Application Note

Technique description –
Envelope analysis for effective
rolling-element bearing fault
detection. Fact or fiction?
Application Note

Technique description – Envelope analysis

for effective rolling-element bearing fault
detection. Fact or fiction?
ABSTRACT
Envelope analysis has been used for many years for diagnosing rolling-element bearing defects, but
there is still considerable confusion on how it works and how effective it is. This Application Note
intends to clear up this misunderstanding.

Introduction friction, changes in pressure on the

bearing surfaces, or from repetitive
Envelope detection, also impact forces due to local surface
sometimes referred to as defects. That means:
“amplitude demodulation”, is a
well-known signal processing 1. Amplitude modulation of the
technique used within the field of random friction forces, mostly
electronics and due to mounting errors like
telecommunications. radial tension or bearing
misalignment.
During the 1980s, machine
monitoring systems began using
this technique primarily for rolling- 2. Amplitude modulation of Figure 1.A defect in the outer race
element bearing (REB) fault structural resonance excited Causes a shock impulse to spread
detection and diagnostics. As by repetitive periodic impacts. through the bearing components
digital technology evolved and This occurs when there are and machine structure.
made it easier to implement such localised defects on the races
techniques in low-cost, easy-to- or rolling-elements, e.g. in the
use field instruments, envelope case of indentations or cracks. problem) will show up in the
analysis became a very popular envelope spectrum. (Note that they
tool amongst maintenance 3. Amplitude modulation of appear also in the original
personnel. deterministic frequencies spectrum but are more difficult to
(pure tone), i.e. characteristic extract and identify.)
Envelope detection for REB faults frequencies of other machine When applied to REB diagnostics,
utilises the frictional forces elements (gear-mesh the process of envelope analysis
produced by fault-free, rolling- frequency, slot harmonics, can be described as:
element bearings. These forces blade-pass frequency, etc.),
are influenced by surface and by bearing frequencies.
lubrication quality and they • Selecting a frequency range in
generate broadband random Both amplitude modulation due to the vibration spectrum where
stationary vibration. When a fault modulating forces (geometric the amplitude modulation
develops, the vibration becomes faults) and an increase in random occurs and removing all the
amplitude-modulated due to stationary forces caused by components outside of the
periodic changes in the forces. frictional changes (lubrication band. This is under the
This can originate from changes in
Application Note | Technique description – Envelope analysis for effective rolling-element bearing fault detection. Fact or fiction? 2
• assumption that the frequency
components extracted are only
related to bearing faults and not
to other machine faults.

• Rectifying the remaining signal

(carrier) to keep only its
envelope (which represents the
modulation effect) and re-
analysing the latter in a low
frequency range to identify the
modulating frequency.

These are the basic principles of

envelope analysis that are readily
defined and accepted. However,
when it comes to a discussion on
the implementation of envelope
analysis for REB fault detection
and diagnosis, several different Figure 2. Comparison between narrow-band and envelope techniques. The
narrow-band spectrum (upper) ,taken from a bearing which has a fault in the
opinions emerge. These can be
outer race, shows no sign of the fault. The lower display shows an envelope
basically classified into four signal of the same signal.
groups:

• Envelope analysis works, but faults are of interest, and envelope visible as well as a broadband
only selectively on the high- analysis should therefore be used increase in the original FFT
frequency structural resonance. selectively on the high-frequency spectrum itself.
structural resonance (see This approach is the one most
• Envelope analysis works, but ‘Introduction’ point 2). By selecting commonly used in the field.
only selectively outside of the the high-frequency resonance, it Regular condition monitoring
structural resonance, where the makes in easier to avoid techniques are used to highlight
spectrum is flat. interferences from other vibration suspected resonance excitation
sources (e.g. gear-mesh, blade- caused by a local bearing problem
• Envelope analysis works, pass, electrical forces, etc.) and and then envelope analysis is used
without being selective, on a their own modulating effects. to pinpoint the source of the
broad middle frequency range problem.
A disadvantage of this approach is
• Envelope analysis does not that the system is made much less
work. sensitive to random, friction-force Selective envelope
modulation caused, for example, detection outside of the
by uneven radial tension, structural resonance
Selective envelope misalignment or race slip. The
detection around high- argument to counter this is that
In another approach, contrary to
frequency structural other sources of friction-force
modulation, other than those the previous one, envelope
resonance analysis is performed outside of
produced by impacts, are readily
visible in the low-frequency part of the resonance area where the
This approach is based upon the the original FFT spectrum. spectrum is relatively flat. The
belief that only localised REB Lubrication problems – without argument for this is that any
modulation effect – are clearly

Application Note | Technique description – Envelope analysis for effective rolling-element bearing fault detection. Fact or fiction? 3
distortion produced by the
structural resonance is avoided,
allowing one to get a ‘true’
representation of the forces and
their modulation. Consequently, all
types of faults can be ‘quantified’
with indicators such as ‘modulation
depth’ (difference between an
harmonic level and the noise
carpet level), and the harmonic
content of the envelope spectra.

