International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), International Journal of Mechanical Engineering ISSN

N 0976 6359(Online) Volume 2, Number 1, Jan - April (2011), IAEME

and Technology (IJMET), ISSN 0976 6340(Print) ISSN 0976 6359(Online) Volume 2 Number 1, Jan - April (2011), pp. 60-69 IAEME, http://www.iaeme.com/ijmet.html

IJMET

IAEME

ESTIMATION OF MISALIGNMENT IN BEARING SHAFT BY SIGNAL PROCESSING OF ACOUSTIC SIGNAL

Naveen Rathi1, Amit Gupta2, B. Manpreet3, Rajesh Kumar4 , Vikas Kumar5 Pursuing M.Tech from NCCE ,Israna, Panipat, Haryana, India er.naveenrathi@gmail.com 2 Department of Mechanical Engineering, NCCE ,Israna, Panipat, Haryana, India eramit81@yahoo.co.in 3 Pursuing PHD from SLIET Longowal -148106 (Pb), India bainscoolbains@yahoo.com 4 Department of Mechanical Engineering, SLIET Longowal -148106 (Pb.), India 5 Pursuing M.Tech from NCCE ,Israna, Panipat , Haryana, India vikas4m@gmail.com ABSTRACT Acoustic Emission (AE) is being extensively used as a Non Destructive Technique (NDT) for diagnosis of rotating components. The main theory behind this diagnosis is that while rotation, acoustic energy level of defective portion in rotating element is different. In the present study a signal processing technique is proposed to identify the variation in acoustic signal and results are verified for misalignment of the bearing shaft. Two different functions Fast Fourier Transformation (FFT) and Decomposition are used to represent the Acoustic signal at different levels of misalignment. Result reveals that the proposed methods are effective in estimating the misalignment present in the bearing shaft. Statistical parameters such as Standard deviation and Shannon entropy are also increases with increase in misalignment in the bearing shaft. Keywords: acoustic emission, condition monitoring, fault diagnosis bearing, misalignment of bearing shaft, signal processing. I. INTRODUCTION Vibration analysis is widely used in diagnostics of faults in machinery. There are many analytical techniques such as Resonance demodulation [1], Instantaneous power spectrum distribution[2] and Conditional moments analysis[3] etc which have been developed for processing vibration signals to obtain useful diagnostic information about processing gear faults. Over the last few decades the vibration analysis by using acoustic condition monitoring of rotating component has received very little attention. This was probably due to perception that monitoring of air borne sound from a machine is noisy and complex in normal industrial environment. During the last few years a significant process in the capability of acoustic instrumentation together with the signal processing techniques has made it possible to extract useful diagnostic information from contaminated acoustic signals. Number of signal processing techniques like by using Discrete wavelet transform,, Morlet wavelets, and Wavelet transform etc have been developed to diagnose the faults in bearing and removal of noise from the signal in other industrial and research applications [4-10].
1

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 2, Number 1, Jan - April (2011), IAEME

In the present work experiments are conducted to identify misalignment of bearing shaft by recording the acoustic signal in the computer. The recorded acoustic signal is processed in Matlab6.0 by using two different functions Fast Fourier Transformation (FFT) and Decomposition for the analysis purpose. II. THEORY A .Fast Fourier Transformation (FFT) The FFT is essence, decomposes or separates a waveform on function into sinusoids of different frequencies It identifies or distinguishes the different frequency sinusoids and their respective amplitudes [4]. The Fourier transform f(s) of function f(x) is expressed as f(s) = f (x) exp (-i 2xs) do. (1) Applying the same transform to f(s) gives f (w) = f (s) exp (-i 2ws) ds. (2) If f(x) is an even function of x, that is f(x) = f(-x), then f(w) = f(x). If f(x) is an odd function of x, that is f(x) = -f (-x), then f(w) = f(-x). When f(x) is neither even nor odd, it can often be split into even and odd parts. It is often useful to think of functions and their transforms are occupying two domains which are called as upper and lower domains. B. Wavelet decomposition Many applications use the wavelet decomposition taken as a whole. The common goals concern the signal or image clearance and simplification, which are parts of de-noising or compression. When trying to classify the applications by domain, it is almost impossible to sum up several thousand papers written within the last 15 years. The decomposition process can be iterated, with successive approximations being decomposed in turn, so that signal is broken down into many lower resolution components. This is called the wavelet decomposition tree. The original signal S is broken down to lower resolution components like cA1 and cD1. Then is further broken out cA2 and cD2as shown in Figure 2.1. Looking at a signals wavelet decomposition tree can yield valuable information as shown below in Figure 2.2 Since the analysis process is iterative, in theory it can be continued indefinitely. In reality, the decomposition can proceed only until the individual details consist of a single sample or pixel. In practice, youll select a suitable number of levels based on the nature of the signal.

