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Bearing Fault Detection Using Vibration Analysis

The document describes an experimental investigation into bearing fault detection using vibration analysis. The aims are to design a test rig to measure bearing vibrations under different speeds and loads, introduce localized defects to bearings, and compare the vibrations of defective and healthy bearings using time and frequency domain analysis. It provides details of the test rig components including a ball bearing, shaft, DC motor, motor drive, and supporting base. Mathematical models are presented to calculate characteristic fault frequencies from bearing geometry and rotations speeds. Empirical models are also provided as approximations when full parameters are unknown.

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Arkit Kabir
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336 views24 pages

Bearing Fault Detection Using Vibration Analysis

The document describes an experimental investigation into bearing fault detection using vibration analysis. The aims are to design a test rig to measure bearing vibrations under different speeds and loads, introduce localized defects to bearings, and compare the vibrations of defective and healthy bearings using time and frequency domain analysis. It provides details of the test rig components including a ball bearing, shaft, DC motor, motor drive, and supporting base. Mathematical models are presented to calculate characteristic fault frequencies from bearing geometry and rotations speeds. Empirical models are also provided as approximations when full parameters are unknown.

Uploaded by

Arkit Kabir
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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EXPERIMENTAL

INVESTIGATION OF BEARING
FAULT DETECTION USING
VIBRATION ANALYSIS

Name Enrollment No.


1. MAHTO RAMESH 160050119039
2. KABIR ARKIT 160050119030
3. CHANDRA ARGHADIP 160050119016
Introduction
 A ball bearing inside a machine is used to provide a high precision
position and load-carrying capacity between a rotating shaft and a
fixed housing.

 This function is aimed to provide a low friction torque, low vibration


and low noise emission.

 The unpredictable failures can cause damaging of expensive


machine components, personal injuries and stopping of expensive
production procedures.
 The research problem in this thesis is monitoring the bearing vibration as
it is extremely essential for giving an understanding of the health
condition of the bearing.

 This research aims at studying the behavior and reasons of failure of one
of bearings types under predetermined conditions .

 Preventive maintenance is done on machinery in order to ensure that the


machine stays in operation.

 This preventive maintenance is initiated based on observed diagnostic


data such as pressure, temperature, vibration level, etc.
Aim and Objectives:-

 To design, manufacture and tune a test rig for measuring the bearing
vibrations under different speeds and loads.

 To find a proper method to seed localized defects inside the bearings.

 To compare the defected bearing vibration response with a healthy


bearing and generate results accordingly using time-domain and
frequency-domain analysis.
Ball Bearings:-
• Ball bearings use balls as rolling elements between two rings.

• Ball bearings can support both radial loads (perpendicular to the shaft) and
axial loads (parallel to the shaft).

• For lightly loaded bearings, balls offer lower friction than rollers. Ball
bearings can operate even when the bearing races are misaligned.

• Ball bearings may have high point loads, limiting total load capacity
compared to other bearings of similar dimensions.

• Here we are using O.D 52mm and I.D 20mm


Shaft:

 A Shaft is a rotating machine element, usually circular in


cross section, which is used to transmit power from one part
to another, or from a machine which produces power to a
machine which absorbs power. The various members such
as pulleys and gears are mounted on it.

 Here, we are using 20 mm diameter shaft of the material


mild steel with 17cm length.

 The density of mild steel is approximately 7.85 g/cm3


(7850 kg/m3) and the Young’s modulus is 200 Gpa.
DC motor & Motor drive:

 For achieving required RPM for the testing at


the critical speed we are using 0.5HP/372W
DC motor.

 Rotomag DC motor is capable to delivering


1500RPM at motor shaft for controlling shaft
speed we use DC Motor drive controller.

 DC Motor drive is mainly used in our project to


change the RPM of the motor to the shaft.
Supporting Base
• Supporting base is designed to reduce external vibrations as much as
possible.
• Mild steel is used as material for base plate
• Its dimensions are 1700 x 150 x 25
Vibration and Noise Generation in
Bearings
• These vibrations are often caused either by varying compliance or
the presence of defects in the bearing.

• Vibration is detected in the rolling element bearings when the


applied load is radially upon them, even if they are aligned and
installed correctly.

• The main reason for these vibrations is due to the finite number of
rolling elements which change its position continuously in the load
zone.
 As the bearing rotates, the rolling elements carrying the load
changes which results in a continuous variation in the total stiffness
of the bearing assembly.

 This phenomenon is known as varying compliance vibrations.

 Apart from normal operation vibrations, the bearing could


experience high levels of vibrations in case of a defect in its body.

 The defects in the bearings can be of the following two types:


1)Localized Defects
2)Distributed Defects
DESIGN OF THE TEST RIG
• The test rig consists of different mechanical parts which provide
different functions:

1)An electric Motor providing the driving function;

2)Through a Flexible Coupling the motor is coupled to the rotating


shaft and the rest of the machine.

