Demystifying

D
Demodulation
d l ti
for
Rolling Element Bearing Analysis

Dennis Shreve
GE-Bently / Commtest Instruments

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 RollingElementBearingAnalysis
Therearelotsofproductofferings,tools,and
techniquesavailable.
Sometimesjustmakingthechoicescanbea
bitintimidatingandoverwhelming.
Weneedtotakeawaysomeofthemystery.
Weneedtomakethebestofthetechnology.
Wewillnowexaminethehistory,scientific
y,
terminology,andindustryjargon.

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 GettingDowntoBasics
Abearingcarriestheloadbyroundelementsplaced
betweentwopieces.
Relativemotionoftwopiecescausesrolling,withvery
R l i i f i lli ih
littleresistanceorfriction.
Startedwithlogsonthegroundwithastoneblockon
t ! (L
top!(Logatbackwasmovedtofront,sequentially.)
tb k dt f t ti ll )
Rollingelementsinacircularbearingarecaptiveanddo
notfalloutunderload.
Rollingelementbearingsofferagoodtradeoffoncost,
ll l b ff d d ff
size,weight,carryingcapacity,durability,accuracy,low
friction,..andthelistgoeson.

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 WhyDoBearingsFail?

Poordesign.
P d i
Misapplication.
Poorinstallation.
Improper loading.
Improperloading.
Improperstagingandhandling.
P
Poorcareandmaintenance.
d i t
Design Engineering ApplicationEngineering
DesignEngineering Application Engineering Maintenance
Maintenance

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 FactsonBearingLife/Failure

Lessthan10%achievedesignlife.
Less than 10% achieve design life **
16%failduetohandlingandinstallation.
14%failduetocontamination.
36%failduetoinadequatelubrication.
34%failduetofatigueissues(excessiveloading).
Any extra loading (e g misalignment unbalance resonance)
Anyextraloading(e.g.misalignment,unbalance,resonance)
reduceslifebyacubedfunction.
L10=(16,667/RPM)*(ratedload/actualload)3
10%extraloadingcutslifeby1/3
l d lf b /
20%extraloadingcutslifebyhalf!

** Source: SKF Bearing Journals

**Source:SKFBearingJournals.

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 WhatDoWeWishToAccomplish?
Earlydetectionofeventheslightestfault
appearing with the bearing
appearingwiththebearing.
Avoidanceofanydowntimeandsecondary
damage due to bearing failure
damageduetobearingfailure.
Pinpointthefaultycomponentandpossible
cause of the excessive vibration
causeoftheexcessivevibration.
Decideacorrectivecourseofaction.
Followupandverify.
Follow up and verify
FamiliarKeyElements:Detection Analysis Correction Verification

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 VibrationandtheSources
Wecantypicallybreakvibrationdownto4
maincomponents:
Forced vibrationduetounbalance,misalignment,
bladeandvanepass,gearmesh,looseness,
impacts,resonance,etc.
Resonance responseduetoimpacts.
Stress wavesorshockpulses.
Frictional vibration.

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 WhatAreWeLookingFor?
Detectionofaeventheslightestmetaltometal
contactfromimpactingcomponentsorinadequate
l b
lubricationinabearing.
b
Aslightringingcausedbyabearingfaultresonating
anatural frequency
q y inthemachinerysetup.
y p
Presenceofhighfrequency,lowenergyvibration.
Sometimesnotedasraisingthecarpetlevelin
the noise floor in acceleration readings
thenoisefloorinaccelerationreadings
especiallyathighfrequency.
Capabilitytodetectanincipientfailurewithsenses
that transcend normal human abilities sight
thattranscendnormalhumanabilities..sight,
sound,touch,smell,etc.
Note:Itisnotimportantastowhat naturalfrequencyisexcited;themeasurementjust
needstoberepeatable.
d b bl

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 TellTaleSignsinAcceleration

PresenceofverysmallpeaksatHighFrequency!