This is a very attractive approach

even if it would seem difficult in
such a complex structure as the
body of a machine to identify a
Figure 3. Envelope spectra from a healthy (upper) and a damaged
frequency range without either (lower) bearing, showing how the envelope spectrum only displays
resonance or anti-resonance peaks if a fault is present.
components. However, it has been
successfully used in Russia where
experiments on numerous machine speed. The size of the cancellation’ to separate such
bearings have yielded methods of bearing does depend upon it and effects.
distinguishing between different therefore the resonance
types of faults and their severity. subsequently depends on the size Envelope detection – Best
of bearing.
avoided!
Broadband envelope
The advantage of using the natural
detection frequencies of the bearing As the popularity of envelope
elements is that they are equally analysis has increased, so has the
Whereas the first two methods excited/influenced by random-force ambition level of its practitioners.
require measurement data to modulation and impact-force Scalar descriptors have been
pinpoint the location of structural modulation, as opposed to the high derived from the envelope spectra,
resonances, the third approach structural resonance frequencies, simplifying the trending of the
does not. which are more sensitive to phenomena. Empirical algorithms
impacts. The main disadvantage based upon statistical data have
A default ‘middle-frequency range’ however is that this middle- also been developed in an attempt
is selected, typically starting from frequency range happens to be to derive absolute limits. In an
above 4 to 5 times the highest where all the other machine attempt to eliminate the need for
REB frequency and going up to 5 components have their trending altogether, specific
kHz. In theory this broadband will characteristic frequencies – e.g. descriptors have been used for a
cover the range corresponding to gear-mesh frequency and ‘single-shot’ assessment of REB
the natural resonance frequencies harmonic, blade-pass frequency, condition.
of the rolling-element bearings and slot-passing frequency – and these
hence will detect most bearing are in turn amplitude-modulated by But these are giant leaps! The
faults. The selected frequency neighbouring elements including nature of the signal transmission
range is dependent upon the the bearing frequencies. However, path, the differences found
machine speed; This is not there are investigations into the amongst machines of the same
because the bearing’s natural use of additional signal processing type and the very nature of the
frequencies depend upon the such as ‘self-adaptive noise processing technique used make it
fundamentally difficult to quantify

Application Note | Technique description – Envelope analysis for effective rolling-element bearing fault detection. Fact or fiction? 4
the default with a representative Conclusion But why carry around a complete
absolute value. Even if the nature toolbox if you are going to use only
of the transmission path did not one tool? It is always
complicate the interpretation, the Every good tool has its uses and recommended to use envelope
natures of the faults themselves its special place amongst the other analysis as part of an overall
make maintenance decisions tools in your toolbox. As a good maintenance strategy together with
difficult. For example, which is tool, envelope analysis is no other signal processing
more dangerous: A large different. Based upon the techniques, especially if a decision
indentation or a small transverse evaluation of amplitude modulation to shut down critical machinery is
crack in the race? The first of random vibration and structural involved. FFT spectrum should be
produces more modulating energy resonance, there is no doubt that considered because it shows the
but can run for a long time envelope analysis is an efficient entire original signal, while
provided there is adequate way to detect, diagnoses and Cepstrum analysis, a purely linear
lubrication; the second can cause assess the condition of a rolling- transformation, can be used to
a collapse at any moment! element bearing. separate effects due to the
Envelope analysis also has a transmission path from those due
The consequences of such much broader field of application if to exciting forces. It is even
investigations have been profound. one considers that its main benefit possible to determine the size of
Faulty diagnoses and consequent is to ‘shift’ the high-frequency the cavity or a spalling, which is
errors in judgement have seriously modulation effect into the low- more related to the severity of the
undermined envelope analysis and frequency range. It therefore fault than the extent of the
alienated the technique further removes the need for an extremely modulation.
from the sceptics. This unfortunate high resolution that is often
situation has been further muddled incompatible with the lack of speed Finally can one conclude what is
by the issue of displacement stability encountered in rotating the correct approach to envelope
sensors vs. acceleration sensors. machines. Amplitude demodulation analysis? In the end, since no
of pure-tone components is an article, conference paper or theory
Some of the major arguments for indicator of fault identification. can replace years of successful
the validity of the demodulation Some examples of this are monitoring experience with
technique are in fact more based modulation of the slot harmonics in envelope analysis, there can only
upon a preference for shaft electrical machines by the slip be one approach – try it and see
displacement measurements than frequency, the gear-meshing the results for yourself!
for acceleration sensor-based frequency by one of the gears, or
vibration measurements. However, modulation of the blade-passing
there is absolutely no foundation frequency by the rotating speed.
for this, since signals from
displacement sensors do not show In addition, the use of the Hilbert
more of the ‘real thing’ than those transformation on a time signal Brüel & Kjær Vibro GmbH
from acceleration sensors. Both zoomed around the carrier Leydheckerstrasse 10
show symptoms of the faults; the frequency, rather than filtering and 64293 Darmstadt - Germany
changes in the forces acting on the rectifying as is commonly done for Phone: +49 6151 428 0
rotating elements alone, and not the REB fault diagnosis, provides Fax: +49 6151 428 1000
the resulting vibration, give a true not only amplitude- demodulation [email protected]
representation of the fault. but phase-demodulation and www.bkvibro.com
Unfortunately these forces cannot frequency-demodulation as well.
be directly measured. Frequency-demodulation opens up BAN 0024-EN-12
the field of new gearbox fault Date: 14.10.2014
diagnostics and the not very well
known problems of torsion.

Application Note | Technique description – Envelope analysis for effective rolling-element bearing fault detection. Fact or fiction? 5