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Everything should be as simple as possible, but no simpler. AE A new approach to rolling element bearing life estimation, and extension.
US PATENT 6,763,312 B1
John E. Judd Dynamic Measurement Consultants, LLC jejvibes@aol.com
Introduction
The useful operating life of a rolling element bearing is influenced by a number of factors. Some of the factors are controlled by the designer, others are controlled the user. Bearing LIFEGUARDTM is a metrics based system for monitoring and optimizing key factors under user control.
RELIABILITY
RELIABILITY A DEFINITION The probability that a component part, equipment, or system will perform its intended function, under specified conditions of environment, and satisfactory maintenance, for a specified period of time. [Ref 9]
HELP!
This is what the emissions from the bearing look like! All the information you need is there!
g units vs time. Time> Frequency > Acceleration frequency spectrum.
Control & Minimize the Forces that act to shorten bearing life. Monitor the actual condition of bearing.
BEARING FAILURE
L10 Bearing life is defined as the number of cycles that 90 % of an apparently identical group of bearings will run before spalling defect reaches 0.01 inch2 (6mm2). Timken specifies L10 for 90x106cycles. ISO 381 specifies for 1x106 cycles.
4.5
1-2=Optimum near L10 life. 2-4=Slightly High (Monitor) 4-7=Excessively High (Action) 7-10=Danger! (Shut down)
1-2= Optimum L10 life 2-4= 10 to 30% life reduction. 4-7 = 30 to 70% life reduction 7-10 =70 to 80% life reduction
SAMPLE
Main Campus
SAMPLE
35 30 25 20 15 10 5
L-FACTOR
AHU PUMPS MOTORS
ILLUSTRATION
100
75
50
25
FAIL
BAD
AHU PUMPS MOTORS BAD MOTORS
40 30 20 10 0 1 ALERT BAD
L-FACTOR
1-3
3-7
7-10
SAMPLE
MACHINE DEGRADATION FACTOR DISTRIBUTION Things that indicate machine is in failure state
50 45 40 35 30 25 20 15 10 5 0 3
D-FACTOR NUMBER
AHU-SAMPLE
10
15
D- FACTOR NUMBER[Sample]
1.4 g
Detailed acceleration spectrum taken after bearing failure alert. Top-before bearing replacement. BD =12 Lower-after replacement. BD =2
DEGADE FACTOR=12
3kHz
FACTORS
1) ROTATIONAL SPEED 2) RATIO OF RATED LOAD/APPLIED LOA 3) ENVIRONMENT 4)BEARING MATERIAL 5) TIME AT LOAD 6) ASSEMBLY 7) LUBRICATION
IMPORTANT POINTS
to note in L 10 equation:
LIFE VS BEARING LOAD
2 X INCREASE RPM DECREASE BEARING LIFE factor 2 2X INCREASE BEARING LOAD DECREASE BEARING LIFE factor (C/PL)3.3! INCREASE BOTH X 2DECREASE BEARING LIFE factor 20! Drop bearing load from 50 to 40% -double bearing life!
% L 10
WB,K2
FAILURE CHARACTERISTICS
STUDIES BY FAA, NASA AND OTHERS HAVE CONCLUDED: MOST BEARING FAILURES ARE RANDOM AND SCHEDULED PREVENTIVE MAINTENANCE ALONE IS NOT THE MOST COST EFFECTIVE MAINTENANCE STRATEGY !
B C
2%
1%
17%
5%
4%
3%
7%
E F
14%
15%
42%
68%
66%
29%
REF 4
High Number of Excessively High Stress Cycles Lead to Subsurface Material Fatique.
