Cage
Ring
Ball
Inner race
Bearings are used for almost every machine

that rotates.
Rotational forces are very important for motion
of machines.
Bearings reduce the energy losses by providing
rolling friction instead of sliding friction at the
mechanical and electrical systems.
Bearing basically consist of three parts:

1. Inner race
2. Ball element
3. Outer race
Outer race
H.M.Ertun
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27.09.2011
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Predictive maintenance
Condition monitoring
Predictive maintenance is an important

problem for the machining operations having
roller bearing elements.
If the condition of roller element bearing is
not monitored and diagnosed in time, the
defects occurred on the bearing may lead to
Condition monitoring based on bearing fault

diagnosis is necessary to the rotating
machinery in automation systems.
Bearing faults are widely responsible of
many loss of production and
expense of maintenance in rotational mechanic
components.
catastrophic results on the rotating machining

operations, or
at least they may cause downtime.
H.M.Ertun
The malfunctions are about 40% bearing

sourced.
H.M.Ertun
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Monitoring techniques
The key points of the study

For the detection and diagnosis of bearing faults:
Frequency analysis
Different radial loads
Predictive
maintenance
0.4, 0.6, 0.8 bar
Shaft-bearing mechanism
2400 rpm
Artificially defected bearings:

Vibration analysis
Most frequently
used technique.
Based on the
idea that all
rotating machines
have frequency
spectrum related
to its geometry.
H.M.Ertun
EDM (Electrically Discharge Machining)

0.5 mm (incipient), 1 mm (moderate), 2 mm (severe)
Current analysis
Vibrating machines
consumes more
energy.
This energy appears
at current signals.
Vibration data collected

Accelerometer, DAQ card
Signal processing with MATLAB

Collect, sample, digitize and process on the vibration data
High frequency demodulation technique

Fault frequency components
To determine level of fault and effect of the radial load
H.M.Ertun
REM 2011
27.09.2011
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Theoretical information
f
R
BPFO ( Hz ) N s (1 b cos )
2
dm
Rb
dm
Rb
Roller element bearing

D = 52 mm
dm = 38.95 mm
Rb = 7.895 mm
w = 15 mm
contact angle () = 0
H.M.Ertun
High Frequency Demodulation

Demodulation or envelope analysis involves
three steps:
R
1
BPFI ( Hz ) N . f s (1 (1 b cos ))
2
dm
BPFI ( Hz ) N . f s (1
1-) Band Pass Filtering

2-) Half-wave Rectification
3-) Low Pass Filtering
R
1
(1 b cos ))
2
dm
BPFO:Ball Pass Frequency Outer Race

BPFI : Ball Pass Frequency Inner Race
BSF : Ball Spin Frequency
N : number of balls
fs : revolutions per second of the inner race or the shaft
-1
-2
-3
0.2
0.4
0.6
0.8
1.2
1.4
1.6
1.8
2
5
x 10
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Envelope analysis
FFT of the envelope signal

120
Shock pulses
IR
2*speed
Resonance frequency
FFT Magnitude
80
Band pass filtering

Half wave rectification
2*IR
IR+2*speed
IR-2*speed
3*IR
2*(IR+speed)
40
3*IR-2*speed
2*(IR-speed)
Low pass filtering

0
20
70
120
170
220
270
320
Frequency (Hz)
370
420
470
FFT of the final envelope signal

H.M.Ertun
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27.09.2011
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Experimental setup
Bearing used in the experiments
Bearing shaft mechanism

AC electric motor
NI 6211 DAQ card
Piezotronics
accelerometer
(PCB 352C65)
ORS 6205 polyamide cage groove type radial bearing
Bearing fault
Bearing on the load distribution

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Outer race fault
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For normal bearing

Normal Bearing 0.4bar
400
B=189
350
OR=144
Normal bearing with 0.4 bar radial load
IR=216
300
EXPERIMENTAL RESULTS
Amplitude
250
X: 145
Y: 202.3
200
Fault frequency component: 202 Hz
150
100
Hz=40
50
0
50
100
150
200
Frequency (Hz)
250
300
Normal Bearing 0.6 bar

400
OR=144
B=189
X: 145
Y: 314.4
350
IR=216
300
250
Amplitude
200
150
100
Hz=40
50
0
-1
50
100
150
200
Frequency (Hz)
250
300
Normal Bearing 0.8 bar

400
-2
OR=144
B=189
350
X: 145
Y: 354
300
IR=216
-3
0.2
0.4
0.6
0.8
1.2
1.4
1.6
1.8
Amplitude
250
2
5
200
150
x 10
100
Hz=40
50
H.M.Ertun
15
50
100
150
200
Frequency (Hz)
250
300
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For bearing with 0.5 mm fault (incipient fault)
For bearing with 1 mm fault (moderate fault)
0.5mm Outer Race Fault 0.4 bar
1000
1mm Outer Race Fault 0.4 bar
900
1000
Bearing with 0.5 mm fault under 0.4 bar radial load
B=189
800
OR=144
IR=216
700
900
Amplitude
Bearing with 1 mm fault under 0.4 bar radial load
IR=216
700
X: 145
Y: 323.6
400
300
600
Amplitude
500
200
B=189
OR=144
800
600
X: 146
Y: 465
500
300
200
400
Hz=40
100
50
100
150
200
Frequency (Hz)
250
Hz=40
100
300
50
100
150
200
Frequency (Hz)
250
300