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 FaultFrequenciesIsntItJustMath?
Yes.JustknowFTFI,BSF,BPFO,andBPFI.
fixedinnerrace

(
(assumesafixedouterrace)
fi d t )

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 ALookatGeometry
Impactsper
Revolution

BallBearings
g Roller Bearings
RollerBearings

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 Fortunately..ItsAllWorkedOut

Note:BPFI+BPFO=Numberof
Elements;typicallya60/40relationship.
(Seedataatleft.11.349+8.651=20
rollingelements.)
g )

Also,sometimesestimatedas:
BPFI=NB/2+1.2
BPFO=NB//2 1.2

NonSynchronousFrequencies

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 WhatAreTheTypicalFailureStages?
STAGE1:
Presenceofultrasonicfrequencies(typicallywell
P f lt i f i (t i ll ll
above5KHz)thatarebarelydetectable.
Verylowamplitudesappearingintheacceleration
Very low amplitudes appearing in the acceleration
measurement.
L10 liferemainingatthispointis1020%
g p
Lubricateandmonitor.

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 TypicalFailureStages?
STAGE2:
Moreringingoccurring,andpresenceof
frequenciesof500HZto5KHz.
Faultfrequenciesshowupwithmodulation
Fault frequencies show up with modulation
(sidebands).
Timewaveformofaccelerationshowsimpacting
Time waveform of acceleration shows impacting
(flattoppedornotched).
L10
10 bearinglifedownto510%
Lubricateandmonitor.

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 TypicalFailureStages?
STAGE3:
Energyspreadsmoredownthespectrum.
Defectfrequenciesbegintobemoreprominent.
Moreharmonicsandsidebandsshowup.
Weartendstoflattenoutpeaksandpatterns.
Bearingtemperatureincreaseisnowapparent.
Itistimetoorderpartsandstartanactionplan!
L10bearinglifeisnow5%orless.

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 TypicalFailureStages?

STAGE
STAGE4:4:
1Xenergybeginstoincreaseasclearanceisquite
noticeable.
Broadbandspectralnoiseisevidentbyaraisednoise
floor.
Failureiseminent!
L10lifehas1%remainingatbest
Replaceimmediately.

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 WhatDoTheExpertsSay?
ultrasonic
impactsandringing
present

CourtesyofTechnicalAssociatesofCharlotte

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 WhatCausesThisVibrationEnergy?
Contactbetweentwometalsurfaces.
Ashock(orpressure)waveiscreated.
( p )
Analogyisthewavesetupbyanearthquakeortsunami.
Aripplefromapebbletossedinapondisanother
example.
Resultingsignalpropagatesthroughthemetalsurfaceswhen
there are no air gaps to filter (good metaltometal
therearenoairgapstofilter(goodmetal to metalcontact).
contact)

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 HowCanWeDetectEarlySigns?
Specialinstrumentationanddetectioncircuits.
Specialsignalprocessing.
Special signal processing
Detectionofsmallspikeswithshortdurationandringing
characteristics.
Asmalltelltalesignalinthepresenceoflotsofnoiseand
higheramplitudes(ahighdynamicrange>95dB).
Accelerometerwithasolidmounting.
Accelerometer with a solid mounting.
Goodmeasurementpractices.
Specialmeasurementfordefectdetection,plusnormal
readingsin3axes.
di i 3

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 HowHaveSolutionsSuppliers
Add
AddressedThisNeed?
d hi d?
Lots
Lotsandlotsofcompetitiveandcomplementary
and lots of competitive and complementary
offerings,somedatingbacktotheearly 70s:
SpikeEnergyandSpikeEnergySpectrum
ESP(EnvelopeSignalProcessing)
HFD(HighFrequencyDetection)
SEE(SpectralEmittedEnergy)
( p gy)
PeakVue
ShockPulse
Stress Waves
StressWaves
Enveloping(orDemodulation)
Cepstrum