3)An accelerometer is mounted on the bearing for the Bearing


vibration measurement function.
Supporting Function:-
The supporting function of the test rig is provided by the following major
four components:

 Shaft
 Housing
 Rotor Disc
 Support base
 Coupling
EXPERIMENTAL SETUP
MATHEMATICAL MODEL
• A faulty rolling bearing usually emit the following main frequencies:-

• FTF – (FUNDAMENTAL TRAIN FREQUENCY)-Frequency emitted by the


faulty cage;
• BPFO -(BALL PASS FREQUENCY OF THE OUTER RACE)-Frequency emitted
by a rolling element bearing when it impacts a superficial defect in outer
race;
• BPFI -(BALL PASS FREQUENCY OF THE INNER RACE)-Frequency emitted by
a rolling element bearing when it impacts a superficial defects in inner
race;
• BSF -(BALL SPIN FREQUENCY)-Frequency emitted when a rolling element
bearing with a superficial defects impacts the inner or outer races;
• The frequency spectrum of a faulty rolling bearing includes not only the
inner or outer races rotation frequencies but also the harmonics
corresponding to the faulty frequencies.
• A faulty rolling bearing produces certain frequencies depending on rolling
element bearing geometry, which is shown in fig.1 & fig.2, number of
rolling elements and shaft speeds.
The cage angular speed is given as follows:-
𝜔=𝑣⁄ r (1)

The outer race angular speed is given by equation,


𝜔=v⁄𝑟 (2)

And the inner race angular speed is given as follows,


𝜔𝑖=𝑣⁄𝑟 (3)

Considering there is no sliding between the rotating parts, the cage linear
speed can be given by,
𝑣={𝑣+𝑣}⁄2={𝜔𝑟+𝜔𝑟}⁄2 (4)
Analysis Fig.2 the following can be achieved,
𝑟=𝐷𝑝⁄2 (5)

𝑟=𝐷𝑝⁄2−𝑑𝑐𝑜𝑠(𝜃)⁄2 (6)

𝑟e=𝐷𝑝⁄2+ 𝑑𝐶𝑂𝑆(𝜃)⁄2 (7)

rr=d/2 (8)

Putting all the results together, the cage angular speed can be given as follows,
𝜔𝑔=1/2[𝑓=(1−ⅆcos(𝜃)/𝐷𝑝)+ (1−acos[𝜃]/𝐷𝑝)]
(9)
This eq., gives the value of the ftf, which can be expressed in (Hz) as follows,
FTF = 𝑓=1/2[𝑓𝑖=(1−𝑑cos(𝜃)/𝐷𝑝)+ 𝑓𝑒(1+acos[𝜃]/𝐷𝑝)]
(10
By other words, these equation provides the cage rotation frequency, which when
appears in the frequency spectrum is related with the unbalanced of rotational
elements – cage and rolling elements due to wear or looseness development. The
defect frequency called BPFO can be evaluated multiplying the number of rolling
elements by the relative angular speed between cage and outer races. Thus; BPFO
can be given as,

BPFO = N ( 𝜔−) (11)

Putting Eq. (9) into (11) the following is obtained,

BPFO =N{1/2[𝑓=(1−𝑑cos(𝜃)/𝐷𝑝)+ 𝑓(1+acos[𝜃]/𝐷𝑝)] -𝑓𝑒} (12)

Through mathematical manipulation Eq.can be written as follows,

BPFO = 𝑁/2⁄(𝑓−𝑓)[1−𝑑cos(𝜃)/𝐷𝑝] (13)

In a similar way the defect frequency quoted above as BPFI can be evaluated multiplying the
number of rolling elements by the relative angular speed between cage and inner race, being
given as follows,
BPFI = N (−) (14)
• Putting equation (9) into (14) and doing some simplifications the following formula
is achieved to evaluate BPFI,
BPFI= 𝑁/2(𝑓𝑖−𝑓𝑒)[1+{dcos[𝜃]/𝐷𝑝}] (15)
• The defect frequency called above as BSF can be defined as the rolling element
frequency rotation, ball or roller, by its own centre. The ball or roller angular speed
in turn its own centre is given as follows,
𝜔r=Vr/rr (16)

• Considering that only a pure rotation exists and there is no sliding, the ball or roller
tangential speed in the contact point with the inner race is given by the following
formula,
𝜔r=(i- g)ri/rr (18)
• Putting equations (6), (8) and (9) into equation (18) the following equation is
achieve to evaluate the defect frequency BSF,
BSF=fr=Dp/2d(fi-fe)[1-{dcos [𝜃]/Dp}^2] (19)
Simplified mathematical model
• Therefore, when the outer race is considered stationary the mathematical
model to compute the values for the defect frequencies can be written as
follows,
• FTF=1/2(fi)(1-dcosθ/Dp)
• BPF =N/2(fi)(1-dcosθ/Dp) (20)
• BPF =N/2(fi)(1+dcosθ/Dp)
• BSF =Dp/2d(fi)[1-(dcosθ/Dp)^2]

•Comparing the above equations (20), the following relationships between them can
be written,

BPFO =N(FTF)
BPFI =N(fi – FTF) (21)

•Therefore, to compute the values of the defect frequencies is compulsory to know


the geometric rolling bearing characteristics.
Empirical mathematical model
• When the contact angle is unknown but the remaining parameters
are known, the mathematical model (20) can be used doing θ=0.
• If in extreme cases the number of parameters known not allows the
use of the mathematical model (20), alternatively, the following
equations, which have been achieved empirically, can be used to
compute approximated values for the frequencies emitted by a
faulty rolling bearing,
FTF =0.4fi
BPFO =0.4Nfi
BPFI =0.6Nfi

The empirical mathematical model is based on the fact that in a complete


rotation of the inner race, about 40% of the rolling elements contact a
defect in the outer race and 60% of the rolling elements contact a defect
in the inner race
COST ESTIMATION
Parts Cost (INR)
1) D.C Motor & vfd 7000/-
controller
2) Coupling 1000/-
3) Shaft 1500/-
4) MS Base Plate 6500/-
5) Machining 2050/-
6) Bearing 300/-
7) Rotor Disk 1500/-
8) Accelerometer(Rent) 7000/-
9) Paint 850/-
10) Total Rs 27,700

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