Figure 2.1: Wavelet decomposition tree

Figure 2.2: Wavelet decomposition tree with valuable information

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 2, Number 1, Jan - April (2011), IAEME

In our work we have used Daubechies 4th order is used as mother wavelet, which is compactly supported orthogonal wavelet. Daubechies wavelet allows specific parts of the spectrum to be filtered and can potentially give more detail in the time series, compared to the conventional filter [8]. III. EXPERIMENTAL SET UP In this paper we diagnose the defect of misalignment in the bearing shaft. An experimental setup is made for the analysis purpose. We have taken the cage bearing (NBC make, 6004)having 9 balls for our study. A motor (200 watt) is used to drive bearing arrangement and a mike (Logitec make, 20 Hz to 16000 Hz frequency range) is used to record the acoustic signal generated by the bearing housing by placing it 1cm apart from that. In first set of reading shaft is made to run at 1460 rpm with he help of motor and without any misalignment by providing support at pulley which is mounted at the other end as shown in figure 3.1. Later weight is applied to introduce the misalignment in the shaft as shown in figure 3.2 at three different levels by own weight of shaft and pulley, adding further 2kg and adding 5kg (in total), which is also measured in terms of angle as 0.35, 0.72 & 1.04 degrees respectively. Signal (in wav format) generated by the bearing is recorded for 2 sec duration with the help of mike and saved in the computer for the processing. These signals then processed in the Matlab6.0 software for generating the raw signal, FFT(Fast Fourier Transformation) and decomposition at 6th level by using db4 as mother wavelet. Which are shown in the next section.

Figure 3.1 Experimental se up with support at the end

Figure 3.2: Experimental setup with induced misalignment

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 2, Number 1, Jan - April (2011), IAEME

IV. RESULTS AND DISCUSSIONS Raw signal (amplitude vs time), Fast Fourier Transform FFT(energy vs frequency domain) are drawn and compared in this section. A simple raw signal of case having no misalignment is shown in Figure 4.1 and the other cases of misalignment are having almost similar view of raw signal as in case of no misalignment. FFTs are also shown below for four different cases given below. Case1: FFT of Shaft without misalignment rotated at 1460 rpm in figure 4.2(a) Case2: FFT of Shaft with misalignment because of its own weight of shaft and pulley or (Equivalent to 1 Kg point load at the pulley) at 1460 rpm in figure 4.2(b) Case3: FFT of Shaft with misalignment with 1.5 Kg additional load at the pulley at 1460 rpm in figure4.2(c) Case4: FFT of Shaft with misalignment with 3.0 Kg additional load at the pulley at 1460 rpm in figure 4.2(d)

Figure 4.1: Raw signal of without misalignment at 1460 rpm

Figure 4.2 (a): FFT of the signal without misalignment at 1460 rpm

Figure 4.2 (b): FFT of the signal having misalignment because of its own weight or Equivalent to 1Kg point load at 1460 rpm

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 2, Number 1, Jan - April (2011), IAEME

Figure 4.2 (c): FFT of the signal having misalignment because of its own weight and additional 1.5 Kg load at 1460 rpm.

Figure 4.2 (d) FFT of the signal having misalignment because of its own weight and additional 3 Kg load The peaks are coming at the multiple of 24.3Hz which are the harmonics of fundamental frequency of rotation, S.No Case Respective height in ( mm) 135.26 133.00 Angle of Misalignment 0 0.35 4th peak energy value 155 255

1. 2.

3. 4.

Without misalignment Misalignment by own weight of pulley and shaft Misalignment by 1.5Kg additional load Misalignment by 3.0Kg additional load

130.58 128.50 Table 4.1

0.72 1.04

650 780

This can be calculated by 1460 / 60= 24.3 rotation per second (Hz) We have marked the energy values corresponding to 4th consecutive peak of 24.3 Hz (ie 97.2Hz) on each FFT graph and their respective values are measured as 155, 255, 650, and 780 for the

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 2, Number 1, Jan - April (2011), IAEME

Case1, Case2, Case3 and Case4 respectively, Which are described in Table 4.1 and shown in Figure 4.3 (Graph between Energy of 4th consecutive peak of rotational frequency vs Angle of misalignment ). The trend shown by energy level at 97.2Hz (4th harmonic of 24.3Hz) frequency in FFT graph is the clear indication of misalignment, as misalignment increases energy level increases. So the 4th consecutive peak of rotational frequency must be observed very precisely to avoid the damages caused by the misalignment.

