Filters and Enveloping - A Practical Discussion -

William Tudoroff Condition Monitoring Services Product Manager Rockwell Automation

Copyright 2005 Rockwell Automation, Inc. All rights reserved.

Agenda Sample

1. Basic Filter Terminology 2. Basic Filter Theory 3. Rolling Element Bearing Faults 4. Applying Envelopes

Copyright 2005 Rockwell Automation, Inc. All rights reserved.

Consider This Simple Vibration Signal in the Time Domain

0 1

20 Hz Time Waveform

60 Hz Time Waveform

Raw Time Waveform

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Or in the Frequency Domain

Amplitude

20 Hz

40 Hz

60 Hz

Frequency

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Basic Filter Terminology High Pass Filter High Pass Filter Allows Frequencies Higher than the filter value to be retained in the signal also known as the Low Corner Frequency*
40 Hz High Pass Filter

Amplitude

20 Hz

40 Hz

60 Hz

Frequency

*Remember If its an important concept in the world of Vibration, there must be more than one name for it
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Basic Filter Terminology Low Pass Filter Low Pass Filter Allows Frequencies Lower than the filter value to be retained in the signal also known as the High Corner Frequency or Frequency Maximum
40 Hz Low Pass Filter

Amplitude

20 Hz

40 Hz

60 Hz

Frequency

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Basic Filter Terminology Band Pass Filter Band Pass Filter Allows Frequencies in the Band defined by the filter value to be retained in the signal also known as Enveloping
30 - 50 Hz Band Pass Filter

Amplitude

20 Hz

40 Hz

60 Hz

Frequency

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Basic Filter Theory When Does the Filtering Occur? Although we have visualized the filter in the Frequency Domain the actual signal processing can occur in either the Frequency or Time Domain. Also, when filtering in the Frequency Domain, this can occur in the hardware as the data is being processed, or in the Software, after the data has been processed

Copyright 2005 Rockwell Automation, Inc. All rights reserved.

Basic Filter Theory Analog Filter

Filtering in the Time Domain is also called an Analog Hardware Filter because the filtering occurs during the actual capture of the Time Waveform.

Analog Input

Analog Filter

Analog to Digital
Converter

Digital Output

Digital Signal
Processor

Copyright 2005 Rockwell Automation, Inc. All rights reserved.

Basic Filter Theory Analog Filter

Raw Time Waveform (Analog Input from Sensor)

If the Raw Time Waveform was made up of the 20 Hz and 60 Hz Signals Below 0 1
20 Hz Time Waveform

40 Hz Analog High Pass Filter

60 Hz Time Waveform

This becomes the Analog Signal Sent to the Analog to Digital Converter
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Basic Filter Theory Analog Filter is a Roll Off Filter

An Analog Filter is considered a Roll-Off Filter in other words the filter is not a brick wall but allows some of the signal beyond the filter value to pass through The Filter Attenuates or reduces the amplitudes of the frequencies below the filter value The filter values will be defined by the hardware manufacturer as they are an actual Analog Chip Lets visualize it in the Frequency Domain even though the filtering is occurring in the Time Domain

Copyright 2005 Rockwell Automation, Inc. All rights reserved.

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Basic Filter Theory Analog Filter is a Roll Off Filter

40 Hz High Pass Filter Roll-Off

Amplitude

20 Hz

40 Hz

60 Hz

Frequency

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Basic Filter Theory Digital Filter

Filtering in the Frequency Domain is often called a Digital Hardware Filter because the filtering occurs during the actual Digital Signal Processing of the Time Waveform into a Frequency Spectrum

Analog Input

Analog Filter

Analog to Digital
Converter

Digital Output

Digital Signal
Processor

Fast Fourier Transform, Integration and Digital Filtering Occur Here

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Basic Filter Theory Digital Filter

A Digital Filter is considered an Absolute Filter in other words the filter is essentially a brick wall, allowing none of the signal beyond the filter value to pass through The filters available are dependent on the hardware being used Most common example is the Frequency Maximum (FMAX) setting we are all familiar with 40 Hz FMAX

