Bearing Failure Cause Estimation via Multi-Speed Vibration Analysis
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Solution Overview
Problem
Existing methods for diagnosing bearing failures in machine tools are inadequate for determining the cause of failures, leading to difficulties in identifying the root cause and preventing recurrence.
Innovation Solution
A method and device that measure vibrations at multiple rotation speeds, perform frequency analysis, and calculate vibration mean values to extract bearing-caused vibration values. These values are then used to determine if the bearing is abnormal and estimate the failure cause based on the relation of vibration values at specific frequency ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vibration measurement and frequency analysis are performed using conventional methods, then bearing abnormality can be detected, but the cause of failure cannot be accurately determined
Solution Approach 1:
The patent segments the vibration analysis into multiple rotation speed measurements, extracting vibration values at specific frequency ratios (1x, 2x, 3x, 4x rotational frequency) to differentiate between various failure causes. This segmentation allows identification of whether poor lubrication or foreign matter intrusion caused the failure by analyzing the distribution pattern across different frequency components.
Solution Approach 2:
The patent changes the measurement parameter from single-speed vibration analysis to multi-speed vibration analysis. By measuring vibrations at multiple rotation speeds and analyzing the relationship between vibration values at different frequency ratios, the system can identify failure causes that are not detectable through conventional single-point analysis.
2Measurement precision
If comprehensive investigation of failure causes is performed, then accurate cause determination is achieved, but productivity is reduced due to time consumption
Solution Approach 1:
The patent performs preliminary vibration measurements at multiple rotation speeds during the bearing operation phase, before failure occurs. This preliminary data collection enables rapid cause identification after failure, eliminating the need for time-consuming post-failure investigations and allowing quick restoration decisions.
Solution Approach 2:
The patent replaces manual investigation methods with automated vibration analysis. The system automatically measures vibrations at multiple speeds, calculates frequency ratios, and determines failure causes through programmed algorithms, substituting time-consuming manual inspection with rapid computational analysis.
3Ease of operation
If vibration measurement is performed at a single rotation speed, then measurement simplicity is maintained, but the ability to distinguish failure causes is insufficient
Solution Approach 1:
The patent creates a universal measurement approach that works across different bearing types and failure modes. By measuring at multiple rotation speeds and analyzing frequency ratio relationships, the same measurement protocol can identify various failure causes (poor lubrication, foreign matter, etc.) without requiring different measurement procedures for each case.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables effective measurement and diagnosis of bearing states, allowing for accurate estimation of failure causes, which aids in determining cost responsibility and implementing preventive measures.
Implementation Method 1
measuring a vibration when the rotator is rotated at a constant velocity at a plurality of rotation speeds
Data Source
AI summary
A method for estimating a cause of a bearing failure includes: calculating a magnitude of a vibration with respect to a frequency calculating a vibration mean value by removing an influence of the rotation speed and calculating a mean value of the magnitudes of the vibrations having a same ratio of the frequency with respect to a rotational frequency from a result of the frequency analysis at the plurality of rotation speeds obtained in the calculating of the magnitude; extracting a bearing-caused vibration value of a characteristic ratio frequency from the vibration mean values; determining whether or not the bearing is abnormal based on the bearing-caused vibration value; and estimating a failure occurrence cause based on a relation of the bearing-caused vibration values in the integer multiplied characteristic ratio frequencies at which the vibrations are caused by the bearing when the bearing is determined to be abnormal in the determining.