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Extensive literature is available on diagnosing rolling element bearing defects using vibration analysis. However, answers to many questions remain elusive, such as the effects of rotor weight (load), speed, and damage severity on the vibration signature. SpectraQuest plans to publish a series of articles addressing these issues. This article, first in the series, will cover the effect of rotor weight, speed, and defect severity on outer race fault spectra. SpectraQuests Machinery Fault Simulator (MFS) provides a platform to study bearing faults. The following tests are performed on MB ER-10K bearings with lightly and moderately faulted outer race. To acquire and analyze data, VibraQuest data acquisition and analysis software, SpectraPad portable data acquisition device, and six PCB accelerometers were used.
Test Setup
Test Setup with one loader installed The whole test setup is demonstrated in the picture above. The belt drive is not connected to prevent interference in spectrum. The faulted bearing is installed in the inboard bearing housing. Accelerometers are installed in vertical and horizontal directions on the motor and two bearing housings.
Faulted bearing
Two loaders are installed The above picture shows the configuration with two loaders installed.
SpectraPad Portable Data Acquisition Device All the sensors are connected to the portable SpectraPad, shown above. The SpectraPad communicates with a laptop via PCMCIA.
Test Procedure
1. Mount the lightly faulted bearing in the inboard bearing housing. 2. Mount all the sensors and connect them to the SpectraPad unit. 3. Start VibraQuest software data acquisition panel, and run the MFS with 3 different rotor weights (normal configuration of 2 pound weight with 2 disks, 1 loader of 14 pounds, and 2 loaders totaling of 26 pounds) at 4 different rotating speeds (1000, 1500, 2000, and 4000 RPM). Collect the data while machine runs in a steady state condition. Data is collected for each configuration at a max frequency of 5kHz with 3,200 spectral lines and 32 blocks. 4. Repeat the above steps for moderately faulted bearing.
Typical Spectra
Above is an illustration of typical spectra showing the outer race fault defect for 1000 RPM running speed. Note that there are several harmonics of running speed but the amplitudes are very small and the bearing fault amplitude is even smaller. A very high resolution is needed to detect outer race defects in the presence of third harmonic of running speed. The harmonics can happen due to many reasons, such as small unbalance, bearing clearance, machine non-linearity, etc. The resolution for this graph was 25,600 spectral lines.
100 200 400 800 1,600 3,200 6,400 12,800 25,600 51,200 102,400
50.0000 25.0000 12.5000 6.2500 3.1250 1.5625 0.7813 0.3906 0.1953 0.0977 0.0488
3,000.0000 1,500.0000 750.0000 375.0000 187.5000 93.7500 46.8750 23.4375 11.7188 5.8594 2.9297
Spectral Resolution Needed for Detecting Bearing Faults for MB ER-10K bearing at the Running Speed of 2,004 RPM using a Hanning Window
Notation Fault Frequency Multiplier Fault Frequency (Hz) Harmonics of the Running Speed Harmonic Frequencies (Hz) Delta Frequencies (Hz) Resolution to Detect the Fault Frequencies = Delta Frequencies/4 (Hz)
5 3 2
RPM Harmonics
1 2 3 4 5 6 7 8
33.411
66.823
100.234
133.646
167.057
200.469
233.880
267.291
It can be seen from our table that extremely high resolution is needed to detect bearing faults and the leakages or spectral smearing is eminent in the analysis using conventional FFT Analyzers.
The graph above displays outer race bearing fault very close to third harmonic of RPM. A 25,600 lines of spectral resolution is needed to see the defect. The graph below shows the same data with 6,400 lines of spectral resolution. The fault frequency is between the two cursors and it is not possible to detect bearing defects due to the data smearing and poor resolution.
2.00E-04
1.50E-04
IB rgH IB rgV
1.00E-04
5.00E-05
2 Loaders
1500RPM
7.00E-05 6.00E-05
2.00E-05
1.00E-05
2000RPM
1.60E-04 1.40E-04
1.20E-04
Amplitude (g)
1.00E-04
8.00E-05
IBrgH IBrgV
6.00E-05
4.00E-05
2.00E-05
Loading Condition
4000RPM
4.50E-04 4.00E-04 3.50E-04 3.00E-04
Amplitude (g)
2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00 No loader Inside loader 2 Loaders
IBrgH IBrgV
Loading Condition
Moderately faulted bearing The below four graphs are peak amplitudes of spectra at BPFO in horizontal and vertical direction of the inboard bearing at four different speeds of 1000 RPM, 1500 RPM, 2000 RPM, and 4000 RPM. One cannot see much clear-cut trained in the data there is a scatter in the data. This indicates that rotor weight does not affect the amplitude of the BPFO fault. 1000RP M
2.50E-04
2.00E-04
Amplitude (g)
1.50E-04
IBrgH IBrgV
1.00E-04
5.00E-05
Loading Condition
1500RP M
Amplitude (g)
6.00E-05 5.00E-05 4.00E-05 3.00E-05 2.00E-05 1.00E-05 0.00E+00 No loader Inside loader 2 Loaders
IBrgH IBrgV
RPM
2000RP M
Amplitude (g)
1.20E-04 1.00E-04 8.00E-05 6.00E-05 4.00E-05 2.00E-05 0.00E+00 No loader Inside loader 2 Loaders
IBrgH IBrgV
Loading Condition
4000RP M
4.00E-04
3.50E-04
3.00E-04
Amplitude (g)
2.50E-04
2.00E-04
IBr IBr
1.50E-04
1.00E-04
5.00E-05
Loading Condition
2.00E-04
Amplitude (g)
1.50E-04
1.00E-04
5.00E-05
2000RPM
4000RPM
Inside loader
Amplitude (g)
2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00 1000RPM 1500RPM 2000RPM 4000RPM
IBrgH IBrgV
RPM
2 loader s
3.00E-04
2.50E-04
2.00E-04
Amplitude (g)
1.50E-04
IBrgH IBrgV
1.00E-04
5.00E-05
RPM
Moderately faulted bearing The below three graphs are peak amplitudes of spectra at BPFO in horizontal and vertical direction of the inboard bearing at four different speeds of 1000 RPM, 1500 RPM, 2000 RPM, and 4000 RPM with varying weights. One cannot see much clear-cut trained in the data there is a scatter in the data. This indicates that rotor weight does not affect the amplitude of the BPFO fault. No loader
3.50E-04
3.00E-04
2.50E-04
Amplitude (g)
2.00E-04
IBrgH IBrgV
1.50E-04
1.00E-04
5.00E-05
RPM
Inside loader
4.00E-04
3.50E-04
3.00E-04
Amplitude (g)
2.50E-04
2.00E-04
IBrgH IBrgV
1.50E-04
1.00E-04
5.00E-05
RPM
2 loaders
8.00E-05
IBrgH
IBrgV
2000RPM
4000RPM
Conclusions
The results of the study seem to indicate that BPFO amplitude is not a strong function of speed, rotor weight, and fault severity within the range of this investigation. Using a high resolution, it should be possible to detect BPFO from the spectral analysis. The spectral resolution needed for detection will be a function of speed and type of bearing defect. The severity levels used for the bearing defect in this study were not high, so this study cannot be used conclusively for detecting bearing defect severity. The only focus of this study was to detect the fault using spectrum data. No other parameters such as RMS level, crest factor, or kurtosis, we were used to compare the results. The next study will perform further analysis on the data.