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 TheChoices

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 IsThereaCommonThread?
Allmethodsarebasedonafundamental concept:Thereare
repetitiveimpactsinthemachinestructurethatindicatebearing
ii i i h hi h i di b i
faults,geardamage,looseness,cavitations,andsimilarfaults.
Machine/bearingresonances(orsensorresonance)areexcited
by the impacts similartostrikingabell.
bytheimpacts similar to striking a bell
Repetitivefaultfrequenciescanbeidentifiedwithspecialsignal
processing filtering,peakdetection,andfrequencyanalysis.
Carefulmeasurementandcollectionmethodsareessentialto
Careful measurement and collection methods are essential to
enablethistechnique.
Advancedsignalprocessingtechnologyandinstrumentation
available today make this a proven analysis tool in routine data
availabletodaymakethisaprovenanalysistoolinroutinedata
collectionprogramsforPredictiveMaintenance(PdM).

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 WhatDoWeNeedToSee?
Spikes fromimpacts.
Ringing fromanaturalresonancebeingexcited.
Demodulation (orothermethod)todetermine
andseetherepeatedfaultfrequency.
Frequency
q y Determination onImpactRateto
p
isolatethefault.

theimpactandringing

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 WhatAretheBasicRequirements?
SolidTransducerMounting.
MountingTargetandOrientationMaintained.
Mounted in Load Zone of Bearing Housing
MountedinLoadZoneofBearingHousing.
BestPossibleMechanicalInterfaceforTransmissionofEnergy.
HighFrequencyEnergyDetectionMethod.
D
DetectionofRepeatedFaultandRingingCondition.
i fR dF l d Ri i C di i
AbilitytoStripOutLowFrequenciesAssociatedwithActual
RunningSpeed.
AbilitytoDemodulate(Envelope)SignalorDeterminethe
Abili D d l (E l ) Si l D i h
PeaksoftheRepetitiveFaultFrequency.
AbilitytoDetectRepetitionFaultFrequency.
AbilitytoShowResultingSignature(FFT)andcomparethe
Abili Sh l i Si ( ) d h
patterntopublisheddata.
High pass RepetitivePeaksinTWF
Highpass Repetitive Peaks in TWF Lowpass
Low pass FFT
FFT

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 WhatDoesDemodulation
R ll M
ReallyMean?
?
ItisanalogoustostrippingouttheinformationfromanAMradio
broadcast.
Spanningthebandforthestationfrequency(5401600KHz)
andpickingoffthebroadcastedsignal.
First need to incorporate a highpass
Firstneedtoincorporateahigh passorband
or bandpass
passfiltering.
filtering.
Eliminateanyhighamplitudesignalsassociatedwith1Xand
multiplesuptoabout10X.
Includeonlythefaultfrequenciesexcitinginherentresonance.
I t if
Intensifyanddrawoutrepetitivecomponentsofthefault.
dd t titi t f th f lt
Converttofrequencyfordisplayofthepattern.
Amplitudeswillshowupasadistinctivesawtoothorcomb
harmonicpatternoftheactualbearingfault.

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 Impact events
generate high-freq
pulses
pulses.

We see...
X We dont see
(but would like)
vibration vibration
BPFO
BPFO

time time

BPFO

frequency frequency

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 The raw signal includes low frequency running speed harmonics:

These are removed by high-pass (or band-pass) filtering:

rectified
enveloped(demodulated)
With envelope detection is applied:

Finally the result is displayed in the frequency domain:

BPFO

Thecomborsawtoothpattern.

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 DifferenceinProcessing
rectified
Demod1 enveloped
(demodulated)

Demod2 rectified decimatedand

averaged

Processing applied:

BPFO
vs.

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 CanTheReadingsBeTrended?

Yes,butconsistencyofmeasurementisof
, y f f
utmostimportance.
Samehardware.
Same hardware.
Samemeasurementlocation.
Solidmountingingoodmechanicaltransferpath.
Solid mounting in good mechanical transfer path
Sameconditions.
Baselineandsetalarms.
Baseline and set alarms
Note:Eachvendortechnologywilltypicallyrequireadifferentbaseline.

