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FACULTY OF ENGINEERING AND
ARCHITECTURE
Outer Raceway Fault Detection andLocalization for Deep Groove Ball
Bearings by Using Thermal Imaging
Raiko Schulz*, Mia Loccufier, Steven Verstockt, Kurt Stockman,Sofie Van Hoecke
ECNDT 2014, PragueOctober 9th, 2014
FACULTY OF ENGINEERING AND
ARCHITECTURE
Table of contents
Condition monitoring (CM) of offshore wind turbine drivetrains
Passive LWIR for machinery fault detection
Test setup
Experimental methodology and results
Conclusions & outlook
Outer Raceway Fault Detection and Localization for Deep Groove Ball Bearings by Using Thermal Imaging 2 / 23
FACULTY OF ENGINEERING AND
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CM of offshore wind turbine drivetrains
Tower
Generator
Gearbox
Mechanical break
NacelleHub
Main shaft
High-speed shaft
Blades
Figure: Wind turbine drive train
Outer Raceway Fault Detection and Localization for Deep Groove Ball Bearings by Using Thermal Imaging 3 / 23
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CM of offshore wind turbine drivetrains
Figure: Main bearings in a wind turbine drive train
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Rolling element bearing failures
Figure: Rolling element bearing fault evolution
Outer Raceway Fault Detection and Localization for Deep Groove Ball Bearings by Using Thermal Imaging 5 / 23
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Open challenges
I Real-time condition monitoring
I Early fault detection
I Fault localization
I Fault classification
I Lifetime estimation & maintenance scheduling
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Passive LWIR for machinery fault detectionI Tribological drive train components naturally generate heat−→ Passive thermography
I Early fault detection for relatively low temperatures−→ Long-wave infrared (LWIR)
I LWIR is insensitive to environmental impacts such as dust or fogI Passive LWIR allows non-destructive condition monitoring
NIR lowtransmittanceSWIR MWIRVIS LWIR
0.38 !m 0.78 !m 1 !m 3 !m 5 !m 7 !m 14 !m
Figure: Infrared spectrum
Outer Raceway Fault Detection and Localization for Deep Groove Ball Bearings by Using Thermal Imaging 7 / 23
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Test setup
Figure: Test setup
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Test setup
bearing parts
1 screw locking
2 rolling element
3 inner raceway
4 cage
5 outer raceway
6 outer ring
7 inner ring
8 inner ring bore
9 single lip seal
Figure: 3D scheme of Rexnord ER10K deep groove ball bearing
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FACULTY OF ENGINEERING AND
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Test setup
FLIR A655sc specifications
array cooling uncooled
sensitivity 7.5 to 14 µm
accuracy ±1 ◦C
resolution 640x480 px
pixel pitch 17 µm
frame rate 50 Hz
standard temperature range -20 to 150 ◦C
Table: Specifications for FLIR A655sc thermal infrared camera
Outer Raceway Fault Detection and Localization for Deep Groove Ball Bearings by Using Thermal Imaging 10 / 23
FACULTY OF ENGINEERING AND
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Experimental methodology and results
I Tests on both healthy and pre-damaged bearings
I Rotational speed of 1,500 rpm
I Measurement period of fifty minutes
I Setup initially being cooled down to ambient temperature
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Experimental methodology and results
I Separation of rings indicating the single bearing componentsI Instead of absolute temperatures, relative temperatures are
discussed in order to reduce environmental impactsI Ambient temperature has been measured by thermocouples and
used as reference temperature
I Finally, both frame-wise and trend analysis
Outer Raceway Fault Detection and Localization for Deep Groove Ball Bearings by Using Thermal Imaging 12 / 23
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Physical scheme and temperature profiles
Figure: Front view of bearing and shaft, and temperature profile directions
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Temperature profiles
Figure: Thermal images of both healthy (left) and faulty (right) bearingswith temperature profile lines
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Temperature profiles
Figure: Thermal image of bearing with outer raceway fault and increasedlower temperature limit
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Temperature profiles
0 5 10 15 20 25 30 35 40 450
5
10
15
20
25
diameter [mm]
rela
tive
te
mp
era
ture
[°
C]
healthy bearing outer raceway fault
outerring
lipseal
innerring
shaft innerring
lipseal
outerring
Figure: Hotspot temperature profiles for both healthy and faulty bearing
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Trend analysis
I Trend analysis for the single bearing components
I Relative temperatures are discussed in order to reduceenvironmental impacts
I Finally, matching of trend graphs with first order dynamics todetermine their time constants
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Trend analysis
0 5 10 15 20 25 30 35 40 45 500
5
10
15
20
25
time [minutes]
rela
tive
te
mp
era
ture
[°
C]
central shaft outer shaft inner ring and shaft contact central inner ring
inner ring and seal contact inner seal outer seal outer ring
Figure: Relative temperature trends for healthy bearing
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Trend analysis
0 5 10 15 20 25 30 35 40 45 500
5
10
15
20
25
time [minutes]
rela
tive
te
mp
era
ture
[°
C]
central shaft outer shaft inner ring and shaft contact central inner ring
inner ring and seal contact inner seal outer seal outer ring
Figure: Relative temperature trends for bearing with outer raceway fault
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First-order step response
0 5 10 15 20 25 30 35 40 45 500
2
4
6
8
10
12
time [minutes]
rela
tive
te
mp
era
ture
[°
C]
trend graph step response
Figure: Relative temperature trend and first-order step response for contactsurface between inner ring and shaft of healthy bearingOuter Raceway Fault Detection and Localization for Deep Groove Ball Bearings by Using Thermal Imaging 20 / 23
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First-order step response
time constants in minutesbearing healthy outer raceway fault
housing 8.0 2.4
inner ring and shaft contact 3.9 1.6
Table: Time constants after fifty minutes
Definition
The time constant of the system response is the time which isrequired by the step response to reach 63% of its final value.
Outer Raceway Fault Detection and Localization for Deep Groove Ball Bearings by Using Thermal Imaging 21 / 23
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Conclusions
I Potential for fault detection as bearing faults lead toI faster temperature increaseI higher maximum temperatures in steady-state
I Potential for fault localization
I Potential for monitoring of fully covered and sealed bearings
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Thank you for your attendance!
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