900 800

y c n e u q e r f l a n o i t a t o r f o k a e p e v i t u c e s n o c h t 4 f o y g r e n E

700 600

500 400

300 200

100 0 0 0.2 0.4 0.6 0.8 Angle of misalignment 1 1.2

Figure 4.3: Graph between Energy of 4th consecutive peak of rotational frequency vs Angle of misalignment Decomposition up to 6th level using db4 as mother wavelet is drawn for the Case1 (Without misalignment) and shown in Figure 4.4 Enlarged views for the 6th level decomposition i.e. a6 for the different cases are shown in the Figures 4.5(b), 4.5(c), 4.5(d) and 4.5(e) for the Case1, Case2, Case3 and Case4 respectively. Impression of each ball can be clearly visible on these enlarged graphs in terms of peaks as shown in Figure 4.5(a). Also for the case of without misalignment (at 1460 rpm) we have marked two point by writing their coordinates which represent the same ball impression after completing one cycle shown in Figure 4.5(b). With the help of these data point we can also calculate the time to complete one cycle and hence rpm of the bearing shaft. As 1 sec signal is decomposed into 44100 data point so Time to complete one cycle=(7568.85-5758.93) /(44100)=1809.92 / 44100=0.041041 So rpm of the shaft can be given by= [1 / 0.041041] * 60=1461.94

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 2, Number 1, Jan - April (2011), IAEME

Figure 4.4 Decomposition up to 6th level by using db4 as mother wavelet without misalignment at 1460 rpm.

Figure 4.5 (a): Enlarged view of 6th level Decomposition a6 for Case1 without misalignment load at 1460 rpm

Figure 4.5 (b): Enlarged view of 6th level Decomposition a6 for Case1 without misalignment load at 1460 rpm

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 2, Number 1, Jan - April (2011), IAEME

Figure 4.5 (c): Enlarged view of 6th level Decomposition a6 for Case2 having misalignment because of its own weight or Equivalent to 1 Kg pulley load at 1460 rpm

Figure 4.5(d): Enlarged view of 6th level Decomposition a6 for Case3 having misalignment because of its own weight and additional 1.5 Kg load

Figure 4.5 (e): Enlarged view of 6th level Decomposition a6 for Case4 having misalignment because of its own weight and additional 3 Kg load

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 2, Number 1, Jan - April (2011), IAEME

Each ball gives two peaks one to the upside and one to the lower side, actually lower side peak is due to the blank space which is coming after ball and gives impression to the lower side. The middle 6 peaks difference has been shown in Figure 4.5(b) with energy variation (upper peak and lower peak) have been measured as 0.070, 0.050, 0.025, 0.020, 0.015 and 0.020 as shown in figure 4.5(b). The average of this is coming out to be 0.033 in the case of without misalignment. In the Case-2 having misalignment due to pulley and shaft weight the 6 intermediate peaks energy variation has been measured as 0.20, 0.12, 0.12, 0.10, 0.10, 0.12 and 0.05 respectively as shown in Figure 4.5(c). The average of this is coming out to be 0.127. Similarly in the next two cases Case3 and Case-4. the average value of energy variation is coming out to be 0.148 and 0.227 respectively. S.No Case Respective height in ( mm) 135.26 133.00 Angle of Misalignment 0 0.35 Average value of energy variation 0.033 0.127

1. 2.

3.

4.

Without misalignment Misalignment by own weight of pulley and shaft Misalignment by 1.5Kg additional load Misalignment by 3.0Kg additional load

130.58

0.72

0.148

128.50

1.04

0.227

Table 4.2
0.25

Average energy variation of 6 intermediate balls

0.2

0.15 Series1 Series2 0.1

0.05

0 0 0.2 0.4 0.6 0.8 1 1.2

Angle of misalignment

Figure 4.6: Graph between Average energy variation of 6 intermediate balls vs Angle of misalignment We can observe that as misalignment increases then 6th level decomposition of signal shows more disturbances (more up and down). This is because of increase in energy at each individual ball of the bearing because of the misalignment in bearing shaft. So we can represent the misalignment in

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 2, Number 1, Jan - April (2011), IAEME

terms of average energy variation of individual balls shown in Table 4.2 and graph shown in Figure 4.6. So this energy variation of individual balls must be monitored properly to avoid the failures due to misalignment. V. CONCLUSION In this paper we have analyzed the fault of misalignment in bearing shaft by using acoustic signal and developed a method to identify such defects. From the experiments following conclusions can be drawn.

1.It is demonstrated that, although the environment influences acoustic signal for condition monitoring, it does not significantly reduce the extraction of useful diagnostic information. It has been demonstrated that acoustic condition monitoring can effectively be used for detection of misalignment in bearing arrangement. 2.The graphs drawn by using FFT and Decomposition functions responded equally for the fault misalignment. Also the signs of increasing misalignment can be noted down clearly with both functions. 3.In vibration monitoring using acoustic signal have certain advantages over the conventional vibration measuring techniques. Firstly in this sensors do not alter the behavior of the machine due to its non contact nature. And time based information is not lost in this method. 4.Acoustic based method provides considerable freedom in positioning of the microphone. For instance, in this application, small variations in distance and plane of the microphone with respect to the bearing had a little influence in detecting the main characteristics of the bearing acoustics. On the other hand, small change in the location of the accelerometers based method had a bigger impact in detecting the main characteristics of the bearing vibration. 5.The method developed in the project can be used for the condition monitoring and for predictive maintenance of the ball bearing for the misalignment.
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