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 ACaseHistoryExample
Automotivepaintfacility
250 HP
250HPmotorsrunning6footbladedexhaustfans.
i 6f bl d d h f
Motorrunningat1792RPM.
Fanbeltdrivenandrunningat820RPM.
B i
Bearingsknown.
k
Excessivevibrationreported.
Initialmeasurementsmadeofvibrationwithacceleration,
velocity and demodulation
velocity,anddemodulation.
Sourceofproblemisidentified,correctiveactionis
recommended.
BearingSKF22218CCKchangedoutatnextproductionbreak.
Bearing SKF 22218CCK changed out at next production break
Letstakealookatinitialresultsfirst,thenBefore/After
comparisons.

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 First,theAccelerationReading

classicalliftingofnoisefloorathighfrequencies

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 Next,Velocity

Highrunningspeedcomponents

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 Now,Demodulation

dominantBPFIfaultfrequency

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 AftertheFact,butnotobvious

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 Velocity BeforeandAfter
FAN02 - Pulley End - Horizontal - Vel Freq 96000 CPM

wer (in/s 0-pk)

Pow 0.46

O/All 0.187 in/s 0-pk

0.35

0.3

0.25

Notethesignificantreductioninamplitude.
0.2
in/s 0-pk

0.15

0.1

0.05

0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000

CPM

1/13/2006 1:29:38 PM O/All 0.187 in/s 0-pk 820 RPM

12/28/2005 4:03:26 PM O/All 0.343 in/s 0-pk 820 RPM

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 Acceleration BeforeandAfter
O/All 0.179 g 0-pk

0.18

0.16

0.14

0.12
Notethereductionofthehighfrequencyenergy.
0.1
g 0-pk

0.08

0.06

0.04

0.02

0 20,000 40,000 60,000 80,000 100,000 120,000

CPM
FAN02 Pulley
y End Horizontal Acc Time 400 ms 1/13/2006 1:56:07 PM O/All 0.179 g 0-pk
p 1785 RPM

FAN02 Pulley End Horizontal Acc Time 400 ms 11/10/2005 12:55:02 AM O/All 0.365 g 0-pk 817.5 RPM

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 Demodulation Before&After
FAN02 - Pulley End - Horizontal - Demod (1000-2500Hz) 30000 CPM

K BPFI
22218CCK
Cursor A: 3871.875 CPM 4.722 orders 0.003 g
O/All 0.149 g rms

CK BPFI
0.04
classicalcombpattern

22218CC
0.035

0.03

CCK BPFI
0.025
ms

22218C
g rm

0.02

0.015

0 01
0.01

0.005
Notethatthedistinctivepeaksaregone!
0

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000 24,000 26,000 28,000 30,000
CPM
1/13/2006 1:34:06 PM O/All 0.052 g rms 820 RPM
12/29/2005 12:46:44 AM O/All 0.149 g rms 820 RPM

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 AnotherRecentFinding

Lowspeedmachineturningat394RPM.
BearingknownasFAG23906B.
Faultfrequenciesknown:
F l f i k
BPFIis18.889
BPFOis16.111
BSFis6.2
FTFIis0.46
Low
Lowvibrationamplitudes,butsomewhatnoisy.
vibration amplitudes but somewhat noisy
Highfrequencyaccelerationdatawastakenalong
,
withroutinemeasurements,nodemod.
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 First,TheHighFrequencyData
High Freq Spectrum
5/8/2009 1:21:42 PM
O/All 0.004 g 0-pk
0.0012

