Session 2020-21

B.tech Project MIN

MIN-400 Report

Detection of bearing faults using time frequency analysis

Techniques

Submitted By: Supervised By:

Gograj Khadda (17117029)
Gwmshrang Basumatary (17117031) Prof. V H Saran
Pankaj (17117053) MIED IIT Roorkee
Rajneesh Bijarniya (17117067)

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 Abstract
Bearing elements are common parts used in rotating machinery used in industrial work and
vehicles. Rolling element bearings involve heavy loads under different operating conditions.
There are many structural faults such as wear pitting, spall etc which may occur in bearing
during operation suddenly. And these faults can affect or damage the whole machining and
this damage to machining can lead to financial losses and sometimes it can be dangerous to
human life. If bearing conditions are detected periodically then we can detect defaults that
can lead to damage to machinery or miss interest the operation and we can repair them on
time and consequently save money and human life. There are many techniques that are
used to detect the bearing fault conditions. The vibration signal generated by bearing
contains important information regarding bearing conditions. This report reviews two signal
analysis techniques (envelope spectrum & spectral kurtosis and wavelet transform).
Vibration signal is used for processing and extracting relevant information regarding
bearing. We can process these vibration signals and extract relevant information and based
upon that information we can predict the bearing condition.

Acknowledgement
We have taken efforts in this project. However, it would not have been possible without the
kind support and help of many individuals. We would like to extend our thanks to all of
them. We are highly indebted to Prof. V.H. Saran IIT Roorkee & PHD scholar Vival Parmar
for their guidance and constant supervision as well as for providing necessary data and
research paper regarding the project & also for their support in completing the project. We
pay our deep sense of gratitude to Head of Department MIED, B.K. Gandhi, IIT Roorkee to
provide us the opportunity to prepare the project. We are thankful to Evaluation Team
under whose guidance we were able to eliminate errors We are immensely obliged to our
friends for their elevating inspiration, encouraging guidance and kind supervision in the
completion of our project.

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 Content
1. Introduction
2. Objective
3. Experimental setup and data collection
4. Methodology
4.1. Envelope spectrum and spectral kurtosis
4.2. Wavelet transform
5. conclusion
6. references

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 1. Introduction –
The dynamic performance of rotating components is highly influential on performance of
any rotating machine. Particularly bearings, which is consider as a heart of rotating
machinery. Fault finding methodologies of rolling bearings had importance in preventing
machinery from failures by giving forewarning. A number of works have been done in this
field of bearing condition monitoring using various non-destructive testing technologies
such as Current signature Analysis, thermographs, wear debris analysis etc. One of the most
preferable and reliable method is vibration analysis technique which is widely used in
bearing diagnostics. In general the defect diagnosis methods comprise of three stages in
vibration based methods. First stage is vibration data acquisition using appropriate sensors,
Next step continued by signal processing statistical feature extraction from time domain
and frequency domain to get the useful information. Signal processing methods such as
Envelope spectrum and spectral kurtosis, empirical mode decomposition, wavelet
transform using different wavelets were used in more effective way and further as a final
step, the condition of rotating component is predictable by maintenance personnel
manually or by means of automated computational intelligence methods such as soft
computing data mining algorithms such as ANN, SVM, etc..

2. Objective –
To diagnose the physical condition of bearing using vibration signal generated by bearing
element during rotation.
To make a model that can classify the defect present in bearing.

3. Experimental setup and data collection-

Data were not taken manually. Case western bearing fault data is used in this project.
Case Western Reserve University Bearing Data Centre
They conducted experiments using a 2 hp Reliance Electric motor and acceleration data was
measured at locations near to and remote from the motor bearings. Motor bearings were
seeded with faults using electro-discharge machining (EDM).
Faults ranging from 0.007 inches in diameter to 0.040inches in diameter were introduced
separately at the inner raceway, rolling element (i.e. ball) and outer raceway. Faulted
bearings were reinstalled into the test motor and vibration data was recorded for motor
loads of 0 to 3 horsepower (motor speeds of 1797 to 1720 RPM).
Bearing Information

Drive end bearing: 6205-2RS JEM SKF, deep groove ball bearing

Size: (inches)

Inside Outside Thickness Ball Pitch

Diameter Diameter Diameter Diameter
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0.9843 2.0472 0.5906 0.3126 1.537
Defect frequencies: (multiple of running speed in Hz)

Inside Outside Thickness Ball Pitch

Diameter Diameter Diameter Diameter

0.9843 2.0472 0.5906 0.3126 1.537

Fan end bearing: 6203-2RS JEM SKF, deep groove ball bearing
Size: (inches)

Inside Outside Thickness Ball Pitch

Diameter Diameter Diameter Diameter

0.9843 2.0472 0.5906 0.3126 1.537

Defect frequencies: (multiple of running speed in Hz)

Inside Outside Thickness Ball Pitch

Diameter Diameter Diameter Diameter

0.9843 2.0472 0.5906 0.3126 1.537

4. Methodology
Two different methodology were used for fault classification.
4.1. Envelope spectrum and spectral kurtosis
When rolling elements hit the local faults at outer or inner races, or when faults on the
rolling element hit the outer or inner races, the impact will modulate the corresponding
critical frequencies, e.g. BPFO, BPFI, FTF, BSF. Therefore, the envelope signal produced by
amplitude demodulation conveys more diagnostic information that is not available from
spectrum analysis of the raw signal.

