Determining faults in multiple bearings using one vibration sensor

• US 6,053,047 A
• Filed: 09/29/1998
• Issued: 04/25/2000
• Est. Priority Date: 09/29/1998
• Status: Expired due to Term

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Allen-Bradley Company LLC (Rockwell Automation, Inc.)
• Inventors: Loparo, Kenneth A., Dister, Carl J., Tompkin, Edward J.
• Primary Examiner(s): CHAPMAN JR, JOHN E
• Application Number:
  US09/163,111
• Time in Patent Office: 574 Days
• Field of Search: 73/593, 73/659, 73/660, 702/35, 702/56, 702/39
• US Class Current: 73/593
• CPC Class Codes: F16C 19/527 related to vibration and noise
• CPC Class Codes: F16C 2233/00 Monitoring condition, e.g. temperature, load, vibration
• CPC Class Codes: G01M 13/028 Acoustic or vibration analysis
• CPC Class Codes: G01M 13/045 Acoustic or vibration analysis
• CPC Class Codes: G01N 2291/2696 Wheels, Gears, Bearings

Abstract

A diagnostic system includes a vibration sensor mounted on a machine which has vibration-generating components having different vibration characteristics with respect to a common sensor. The vibration sensor measures vibrations and sends vibration signals to a diagnostic module for evaluation of the signals. The diagnostic module has software for processing the vibration signals. From a known natural frequency of a vibration-generating component, the diagnostic module measures the amplitude of the vibration signal at more than one harmonic frequency of the known natural frequency and compares the amplitudes to amplitudes at adjacent harmonic frequencies. When a relatively large amplitude is found at a harmonic frequency, that is a harmonic frequency near a resonant frequency of the physical path between the vibration sensor and the vibration-generating component, the diagnostic system can then analyze the shape and magnitude of the vibration signal around that harmonic frequency to evaluate whether each of the vibration-generating components is healthy, broken or about to break.

Claims

1. A dynamoelectric machine diagnostic system, comprising:

a vibration sensor to sense a vibration signature, the sensor mounted on a dynamoelectric machine having at least two bearings with unique vibration characteristics with respect to the sensor; and

a processor operatively coupled to the sensor for receiving the vibration signature from the vibration sensor and evaluating the vibration signature in the vicinity of frequencies associated with the bearings to determine the condition of each of the bearings.

2. The diagnostic system of claim 1, wherein the processor converts received analog signals into digital signals.

3. The diagnostic system of claim 2, wherein the processor processes the vibration signature using a fast Fourier transform.

4. The diagnostic system of claim 1, further comprising a user interface device operatively coupled to the processor.

5. The diagnostic system of claim 1, wherein the vibration sensor is an accelerometer.

6. The diagnostic system of claim 1, wherein the processor evaluates the vibration signatures in the vicinity of resonant frequencies associated with transmission paths between the vibration sources and the vibration sensor.

7. A method for analyzing the health of a dynamoelectric machine, comprising:

providing the machine with vibration-generating components, at least one of which has vibration characteristics different from others;

obtaining a vibration signature from a vibration sensor connected to the machine;

processing the vibration signature, the processing including scanning a frequency region adjacent to a resonant frequency of a vibration transmission path from one of the components to the vibration sensor for harmonic frequencies of the components; and

determining the condition of the components from characteristics of the vibration signature at frequencies associated with each of the components.

8. The method of claim 7 wherein the processing further includes determining at least an approximate value of the resonant frequency of the vibration transmission path.

9. The method of claim 7, wherein the processing includes:

determining at least one critical frequency for each of the components of the machine;

identifying harmonic frequencies of respective of the critical frequencies;

recording the amplitudes of the vibration signature at the harmonic frequencies; and

comparing the recorded amplitudes to identify a sudden increase in amplitude of a harmonic frequency associated with one of the vibration-generating components.

10. A method for analyzing the health of a dynamoelectric machine, comprising:

providing the machine with bearings, at least one of which has different vibration characteristics from the others;

obtaining a vibration signature from a vibration sensor connected to the machine;

processing the vibration signature; and

determining the condition of the bearings from characteristics of the vibration signature at frequencies associated with each of the bearings.

11. A method for analyzing the health of a dynamoelectric machine, comprising:

providing the machine with ball bearings, at least one of which has a different number of balls from the others;

obtaining a vibration signature from a vibration sensor connected to the machine;

processing the vibration signature; and

determining the condition of the bearings from characteristics of the vibration signature at frequencies associated with each of the bearings.

12. A dynamoelectric machine diagnostic system, comprising:

means for sensing vibrations, said means for sensing vibrations operative to sense vibrations from at least two bearings of a dynamoelectric machine;

each bearing having a unique vibration characteristic with respect to the means for sensing vibrations; and

means for processing the vibration characteristics, said means for processing the vibration characteristics being able to correspond the vibration characteristics to the respective bearings and to determine the health of each of the bearings.

13. The machine of claim 12 wherein the means for processing includes means for receiving a vibration signature from the vibration sensing means and evaluating vibration signature in the vicinity of a resonant frequency of at least one of the bearing.