Resonance, with sidebanding

0.001

5KH
5KHzandaboveresonanceswithsidebands
d b ith id b d
0.0008
g 0-pk

0.0006

0.0004

0 0002
0.0002

200,000 400,000 600,000 800,000 1,000,000 1,200,000 1,400,000 1,600,000 1,800,000 2,000,000 2,200,000 2,400,0
CPM

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 Next,theTimeWaveform
EP252 JN1162 - Bracket at Quill bearing - Axial - Acc Spec/Wfm 48000 CPM "Accel 'g' pk LOW"
5/8/2009 1:21:16 PM
Cursor A: 0.372 Revs 0.057 secs -0.001 g
Cursor B: 0.426 Revs 0.065 secs 0.001 g
-0.001
Diff: 0.055 Revs 0.008 secs 0g
Diff: 18.343 orders 7227.271 CPM
0.001 O/All 0.001 g 0-pk

0
g

-0.001

Impacts separated by BPFI

-0.002 RepetitivespikingatBPFI

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

Revs
5/8/2009 1:21:16 PM O/All 0.001 g 0-pk 394 RPM <add note>

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 Finally,theFFTwithOverlays
EP252 JN1162 - Bracket at Quill bearing - Axial - Acc Spec/Wfm 48000 CPM "Accel 'g' pk LOW"
5/8/2009 1:21:16 PM
Cursor A: 15844.093 CPM 40.213 orders 0g
O/All 0.001 g 0-pk
0.0012

EP252 JN1162 - Bracket at Quill bearing - Axial - Acc Spec/Wfm 480000 CPM "Acc pk 'g' HIGH"
5/8/2009 1:21:35 PM
O/All 0.003 g 0-pk
0.001
0.001

PFI (+/- 1X) +2.02%

PFI (+/- 1X) +2.02%
0.0008
0.0008

23960B BPFI (+/- 1X) +2.02%

23960B BPFI (+/- 1X) +2.02%
BPFIFaultFrequencyisevident

23960B BPFI (+/- 1X) +2.02%

23960B BPFI (+/- 1X) +2.02%
g 0-pk

23960B BPFI (+/- 1X) +2.02%

X) +2.02%

23960B BPFI (+/- 1X) +2.02%

23960B BPFI (+/- 1X)) +2.02%

0.0006
+2.02%

2.02%

0.0006
23960B BP

23960B BP
3960B BPFI (+/- 1X) +2
23960B BPFI (+/- 1X

23960B BPFI (+/- 1X) +

g 0-pk

0.0004
0.0004

0.0002
0.0002
2

23

0
0
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000
CPM

-0.0002
0 0002
20,000 40,000 60,000 80,000 100,000 120,000 140,000
CPM

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 PrerequisitesandProcedure
Bearingpartnumber(s)must beknown.
Fault frequencies must beknownandpreloaded.
Faultfrequenciesmust be known and preloaded
Runningspeedmust beaccuratelyrecorded.
Bearing faults excite natural resonances in the machine
Bearingfaultsexcitenaturalresonancesinthemachine
componentsortransducer.
Thefaultfrequencyisrecurring.
q y g
Atechniqueisavailabletodetecttherepetitionratein
time.
Thefaultfrequency(ifpresent)canbeshowninanFFT
displaywithbearingdataoverlays.
3 Musts
M t
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 SummaryRemarks
Rollingelementbearingfailurescanbecatastrophic.
Whilethereare4definedstagesoffailure,thereisnostepbystep
progression.
Adefectivebearingdoesnotfixitself!
Machineryvibrationmeasurementsintimewaveformandspectrum
y p
canprovideearly(telltale)signsofrollingelementbearingdefects.
Specialsignalprocessingtechniques(nowavailableinmostportable
datacollectors)candetectimpactingspikesandpinpointaspecific
) p g p p p p
faultfrequency.
Comparingtheresultingsignature(pattern)topublishedfault
frequenciescanpinpointtherootcauseoftheproblem.
FieldexperiencesinPdMoverthepast30yearshaveproventhe
conceptstobeveryaccurateandreliable.
Considerablecostsavings(inmaintenanceandproduction)are
Considerable cost savings (in maintenance and production) are
affordedbyuseofthistechnology.
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 Q
Questions
ti / Discussion
Di i
on
Rolling
g Element Analysis?
y

Dennis Shreve
Dennis.shreve@ge.com
Commtest Instruments

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