Procedure –

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 Visualize the raw inner race fault data in the time domain fig.1

Fig.1

Visualize the raw data in frequency domain fig.2

Fig.2

Now zoom in the power spectrum of the raw signal in low frequency range to take a closer
look at the frequency response at BPFI and its first several harmonics (fig.3).

Fig.3

No clear pattern is visible at BPFI and its harmonics. Frequency analysis on the raw signal
does not provide useful diagnosis information.

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 Fig.4

Looking at the time-domain data (fig 4), it is observed that the amplitude of the raw signal
is modulated at a certain frequency, and the main frequency of the modulation is around
1/0.009 Hz ≈ 111 Hz. It is known that the frequency the rolling element hitting a local fault
at the inner race, that is BPFI, is 118.875 Hz. This indicates that the bearing potentially has
an inner race fault.

To extract the modulated amplitude, compute the envelope of the raw signal.

Fig. 5

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Now compute the power spectrum of the envelope signal and take a look at the frequency
response at BPFI and its harmonics (fig 5).

It is shown that most of the energy is focused at BPFI and its harmonics. That indicates an
inner race fault of the bearing, which matches the fault type of the data.

Fig.6

As expected, the envelope spectrum of a normal bearing signal does not show any
significant peaks at BPFO or BPFI (fig. 6).

Fig.7

For an outer race fault signal, there are no clear peaks at BPFO harmonics either (fig. 7) .
Does envelope spectrum analysis fail to differentiate bearing with outer race fault from
healthy bearings? Let's take a step back and look at the signals in time domain under
different conditions again.

First let's visualize the signals in time domain again and calculate their kurtosis. Kurtosis is
the fourth standardized moment of a random variable. It characterizes the impulsiveness of
the signal or the heaviness of the random variable's tail.

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 Fig.8

It is shown that inner race fault signal has significantly larger impulsiveness, making
envelope spectrum analysis capture the fault signature at BPFI effectively. For an outer race
fault signal, the amplitude modulation at BPFO is slightly noticeable, but it is masked by
strong noise. The normal signal does not show any amplitude modulation. Extracting the
impulsive signal with amplitude modulation at BPFO (or enhancing the signal-to-noise ratio)
is a key preprocessing step before envelope spectrum analysis.

Kurtogram and spectral kurtosis to extract the signal with highest kurtosis, and perform
envelope spectrum analysis on the filtered signal.

Fig.9

Kurtogram and spectral kurtosis compute kurtosis locally within frequency bands (fig. 9).
They are powerful tools to locate the frequency band that has the highest kurtosis (or the
highest signal-to-noise ratio).After pinpointing the frequency band with the highest
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kurtosis, a bandpass filter can be applied to the raw signal to obtain a more impulsive signal
for envelope spectrum analysis.

The kurtogram indicates that the frequency band centered at 2.67 kHz with a 0.763 kHz
bandwidth has the highest kurtosis of 2.71.

Fig.10

Fig.11

Now use the optimal window length suggested by the kurtogram to compute the spectral
kurtosis (fig.10).

To visualize the frequency band on a spectrogram, compute the spectrogram and place the
spectral kurtosis on the side (fig.11). To interpret the spectral kurtosis in another way, high
spectral kurtosis values indicates high variance of power at the corresponding frequency,
which makes spectral kurtosis a useful tool to locate nonstationary components of the
signal.

By band pass filtering the signal with the suggested center frequency and bandwidth, the
kurtosis can be enhanced and the modulated amplitude of the outer race fault can be
retrieved.
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 Fig. 12

It can be seen that the kurtosis value is increased after bandpass filtering. Now visualize the
envelope signal in frequency domain (fig.12).

Fig.13

It is shown that by bandpass filtering the raw signal with the frequency band suggested by
kurtogram and spectral kurtosis, the envelope spectrum analysis is able to reveal the fault
signature at BPFO and its harmonics (fig.13) .

