Detecting Bearing Faults Poor installatio cocked bearing Bearing installation 1s very important if a hammer is used to pound bearing into place, the roling ele rents and racenays In the two previous articles (Dec/Jan 2011, Apr/May 2011), the focus has been on how the vi- bration changes when a “typical” bearing fault develops. We have explored spectrum analysis, time waveform analysis, and araft of can be, nd aimost high frequency detection tech- “8 vil, ca niques. Butthereareanumber fon can so cm of fault conditions related to 202 the shat or the raceways via surface (gouging. or scratch ing. Those damaged areas wil cause the ‘ration to change in ways described in the previous wo arts: petiole stess waves fd vibration wall be Getected at the key forcing Frequencies (depending on. the damage inficted on thebedrng) However ithe out- ec race of the bearing ls cacke inthe housing othe inner raceiscackedonthe shaft (a there isan angle Between the outer race and te housing or between the ner ace andthe sha then with time the addtional lad onthe rling tlements and acewaye yl cause excessive wear and premature failure fof the bearing, Butwe cn detect thisstuation so that ican be corrected before damages done! rolling element bearings that not necessarily change the vibration patterns in the ways described thus far. Thus, in this axplore fault con- ditions that relate to poor instal lation (cocked on the shaft or on inthe housing), current flow through the bearing (EDM dam- age), skidding, and slipping. 58 uptime Vibration amplitude wil be higher than normal the ail direction however instead of generating vibration atthe beating defect fequer ‘es (GPF PFO, SF and FT, the bration willbe generated at the speed ‘of rotation, Le 1X The wbration at twice tuning peed (2X) and at ha tonics en also ncreaze in amplitude. Te only problem that vibration atthese frequencies can be elevated for other reasons, including unba- ‘nce, misalignment anda bent shat (Figures | and 2) ‘ue ceases jue tdi thing Phase analysis can aid inthis clagnostc proces. n the case ofthe bearing cocked on the shat, with each rotation you have a wobbier motion Phase analy would revel that as you move an accelerometer {around the face ofthe beaing at diferent clock postions, the phase reading would change accordingly, For example, I the phase reading (compared toa tachometer reference or 2 second acelerometer wat 0 degrees a the 12 otlock poston, the reading would be aporaximatey 90" fr 2/07 at 300, 180° a 6:00, nd 270" (or 90" atthe £00 position, igure3) Ifthe outer races coeked inthe housing, the phase readings will de pend on how itis cocked (Le. which point onthe bearing furthest fomgue Pe hangs seni beaig ‘eden ‘estat ‘he machine fae, and whlch is closest). By moving the accelerometer around safely, he analyst would finda 180" phase dflerence between ‘hose two points. Figure} Fluting or EDM. if curent flows between the inne race and outer race through the roles o bal a fting pattem wil be etched onto the bearing surfaces The patterns quite unusual although very recognizable, as shown inthe Photograph. (Figure 3) Current flow can occurfor varity of easors including poor ground Ing when welding is performed insulation breakdown, brush problems Felten obi peng ag ‘on DC eves, ad other reasons). The faut condition s commen in DC ‘meters and its now increasingly common to see this problem on var able frequency drives ‘Because ofthe “washboard” pattem on the bearing surfaces, a series ‘of peaks Is offen seen clustered together up ina high frequency band, ‘typically between 100,000 CPM and 180,000 CPM. It's balleved thatthe peaks appear inthis range because they are excng a bearing resonance; ‘therefore, where they actually appear wil depend upon the bearing. The _eaks may be separated by BPFO, BP or sometimes BSE; however they fre often not observed in the lower frequencies he, at SPFO, BPH, ee) igure) Bearings: Fluting 100,000 CPx 180,00 cm Aue Sanpete pate wines be i OY cas i ‘Orders Skidding If 3 beating fe crac selected for fs application, the lubiant functioning corecy and theres adequate oad onthe roling elersents, ‘then the ong elements should continuously roll aroun the raceways However, it sot uncommon forthe roling elements to side or std {rom time to time when these contions are ot met. Tiss more com ‘mon on not drive endl Bearings, especilyon vertical machines and fat ‘more commoniy with cyindria roller bearings 3s against deep groove balbearings) In mary eases, when skidding is observed shot of grease may top the bearing rom skideing, but minutes or hous later the skid ding wil resume. n some cases the skidding will ccut when the ma- chines started, or on cols days because the ubvcant is mare viscous ‘There ate actualy 2 umber of situations in which skidding sing, oF smearing ean accu, bt for no the focus is thee the rong elements ‘skal through the unloaded portion ofthe beating (i. opposite the load zone) thinkit goes without saying that skidding is very harmful tothe Dearing The meta-to-netal contact causes excessive wear, and heat I iso generated n more tan one case fre andor explosions have re cued, ‘he vibration pattern wil change when bearing is skdng. The re «ozding must be taken, however, when the skiing is ocuring (which ‘an be intermittent Is commen t0 be able 1 hear a high-pitched “ound from the bearing when skidding occur That should be enough ta get your attention; however, an acceleration time waveform also will ‘how high G levels often above 10 Ge High-Frequency noie"is genet ated which wll excite the bearing resonance (as described when fing ‘occurs: however in his case we may expect tosee.a"hump"in the spec ‘rum ke amountan.tisrotuncemmon fer peaks te emerge out ofthe ‘hump that are separated by BPFO. Ifthe surfaces damaged, peaks may be observe atthe defect fre= {quencies You may netic that the peaks become"smeared"(brosder and ‘Shorta, because the frequency ef vibration isnt consistent. sii 1g and loose fit ‘Another fault condition you may encounter is where the Iner race sides on the shat oF the outer ace slides is the housing, due tas Toose uptime 59Fe ttisnot uncommon toscea 3x peak andharmorics) sein amplitude ‘shen the bearig sling on the salt ad you may also wetness a Increase nthe 0 peak when the bearing is oosein thehousing. Observe thebearing Its highly recommended that you look closely atthe surface of 2 bearing when its removed fom the machine. wil tll you a gteat al out the failure mode All ofthe major esting suppliers oer api: {on notes with images that allow you to recognize the makings on the bearing surfaces helping you to determine the rootause Ma bearings the surfaces ofthe beating will provide teal signs. igure 7), Poses 12209 ATEX Certification 60 upume Using a stroboscope I ve cove of thebeating can besaley removed so thattherling ele Sd skidding alts eandons discussed inthis article you synchronize ‘he swobeto the shaft speed, you should not see relate movement be ‘ween the iner race and the shaft If he seobe i synchronized tothe ‘age requency the cage should appear tobe stationary uness skidding occurs. The relate postion of the outer ace tothe housing should not conclusion Thece area numberof out conditions lated tooling element bear ‘houaht must be oven tthe rot suse of these fault conatons. You precision maintenance practices In the fourth and final article we will fexplorehow vibration analysts can contabute to elabiltyimarovement and acthr overran andthe rai Ingmaterals an preaucs. Jason nas een Invohed nvibeaten cnalssin ne USK ons is ative Astro ince 1984 Beit stating Mo onsaing ond redevelopment of ition DM rontenng sits wnew mabroittate com Lots of people talk about doing “Root Cause ae Ree et ee eee ey examples, we show you how to do it! Pascal Plan Ellse Anais athe iy easoably price. practical seminae foe 3 eilled plane personal Inc we Pant sesions cane om two to ve days and can beheld at you it “Training fom the Relisbility Professionals whe “wrote the book on ‘raetcl file analysis” or more details about falls analy ie selnble@rwcmyer.com 6171 Aieport Road Syracuse, NY 15209