1000
900
1000
800
B=189
OR=144
Amplitude
400
300
200
X: 146
Y: 591
600
500
400
300
Hz=40
100
Hz=40
200
IR=216
700
500
B=189
OR=144
800
X: 145
Y: 501.5
600
Amplitude
900
IR=216
700
50
100
150
200
Frequency (Hz)
250
100
300
50
100
150
200
Frequency (Hz)
250
300

1000
900
OR=144
IR=216
800
700
1000
900
Amplitude
400
Hz=40
500
300
200
100
150
200
Frequency (Hz)
250
300
17
400
100
100
IR=216
600
200
50
B=189
X: 146
Y: 758.7
700
500
300
OR=144
800
X: 145
Y: 718
600
Amplitude
B=189
Hz=40
50
100
150
200
Frequency (Hz)
250
300
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For bearing with 2 mm fault (severe fault)
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The comparisons of fault frequency amplitudes

1000
900
OR=144
B=189
IR=216
800
800
Amplitude
700
600
400
X: 145
Y: 596.1
500
Hz=40
700
300
600
200
Outer race fault with radial load

normal
0.5 mm fault
1 mm fault
2 mm fault
100
50
100
150
200
Frequency (Hz)
250
500
300
Amplitude

1000
OR=144
900
B=189
IR=216
800
Amplitude
300
X: 145
Y: 765.3
700
600
200
500
400
400
Hz=40
100
300
200
100
0
50
100
150
200
Frequency (Hz)
250
300
0.4 bar
0.6 bar
0.8 bar

1000
OR=144
900
IR=216
B=189
800
X: 145
Y: 796.7
Amplitude
700
Fault frequency components
600
500
400
300
Hz=40
as the quantity of fault

and the radial load
200
100
0
50
100
150
200
Frequency (Hz)
250
300
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H.M.Ertun
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27.09.2011
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Conclusions
As bearing fault size and the radial load
increase, the amplitude of the fault frequency
components also increases.
It is possible to determine the level of fault
and loading.
The study presented in this paper can be
extended to vibration based condition
monitoring of more complex systems.
H.M.Ertun
21
H.M.Ertun
22

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REM 2011

Outline of the presentation

VIBRATION ANALYSIS BASED LOCALIZED

Bearing allows the motion of the shafts at the desired direction

Bearings are used for almost every machine

Bearing basically consist of three parts:

Predictive maintenance is an important

Condition monitoring based on bearing fault

catastrophic results on the rotating machining

The malfunctions are about 40% bearing

The key points of the study

0.4, 0.6, 0.8 bar

Artificially defected bearings:

EDM (Electrically Discharge Machining)

Vibration data collected

Signal processing with MATLAB

High frequency demodulation technique

Roller element bearing

High Frequency Demodulation

1-) Band Pass Filtering

BPFO:Ball Pass Frequency Outer Race

FFT of the envelope signal

Band pass filtering

Low pass filtering

FFT of the final envelope signal

Bearing used in the experiments

Bearing shaft mechanism

ORS 6205 polyamide cage groove type radial bearing

Bearing on the load distribution

Outer race fault

For normal bearing

Normal bearing with 0.4 bar radial load

Fault frequency component: 202 Hz

Normal Bearing 0.6 bar

Normal bearing with 0.6 bar radial load

Fault frequency component: 314 Hz

Normal Bearing 0.8 bar

Normal bearing with 0.8 bar radial load

Fault frequency component: 354 Hz

For bearing with 0.5 mm fault (incipient fault)

For bearing with 1 mm fault (moderate fault)

0.5mm Outer Race Fault 0.4 bar

1mm Outer Race Fault 0.4 bar

Bearing with 0.5 mm fault under 0.4 bar radial load

Bearing with 1 mm fault under 0.4 bar radial load

Fault frequency component: 324 Hz

Fault frequency component: 465 Hz

0.5mm Outer Race Fault 0.6 bar

Fault frequency component: 502 Hz

Fault frequency component: 591 Hz

Bearing with 1 mm fault under 0.6 bar radial load

Bearing with 0.5 mm fault under 0.6 bar radial load

0.5mm Outer Race Fault 0.8 bar

Fault frequency component: 718 Hz

Fault frequency component: 759 Hz

Bearing with 1 mm fault under 0.8 bar radial load

1mm Outer Race Fault 0.8 bar

Bearing with 0.5 mm fault under 0.8 bar radial load

For bearing with 2 mm fault (severe fault)

The comparisons of fault frequency amplitudes

2mm Outer Race Fault 0.4 bar

Bearing with 2 mm fault under 0.4 bar radial load

Fault frequency component: 596 Hz