BPFO v/s BPFI amplitude -

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Trained the model and develop classifier -
 The histogram shows a clear separation among the three different bearing
conditions.
 The log ratio between the BPFI and BPFO amplitudes is a valid feature to classify
bearing faults.
o classifier
 if log(BPFI Amplitude/BPFO Amplitude)≤−1.5, the bearing has an outer race fault;
 if −1.5<log(BPFI Amplitude/BPFO Amplitude)≤0.5, the bearing is normal;
 if log(BPFI Amplitude/BPFO Amplitude)>0.5, the bearing has an inner race fault

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 Validation using test data sets
sets-
We have 6 data set for testing and
d for all 6 data this classifier work accurattely.

4.2 Wavelet transform

The continuous wavelet transform (CWT) of a finite energy signal x(t) with the analyzing
wavelet is the convolution of x(t) with a scaled and conjugated wavelet.

The wavelet coefficient measures the similarity between the signal xx(t)
(t) and the analyzing
wavelet at different scales and different time positions.

Flow diagram for bearing fault diagnosis

diagnosis-

Three level wavelet tree

tree-

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Wavelet decomposition at 3 level
Decomposed the raw signal at 3 level and get 1 approximation and 3 detailed signal

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Feature Used -

Training data set features -

Above six features are calculated for all 4 coefficient signal and after that these features are
feed as an input to the support vector machine for training.

Testing data set features -

In the same
me way, features are calculated for test data that is different from the train data
and given as input to SVM for prediction.

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Support vector machine -
 It a supervised
ised machine learning model.
 Support Vector Machine algorithm finds a hyperplane in an N N-dimensional
dimensional space(N
— the number of features) that distinctly classifies the data points.
 Hyper planes are decision boundaries that help classify the data points. Data points
falling on either side of the hyper plane can be attributed to different classes.
classes
 To separate the two classes of data points, there are many possible hyper planes that
could be chosen.
 SVM Algorithm finds the hyper plane which has maximum margin.
 Maximizing the margin distance provides some reinforcement so that future data
points can be classified with more confidence.

Multi-class classification
There are mainly two types of multi-class
multi classification techniques:-
1. One vs. All:- N-class
class instances then N binary classifier models
2. One vs. One:- N-class
class instances then N* (N-1)/2 binary
inary classifier models

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Results-

Test Data no. Predicted fault Actual fault

1 Inner Inner

2 Inner Inner

3 Inner Inner

4 Inner Inner

5 Outer Outer

6 Outer Outer

7 Ball Outer

8 Ball Ball

9 Ball Ball

10 Ball Ball

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 11 Ball Ball

12 Ball Ball

13 Base Base

14 base Base

 A model was trained by using processed signal that can classify bearing fault with
training set accuracy 97.06 %. 34 data used for training the model.
 New test signals (14 test set data) were tested and classified by using the model with
92.85 % accuracy.

5. Conclusion
In this proposed work we have processed the vibration signal using envelope spectrum &
spectral kurtosis and wavelet transform techniques.

We have extracted relevant information regarding bearing condition in different formats

using these two techniques. For both methods we have developed model that predicts the
bearing condition based upon the extracted information after signal processing. We have
trained these models using the vibration signal of bearing of known conditions. To test
training accuracy of trained models we have used these models to predict the bearing
condition using the same data that we have used for training. And then we have used some
test data different from training data to bearing condition of wearing to which these this
data belongs.

We can see that both methods give good accuracy in prediction.

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 6. References
 Multifault Diagnosis of Rolling Element Bearings Using a Wavelet Kurtogram and Vector
Median-Based Feature Analysis by Phuong H. Nguyen and Jong-Myon Kim
 https://www.youtube.com/channel/UCVkatNMgkEdpWLhH0kBqqLw
 Bearing fault diagnosis using wavelet packet transform, hybrid PSO and support vector
machine by Rajeswari.Ca, Sathiyabhama. Bb,Devendiran. Sc & Manivannan.Kd
 Rolling element bearing fault diagnosis using wavelet packets, N.G.NikolaouI,
A.Antoniadis
 https://towardsdatascience.com/multi-class-classification-one-vs-all-one-vs-one-
94daed32a87b
 Bearing fault diagnosis using wavelet packet transform, hybrid PSO and support vector
machine by Rajeswari.Ca, Sathiyabhama. Bb,Devendiran. Sc & Manivannan.Kd
 Rolling element bearing fault diagnosis MATLAB documentation
 https://csegroups.case.edu/bearingdatacenter/pages/fault-specifications
 Rolling element bearing fault diagnosis using wavelet packets by N.G.Nikolaou
I.A.Antoniadis
https://www.youtube.com/channel/UCVkatNMgkEdpWLhH0kBqqLw

MATLAB code and data files are available on this link

https://drive.google.com/drive/folders/1DksFmea0HzXfdvusJTzWC1XSvVBkIFLH?usp=shari
ng

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