CYCLES TO FATIQUE FAILURE Cycles to Fatigue Failure
M
120
A X S T R E S S
100
PERCENT LIFE EXPECTANC
100
1000 psi
80 80 60 60 40 40 20 20
0
10^4
L10 Life is reduced at higher stress levels. GENERAL FATIGUE LIFE VS LOAD % 1000000
100 10 0.1
100000 L10 GENERAL FATIQUE LIFE VS LOAD
10000
0.01
1000
Series1
0.001100 0.0001
10
MIN 5,000 15,000 20,000 Min 2,500 2500 lb 5000 lb 10,000 10000 15000 20000 BEARING LOAD Load lb ( Lbs.) lb lb
FATIGUE CURVE
SHAFT RPM VS BEARING LIFE SHAFT RPM VS BEARING LIFE (ANSI STD) (ANSI STD) 100000
10000
1000
EXAMPLE ONLY
100
10
Rotor weight +
Dynamic force= Imbalance + Misalignment + Impacts Imbalance =1/2 rotor mass x (2 RPS)2 *mass cg offset
WEIBULL EQUATIONS:
Re(t)
dFe(t)/dt = f(t)=
for k = 1, = 0
location, =MTTF,
t = time period
Timken Bearing uses = 0, k = 1.5 for L10
10% FAIL
63% FAIL
MTTF(4.81 L10)
K= 0.5 K=1.0 K=1.5 K=2.0
RELIABILITY ESTIMATE
Rs = Probability of system functioning for time t with elements connected in series: k -(t / ) Rs = System Reliability = e Rs = P1*P2*Pn [Ex: 0.8*0.7*0.9= 0.504] Fs = Probability of failure = 1- Rs = 0.496
Lets look at how DF is derived. Lets look at how BD is derived. Finally, lets look at how probability of failure is estimated.
INFORMATION
DYNAMIC FORCES
10 ACTION/LIFE REDUCED ALERT
1
10
PROCESS
OPTIMUM
BEARING CONDITION
NEAR FAIL ALERT OPTIMUM
BD
BEARING CONDITION LE LIFE EXPECTENCY
SIGNAL
FFT
SPLITTER
3 4
DF
LFD ADDER
DYNAMIC FORCE
DISPLAY
DF- A measure of dynamic forces on bearing [20-40% contribution- user selectable] BD- A measure of actual bearing condition. [80-60% contribution.]
DF INCREASE ONLY
10
SAMPLE
BD INCREASE ONLY
DYNAMIC FORCES
1 10
DF DYNAMIC FORCE FACTOR
8.00-10.00
6.00-8.00
4.00-6.00
2.00-4.00
0.00-2.00
10
S 1
be affected by such factors as rotational speed ASSUME RATIO OF RATED TO APPLIED FORCEand imbalance.
DROPS BY 20% AS DF GOES FROM 1 TO 10
CF Vel= 0.4/0.17 = 2.46 BD=4.5, LE=3.9, DF=3.9 HF=7.7 CF=14 KF=.55, ED=4.27
Re
-5.0 -10.0
20.0m
40.0m
60.0m
se 80.0m
100.0m
120.0m
140.0m
160.0m
KURTOSIS FACTOR VS CF & G(RMS) FACTOR 14.0 12.0 10.0 KURTOSIS FACTOR 8.0 6.0 4.0 2.0 0.0
1 2 3 4 5 6 S1 7 S3 S5
12.0-14.0
10.0-12.0
8.0-10.0
6.0-8.0
4.0-6.0
2.0-4.0
0.0-2.0
G(RMS)
CREST FACTOR
Gs
5.0
Re
-5.0
7 4 11 3 1 9 12 8 10 2 6 5
LIGHT ABRASION/ GRINDING COMPOUND LIGHT SCORING ON THREE BALLS LIGHT SCORING CONDITION MILD SCORING ON INNER/OUTER RACE HEAVY SCORING ON INNER RACE MED SCORING INNER/OUTER AND BALL HEAVY SCORING ON INNER RACE/BALL HEAVY SCORING ON OUTER RACE HEAVY SCORING ON BALLS
8 6 4 2 0
V o lt s
8 6 4 2 0
WBK2- ARR
7 4 11
7 4 11 3 1 9 12 8 10 2 6 5 REF IN IN/OU 3 ABR1 1 3BAL 9 10 8 12IN2 3SCR 2 53SCR 6OUT2 BALL ABR3 OUT 1 1.75 1.89 3.2 5.47 5.6 6.9 10 12.2 12.95
1.0
BD =10
