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Corresponding Author: Mrs. H. Mohamadi Monavar, Flat4- No.336- Alley 26- Shahid Ejaredar Ave.- Sepah Squ. Tehran, Iran
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Outer race malfunction frequency fo=n/2 fr {1-(BD/PD) cos$} Roller malfunction frequency fR=PD/BD fr {1-(BD/PD)2 cos2 $} (3) (2)
The time domain and vibration spectrum analyses are widely accepted for detecting malfunctions in bearings[7]. The frequency domain spectrum is more useful since it also identifies the exact nature of defect in the bearings. MATERIALS AND METHODS An experimental test rig built to predict defects in rolling bearings is shown in Fig. 1. The test rig consists of a shaft with fan at the end of it, which is supported on a bearing. The design incorporated a bearing, damage bearing at driven head of electromotor and a coupling disk system.The bench type model is about 0.42 m in length. The unique feature of the rig is that three independent variable speed motors drive the system. This permits the damaged and undamaged bearing signals to be observed simultaneously. The roller bearing is tested at constant speed of 700,1500 and 2100 rpm with Cylindrical roller bearing type TMZ 6205-2RZ (with outer race and inner race defects), have been used for analysis. The details of the bearings used in the present analysis are given in Table 1.
Two types of bearing defects, namely, inner race and outer race defects were studied. Experimental tests were carried out on two sets of bearings. Initially new bearing (good bearing) was fixed in the test rig and signals were recorded using X-Viber. The good bearing was replaced by defective bearing and signals were recorded for each one of the case separately under the same standard condition. Time domain analysis and vibration spectrum analysis were carried out. Time waveform indicates severity of vibrations for defective bearings and vibration spectrum identifies exact nature of defects in bearings. RESULTS AND DISCUSSION The vibration signals of good bearing and defective bearing is shown in Fig. 2, 3 and 4, respectively. The magnitude of peak to peak time response of good bearing
Fig. 2: Overall vibrations of driven end (DE) of electromotor in good bearing position
Fig. 3: Bearing condition of driven end of electromotor in inner race bad bearing position Fig.1: Photograph of set-up
Table 1: Roller bearing details (TMZ6205-2RZ) Parameter Number of rollers Outer diameter, mm Inner diameter, mm Pitch diameter, mm Roller diameter, mm Contact angle, Value 9 51 27 33 8 0
Fig. 4: Bearing condition of driven end of electromotor in outer race bad bearing position
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of electromotor also that showed mean and standard deviation of overall vibration and bearing condition. Fig. 3, 4 showed the experimental overall frequencies of the damaged bearing at rotating speeds of 500 rpm, respectively. According to the results, the mean of overall vibration and bearing condition had significant different another situation and also healthy condition. Table 3, 4 showed the numerical data at 500 rpm rotating speed of electromotor in inner race bad bearing. In order to assess the clarity in different defects in bearings the spectrum analysis is shown in Fig. 5-7 for good bearing, bearing with inner race defect and bearing with outer race defect. The magnitude of spectrum at various harmonic frequencies for defective bearing is found to be quite distinct in comparison to good bearings. The frequency spectrum of the vibration signal from the inner race defect bearing shows the peaks at 12.5Hz, 25Hz and 37.5Hz. CONCLUSION Trend of overall frequencies and vibration spectrum provide useful information to analyze defects in roller bearings. Trend indicates severity of vibration in defective bearings. Vibration domain spectrum identifies amplitudes corresponding to defect frequencies and enables to predict presence of defects on inner race and outer race of roller bearings. The distinct and different behavior of vibration signals from bearings with inner race defect and outer race defect helps in identifying the defects in roller bearings. REFERENCES 1. Albrecht, P.F., R.M. McCoy and E.L. Owen, 1986. Assessment of the reliability of motors in utility application, IEEE Transactions on Energy Conversation, vol. EC-1, no. 1, March 1986. Lindh, T., 2003. On predictive bearing condition monitoring of induction motors, Ph.D. dissertation, Lappeenranta University of Technology, Isbn 951764-3, Isssn 1456-4491,2003. Henderson, D.S., K. Lothian and J. Priest, 1998. Pc based monitoring IEE/IMechE International Conference on Power Station Maintenance Profitability through Reliability, no. 452, March/ April 1998, pp: 28-31. Li, Y. and C. Zhang, 2004, Dynamic Prognostic Prediction of Defect Propagation on Rolling Element Bearing. Journal of Vibration and Acoustics, Trans of ASME, vol 85, no. 1, pp: 214-220. July 2004.
Table 3: Overall vibrations and bearing condition of driven end of electromotor in inner race bad bearing position Test 1 2 3 4 5 6 Mean Standard Deviation Measuring date mm/s RMS Alarm status BC 06-03-2007 07-03-2007 08-03-2007 09-03-2007 10-03-2007 11-03-2007 3.29 3.00 3.48 2.74 2.58 2.53 2.94 0.39 Warning Warning Warning Ok Ok Ok 0.23 0.40 0.49 0.42 0.44 0.40 0.40 0.09 Alarm status Ok Warning Warning Warning Warning Warning
Table 4: Overall vibrations and bearing condition of driven end of electromotor in outer race bad bearing Test 1 2 3 4 5 6 Mean Standard Deviation Measuring date mm/s RMS Alarm status BC 06-03-2007 07-03-2007 08-03-2007 09-03-2007 10-03-2007 11-03-2007 6.47 9.05 9.23 9.64 8.97 9.52 8.81 1.18 Danger Danger Danger Danger Danger Danger 0.73 1.66 1.57 1.54 1.16 1.43 1.35 0.35 Alarm status Warning Danger Danger Danger Warning Warning
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is found to be in the 0.4 mm/s range in comparison to 3.5 mm/s range for defective bearings. Table 2 have been shown measuring date, mm/s RMS, bearing condition (BC) and alarm status for overall vibration and BC for DE 153
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Igarishi, T. and Hiroyoshi., 1980. Studies on Vibration and Sound of Defective Rolling Bearing. Bulletin JSME, vol 25, no. 204, pp: 994-1001. Chaudhary, A. and N. Tandon, 1998. A Theoretical Model to Predict Vibration Response of Rolling Bearings to Distributed Defects under Radial Load. Journal of Vibration and Acoustics, Transactions of ASME, vil 120, no. 1, pp: 214-220. Taylor, I.J., 1980. Identification of Bearing Defects by S pectral Analysis. Journal of Mechanical Design, Transaction of ASME, Vol. 120: 199-204.
NOTATION BD, PD: roller diameter and pitch diameter, respectively, mm fo, fi, fR: outer race, inner race and roller malfunction frequencies, respectively, Hz fr: rotational frequency, Hz n: number of rollers b: angle of contact
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