catalogo fag bearing analyser

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Rolling Bearings

Technical Information

TI No. WL 80-63 E April 2001

Rolling Bearing Diagnosis with theFAG Bearing Analyser



State-Of-The-Art, Condition-Related Monitoring of Plants and Machines

Unforeseen bearing damage, often re-sulting in machine downtimes and pro-duction loss, does not only cause an enor-mous cost in paper mills, oil refineries,steel mills, chemical plants and powerplants. It also causes an unnecessary re-pair expenditure even in less complexproduction plants. Condition-relatedmaintenance helps every machine opera-tor save enormous cost. To this end, anydamage must be detected at an earlystage, diagnosed, and its development

monitored. In this way maintenancework can be scheduled well ahead and thenecessary preparations can be made. Theavailability of machines increases, and theproduction cost is reduced.

Rolling bearing diagnosis with theportable FAG Bearing Analyser

The FAG Bearing Analyser is an effi-cient and reasonably priced vibrationdiagnosis tool for early detection of rolling bearing damage and gear damage.By means of the field-proven envelopedetection method it diagnoses all types of damage that cause noise - i.e. vibrations -,such as cracks, pitting, indentations ordirt. A commercially available laptop isturned into an efficient, reasonablypriced, portable diagnosis device by in-stalling the Analyser software, insertingthe PC card and connecting the dockingstation. It enables the user to determinenot only whether a bearing is intact ordamaged but also which type of damageone is dealing with. It even permits detec-tion of damage in bearings that are in-stalled in a complex machine and whosestructure borne sound signal is, conse-quently, superimposed by the vibrationsof adjacent machine parts.

Other vibration diagnosis methodsthat use the characteristic values of the vi-bration signal (peak value, effective value,mean value) permit no reliable diagnosisof the condition of a rolling bearing andare not suitable for an early diagnosis of damage.

Principle of envelope detection analysis

Faults or damage on machine parts, asa rule, cause additional vibration. Cyclingof discrete damage on a rolling bearing,e.g. pitting in the raceways, causes a peri-odic series of individual shocks. Theseshocks induce structural resonances in thebearing or in adjacent machine parts. Theshock frequency is characteristic of thetype of rolling bearing damage and can becalculated if the bearing geometry and

the speed are known.

Depending on the location of thedamage (outer ring, inner ring, roll ing el-ements) different shock frequencies areobtained that are referred to as kinematicbearing frequencies. These high-frequen-cy vibrations are superimposed by run-ning noise. The original shock values canbe reconstructed for evaluation by filter-ing out all sinusoidal vibrations and recti-fying the signal. The rolling bearing dam-age is characterized by increased ampli-tudes at the corresponding kinematic fre-

quencies and by their multiples and sidebands.

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Measurement and Program Description

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Measurement and ProgramDescription

Before a measurement can be conduct-ed, a configuration file must be generat-ed. All parameters of the measurementare specified in this fi le and can be adjust-ed for the measurement of vibrations andfor the diagnosis/analysis of the signal.

At the beginning of every measure-

ment the configuration files are loaded.During the measuring process the FAGBearing Analyser informs the user via astatus window about which operationsare performed at the moment. The ampli-fication factor is automatically adjustedin the docking station to the maximumpossible resolution without overamplifi -cation (autoranging). Then the FFT (fastfourier transformation) is calculated. Thepickup rate is adjusted automatically independence on the low-pass filter selectedby the user in the configuration fi le. Upto 8192 values can be recorded.

Configuration files can be saved sepa-rately. The same holds for the measuredtime signal, which can be saved both inits own format (IBH 2.0) and as anASCII file. Up to 3000 long-term dataare managed in a ring buffer. In this ringbuffer the measured characteristic valuesand the results of automatic analyses andof the frequency monitoring process aresaved.



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When a data record was loaded, orwhen a measurement was conducted, theBearing Analyser displays the envelopetime signal and the envelope spectrum ina window. By clicking on the “Raw sig-nal” button below the graphic, the rawsignal and the raw signal spectrum aredisplayed. Up to four signals can be visu-alized simultaneously.

On the right, the monitored frequen-cies and/or diagnosis results are displayedif these were selected in the configurationfile.

Time and frequency signals can be ex-amined very effectively by means of thefunctions in the relocatable cursor win-dow. There is a zoom function, and theuser can mark carpet-level characteristic

values. By double-clicking on the damagesimilarity, the detected cycling frequencyand its harmonics can be marked bymeans of a cursor.

The report function permits the userto summarize and print all important di-agnosis results in text form.

Doubleclick onto one of the bearing Components inthe “defect probability” field will show you the founddamage freqencies in the envelope spectre.



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In order to diagnose the condition of arolling bearing, the FAG Bearing Ana-lyser needs information about the speedof the supported shaft and about thestructure of the bearing.

The structure is specified by standard-ized cycling frequencies in which thecomponent dimensions are encoded.

By entering the bearing type in thebearing database window, the user callsup these data from the database. Thedatabase that is part of the delivery scope

contains the data of the commonly usedFAG bearings.

If the required bearing type is not con-tained in the supplied database, this bear-ing type’s data can be added to the data-base. The new bearing data can easily beinput via a so-called bearing calculator. Inthis mask the bearing’s standardized fre-quencies or geometry data must be en-tered directly beside the bearing code.Based on this information, the programcan calculate the standardized (speed-in-

dependent) cycling frequencies; the pro-gram is started by clicking on the Calcu-late button.




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Automatic Diagnosis

The system needs information aboutthe bearing’s operating speed in order tocalculate the speed-related frequencies re-quired for an automatic diagnosis fromthe standardized cycling frequencies.