0.8 PROBABILITY
0.6
K = 1.0 K = 0.5
0.4
K=1.5
0.2
PROBABILITY OF FAILURE VS.MDA-3 BD PROBABILITY OF FAILURE FOR 7 t/MTTF (1-e -(t/mttf)^1.5)MTTF In 1 6 0.1 63.2% 0.311280057 4.81*L10 t/MTTF 2160hrs 2 0.28 1.377086509 FAIL 5 4 0.46 2.680090871 PROB 6 4 0.64 4.007042122 8 3 0.82 5.240971686 10 1 6.321205588 216 2 1.18 7.22464964 1.36 7.95260925 1 1.54 8.520808949 PROBABILITY X 0 20 1.72 8.952060096 BD VALUE 1 2 4 6 8 10 22 1.9 9.271220579
PROBABILITY X10
Gs
0 Re -5.0 -10.0
20.0m
40.0m
60.0m se 80.0m
100.0m
120.0m
140.0m
160.0m
BD = 0.64 HFD = 0.6 CFD = 3.2 KFD= 0.04 EDD = 0.15 HFD= 0.6 CFD= 3.2
S1 X: 6625 Y: 0.00297311
5.0K
Hz 10.0K
15.0K
20.0K
B4-ABR15 (137)
500.0m
400.0m
300.0m
S1 X: 2725 Y: 0.00214685
Ma
200.0m
100.0m
5.0K
Hz 10.0K
15.0K
20.0K
S1 X: 5662.5 Y: 0.00749745
5.0K
Hz 10.0K
15.0K
20.0K
B3-IN (138)
500.0m
400.0m
S1 X: 1337.5 Y: 0.027393
300.0m
200.0m
Ma
100.0m
5.0K
Hz 10.0K
15.0K
20.0K
400.0m
S1 X: 9037.5 Y: 0.101844
300.0m
Ma
200.0m
100.0m
5.0K
Hz 10.0K
15.0K
20.0K
400.0m
300.0m
S1 X: 6000 Y: 0.172742
200.0m
Ma
100.0m
5.0K
Hz 10.0K
15.0K
20.0K
400.0m
300.0m
S1 X: 5987.5 Y: 0.315009
Ma
200.0m
100.0m
5.0K
Hz 10.0K
15.0K
20.0K
B10-OUT2 (143)
500.0m
400.0m
300.0m
S1 X: 5875 Y: 0.264455
100.0m
5.0K
Hz 10.0K
15.0K
20.0K
400.0m
300.0m
S1 X: 6387.5 Y: 0.307514
100.0m
5.0K
Hz 10.0K
15.0K
20.0K
BRG 12, 3SCR2, RMS = 1.40289 BD=6.3, HF=10, CF=14, KF=1.5, ED=5.2
10.0 RMS: 1.4 Live X1 X: 0.0799805 Y: 1.11501 5.0
Gs
0 Re -5.0 -10.0
20.0m
40.0m
60.0m se 80.0m
100.0m
120.0m
140.0m
160.0m
400.0m
300.0m
S1 X: 5925 Y: 0.276644
100.0m
5.0K
Hz 10.0K
15.0K
20.0K
400.0m
300.0m
S1 X: 6637.5 Y: 0.156745
Ma
200.0m
100.0m
5.0K
Hz 10.0K
15.0K
20.0K
Acceleration
Re
-5.0 -10.0
20.0m
40.0m
60.0m
se 80.0m
100.0m
120.0m
140.0m
160.0m
S1 X: 187.5 Y: 0.671253
300.0m
100.0m
5.0K
Hz 10.0K
15.0K
20.0K
GS
0 Re -5.0 -10.0
20.0m
40.0m
60.0m se 80.0m
100.0m
120.0m
140.0m
160.0m
38%
If BD indicates MTTF drops to 8760 t/ = 1 Probability of failure in one year. F(T)= 63%
BEARING
TM
Information in this presentation is provided for illustration of LIFEGUARD TECHNOLOGY & MDA principles only. Use for other purposes without express permission of DMC, LLC is strictly prohibited.
US PATENT #6,763,312 B1
Shock & Vibration Handbook, Cycil Harris, 3rd Edition Rolling Element Bearings-Tedric Harris, 3rd Edition RCM, Condition Monitoring or both? Richard Overman, Veridian Engineering, Maintenance Technology, Jan. 02. NASA-Reliability Centered Maint. & Commissioning. [Appendix A], Feb. 2002 The McGraw-Hill Dictionary of Scientific & Technical Terms-5th Edition. Mil Handbook 217E SAE JA 1011 Surface Vehicle/Aerospace Std.-Evaluation Criteria for Reliability Centered Maintenance. Vibra-Metrics Inc. Vibration Reference Guide.