Purdue University Purdue e-Pubs Open Access Theses Theses and Dissertations 12-2016 Early bearing fault analysis using high frequency enveloping techniques Ilya Shulkin Purdue University Follow this and additional works at: https://docs.lib.purdue.edu/open_access_theses Part of the Mechanical Engineering Commons Recommended Citation Shulkin, Ilya, "Early bearing fault analysis using high frequency enveloping techniques" (2016). Open Access Theses. 896. https://docs.lib.purdue.edu/open_access_theses/896 This document has been made available through Purdue e-Pubs, a service of the Purdue University Libraries. Please contact [email protected] for additional information. Graduate School Form 30 Updated PURDUE UNIVERSITY GRADUATE SCHOOL Thesis/Dissertation Acceptance This is to certify that the thesis/dissertation prepared By Ilya Shulkin Entitled Early Bearing Fault Analysis Using High Frequency Acceleration Enveloping Techniques For the degree of Master of Science Is approved by the final examining committee: Nancy Denton Chair Mark French Haiyan Zhang To the best of my knowledge and as understood by the student in the Thesis/Dissertation Agreement, Publication Delay, and Certification Disclaimer (Graduate School Form 32), this thesis/dissertation adheres to the provisions of Purdue University’s “Policy of Integrity in Research” and the use of copyright material. Approved by Major Professor(s): Nancy Denton Approved by: Dr. Duane Dunlap 10/10/2016 Head of the Departmental Graduate Program Date EARLY BEARING FAULT ANALYSIS USING HIGH FREQUENCY ACCELERATION ENVELOPING TECHNIQUES A Thesis Submitted to the Faculty of Purdue University by Ilya Shulkin In Partial Fulfillment of the Requirements for the Degree of Master of Science December 2016 Purdue University West Lafayette, Indiana ii ACKNOWLEDGMENTS The author would like to thank the following family, faculty, and sponsoring organizations who were instrumental in their support of this work: Parents: Simon & Yelena Shulkin Fiancé: Gabrielle Broughton Committee members: Professors Nancy Denton, Mark French, & Haiyan Zhang Sponsoring organizations: Mechanical Engineering Technology Department at Purdue University, Vibration Institute iii TABLE OF CONTENTS Page LIST OF FIGURES ........................................................................................................... vi LIST OF TABLES ............................................................................................................. ix LIST OF ABBREVIATIONS ............................................................................................. x GLOSSARY ...................................................................................................................... xi ABSTRACT ..................................................................................................................... xiii CHAPTER 1. INTRODUCTION ....................................................................................... 1 1.1 Introduction ....................................................................................................... 1 1.2 Problem Statement ............................................................................................ 2 1.3 Scope ................................................................................................................. 2 1.4 Significance....................................................................................................... 3 1.5 Statement of purpose......................................................................................... 4 1.6 Assumptions ...................................................................................................... 6 1.7 Limitations ........................................................................................................ 6 1.8 Delimitations ..................................................................................................... 7 CHAPTER 2. REVIEW OF LITERATURE ...................................................................... 8 2.1 Introduction ....................................................................................................... 8 2.2 Enveloping & severity ...................................................................................... 8 2.3 Lubrication issues ............................................................................................. 9 2.4 Spectral analysis................................................................................................ 9 2.5 Enveloping implementation ............................................................................ 11 2.6 Instrumentation ............................................................................................... 12 2.7 Enveloping of industrial size equipment......................................................... 14 2.8 Hilbert Transform ........................................................................................... 16 iv Page 2.9 Summary ......................................................................................................... 17 CHAPTER 3. RESEARCH METHODOLOGY .............................................................. 18 3.1 Introduction ..................................................................................................... 18 3.2 Research Design.............................................................................................. 19 3.3 Experimental Control ...................................................................................... 20 3.4 Experimental Design ....................................................................................... 21 CHAPTER 4. RESULTS .................................................................................................. 24 4.1 Envelope Detection and Signal Processing Using LabVIEWTM 2012 ........... 24 4.1.1 Building a Virtual Instrument (VI) ........................................................ 25 4.1.2 Signal Scaling and Parameters ............................................................... 27 4.1.3 Raw Acceleration Waveform Recording ............................................... 27 4.1.4 Power Spectrum and FFT Analysis ....................................................... 28 4.1.5 The Hilbert Enveloped Waveform and Spectrum .................................. 28 4.1.6 Order Analysis Toolkit (OAT) Enveloped Waveform and Spectrum ... 29 4.1.7 LabVIEWTM Data Logging .................................................................... 30 4.2 Bearing Parameters ......................................................................................... 30 4.2.1 Operating Speed Ranges ........................................................................ 31 4.3 Rolling Element Bearing Calculations and Fault Frequencies ....................... 31 4.3.1 Fundamental Train Frequency ............................................................... 32 4.3.2 Ball Pass Frequency Inner Race ............................................................ 33 4.3.3 Ball Pass Frequency Outer Race ............................................................ 33 4.3.4 Ball Spin Frequency ............................................................................... 33 4.4 Bearing Testing Parameters with Traditional Raw Waveform and Power Spectrum Analysis .......................................................................................... 34 4.4.1 Unlubricated ........................................................................................... 34 4.4.2 Lubricated .............................................................................................. 36 4.4.3 Induced Cage Fault Phase1 .................................................................... 38 4.4.4 Induced Cage Fault Phase 2 ................................................................... 41 4.4.5 Induced Cage Fault Phase 3 ................................................................... 43 v Page 4.5 Envelope Data Reduction ............................................................................... 45 4.5.1 Enveloping though the Hilbert Transformation Method (325 RPM) ............................................................................................. 45 4.5.1.1 Unlubricated Bearing Hilbert Envelope Analysis...................... 45 4.5.1.2 Lubricated Bearing Hilbert Envelope Analysis ......................... 48 4.5.1.3 Phase I: Induced Cage Fault Hilbert Envelope Analysis ........... 52 4.5.1.4 Phase II: Induced Cage Fault Hilbert Envelope Analysis .......... 55 4.5.1.5 Phase III: Induced Cage Fault Hilbert Envelope Analysis ........ 57 4.5.2 Order Analysis Toolkit Acceleration Enveloping (325 RPM ................ 62 4.5.2.1 Unlubricated Bearing OAT Envelope Analysis ......................... 62 4.5.2.2 Lubricated Bearing OAT Envelope Analysis ............................ 64 4.5.2.3 Phase I: Induced Cage Fault OAT Envelope Analysis .............. 66 4.5.2.4 Phase II: Induced Cage Fault OAT Envelope Analysis ............. 68 4.5.2.5 Phase III: Induced Cage Fault OAT Envelope Analysis ........... 70 4.6 Performance Analysis of Hilbert and OAT Enveloping Methods .................. 72 4.6.1 Raw Waveform Enveloping Performance .................................... 72 4.6.2 Envelope Spectrum Performance .................................................. 77 4.7 Performance Analysis of Fast Fourier Transform (FFT) with the Hilbert Enveloping Method ............................................................................ 81 4.8 Summary ........................................................................................................