It is also possible to specify a speedtolerance (in per cent) which is taken intoaccount in the automatic diagnosis.

When evaluating a single measure-ment, the result of the automatic diag-

nosis is displayed in the form of damagesimilarities (in per cent).

To this end, the software searches thefrequency spectrum for bearing-specificfrequencies, their multiples and sidebands. In this way damage can be detect-ed and analysed regardless of the absolutemagnitude of the signal power, even with-out a reference measurement.

In addition to the specific frequenciesof a rolling bearing, which the expert sys-tem automatically enters into a frequencytable, up to 7 other frequencies can bemonitored. In the automatic diagnosis

the first three monitoring frequencies arethe cycling frequencies of the rolling ele-ments, outer ring and inner ring.

For every frequency to be monitoredthe basic frequency, a band width and analarm value must be entered.

The system searches the frequencyspectrum of the envelope signal for thehighest peak in the specified band widtharound the basic frequency. If this peakexceeds the alarm value, an alarm is trig-gered.

The user can also specify trigger valuesfor the alarm probability. If a damage

similari ty exceeds this value during a di-agnosis, an alarm is activated, and thecolour of the alarm button changes fromgreen to red.



Installation · Features · Scope of Delivery

Installation of the Software

To permit an easy installation of thesoftware, the setup CD contains a setupprogram that guides the user through theentire installation process. The FAGBearing Analyser software runs underWindows 95, 98 and NT4.0. The screenresolution should be at least 800x600 pix-els. A computer with a Pentium processorand at least 16 MB RAM should be avail-

able.

Features of the “FAG BearingAnalyser” Software

– Simultaneous measurement of raw sig-nal and envelope signal

– Automatic frequency analysis by afuzzy-based expert system

– Monitoring of the envelope carpet leveland of the carpet level ratio of envelopesignal to raw signal

– Monitoring of freely definable frequen-cies in the envelope spectrum

– Integrated database system for 4200standard FAG rolling bearings

– Integrated “bearing calculator” for easyinput of not yet defined bearings

– Graphic presentation of the measuredsignals and their spectra. Tools for athorough manual analysis, e.g. a har-monic cursor and various zoom func-tions

– Various tools for printing the graphicsand reports or for copying them intothe Windows clipboard from wherethey are imported into other Windowsprograms

– Trend function for long-term monitor-ing

1 docking stationfor connecting the sensor and process-ing the signals, power supply via note-book and PC card cableOrder code:BA98.DOCK

1 acceleration pickupwith 1.5 m cableOrder code:SENSORPZA12.2M

1 magnetic base for attaching pickupOrder code:MAGNETD30.M6

1 setup CD,software as described aboveOrder code:SOFTW.BA98

1 data acquisition card

NI DAQ-Card 700,Order code:BA98.CARD

1 user manual

1 extension cable (5 m)

1 extension cable (10 m)

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Standard scope of delivery:

Order code (complete system): BA98.SYS

The FAG Bearing Analyser comes ready to use, with the following accessories:

Accessories in bold print can also be ordered individually as replacement parts.



Technical Data

Designation FAG Bearing Analyser Order code (complete system): BA98.SYS

Dimensions (docking station) 290 mm wide, 230 mm long, 35 mm high

Weight (docking station) ca. 1.5 kg

Power supply Via notebook

Operating time 1.5 to 2.5 h, depending on the notebook’s type of battery

Temperature range 0 to 50 °C

Operation Windows-based softwareTouchpad or mouse

Data recording capacity 256 to 8192 samples (corresponding to a frequency resolution of 100 - 3200 lines)

Entries 2 Lemosa sockets, 4-pole, for acceleration pickup (4 mA ICP power source, 24 V)1 trigger entry per channel (2nd entry in preparation)

Voltage ranges +/-5 mV to +/-5 V (peak-peak)+/-15 V max. input voltageSoftware issues warning if input sensitivity is exceeded.

Frequency ranges Simultaneous measurement of general vibration signal and envelope signalBand width: 5 H z - 20 kHz; in this range, frequency bands can be selected as required

Triggering Automatic, pre-programmed externally

Process window Hanning

Filter functions High-pass filter can be switched: 750 Hz/2 kH z with envelope detection

Interfaces ECP/EPP parallel, serial, external VGA,(depending on notebook) PS/2 keyboard/mouse/keypad,

PCMCIA interfaces (2 x type II or 1 x type I, PC card)Serial infrared interface

Standard scope of delivery Data acquisition card BA98.CARDBA98.SYS Acceleration pickup SENSORPZA12.2M

Magnetic base for fastening the pickup MAGNETD30.M6Software, installed on CD-ROM SOFTW.BA98Docking station BA98.DOCKUser manual, extension cables (5 m and 10 m)

Damage diagnosis Carpet level of the monitored noise for envelope signal and general vibration signalThreshold value monitoring of the amplitudes of up to 10 freely selectable frequenciesAutomatic frequency analysis with fuzzy-/neuro-based expert system

FAG Industrial Services GmbH

Kaiserstrasse 100D-52134 HerzogenrathTel. +49-24 07 / 91 49 0

Every care has been taken to ensure the correctness of the information contained in this publicationbut no liabil it y can be accepted for any errors or omissions.We reserve the right to make changes in the interest of technical progress.

© by FAG 2001 · This publication or parts thereof may not be reproduced without our permission.

TI N o. WL 80-63 E /99/4/01 · Printed in Germany by Weppert GmbH & Co. KG

catalogo fag bearing analyser

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