Amplitude

20 Hz

40 Hz

60 Hz

Frequency
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Basic Filter Theory Software Filter

Filtering in the Frequency Domain after the data has been processed in the hardware is called a Software Filter because many vendors just display Zero amplitude in any bins (lines of resolution) that are being filtered out Thus, an infinite number of filters is available using this method

40 Hz High Pass Filter

Amplitude

20 Hz

40 Hz

60 Hz

Frequency
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A Word About Bearings

The vast majority of bearings are one of two types:

Rolling Element, or Anti-Friction Bearings and Fluid Film Bearings

Eddy Current Probe Accelerometer

bearing

bearing

bearing housing

bearing housing

Soft Metal (Babbitt)

Oil Wedge (load zone)

Rolling Element: Low cost, simple to

Fluid Film: Capable of supporting very high

loads, high temperatures, high speed. Expensive and associated rotor dynamics are very complex.

apply. But are capable of only moderate speeds and relatively light loads. Rotor dynamics arent bad but diagnostics can be complex due to all those spinning balls!
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Rolling Element Bearing Faults

What happens when there is a fault or defect on the inner or outer race of the bearing?
Accelerometer

bearing

bearing housing

We feel an impact anytime a ball or roller passes over the defect Fault or Defect on Outer Race This impact energy is typically very low amplitude
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Rolling Element Bearing Faults In fact, the vibration energy from a bearing fault is so small sometimes that it gets hidden by all the other machine vibration going on:
Unbalance, Looseness, Misalignment, etc

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Remember our Band Pass Filter or Envelope If we pass the signal through the right Envelope or High Pass Filter, we could theoretically leave only the vibration generated by our bearing fault
Band Pass Filter

Amplitude

Frequency

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Enveloping and High Pass Filtered Signal Our Enveloped or High Pass Filtered Signal would look like this:

Amplitude

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What Envelope or High Pass Filter Should We Use? We need to know what frequency or frequencies we are trying to isolate The frequencies are generated by the impact of the ball or roller as it passes over the defect on the race

So what frequency is this?

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What Envelope or High Pass Filter Should We Use?

If we envelope properly, we should be able to eliminate all the higher amplitude, low frequencies that are present in the signal:
Unbalance Frequency (1X) Misalignment Frequencies (1X and 2X) Looseness Frequencies (1X and 2X and possibly more running speed harmonics) Fundamental Bearing Defect Frequencies (Non-harmonics from around 3X to around 40X)
Amplitude

So what frequency is this?

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Bearing System Natural Frequencies If we envelope properly, all we should have left is the bearing natural frequency response to the impacts that are occurring as the balls or rollers pass over the defect(s) Why?
Because this gives us a measure of the energy generated by any impacts or impulses on the system Since we are measuring the amount of resonance occurring in the system, it will be very sensitive to the severity of the impacts and hence, the severity of the fault If measured properly, we should see almost all bearing related energy

Copyright 2005 Rockwell Automation, Inc. All rights reserved.

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What High Pass or Envelope Filters are Available in the Hardware?

Rockwell Automation (Entek and IRD Brands)
Use Analog High Pass Filters 100 Hz, 200 Hz, 500 Hz, 1 KHz, 2 KHz and 5 KHz

SKF
Use Analog Envelope Filters 5 to 100 Hz, 50 to 1000 Hz, 0.5 to 10 kHz, 5 to 40 kHz and 250 to 350 kHz

CSI
Use Analog High Pass Filters 500 Hz, 1 KHz, 2 KHz and 5 KHz

Both CSI and Rockwell Automation then apply a digital low pass filter to the signal to create the Envelope

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What Does the Spectrum Look Like?

Amplitude

What are These?

Amplitude

Frequency
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Where Do the Sidebands come from?

Amplitude

Sideband or Modulating Frequencies

Amplitude

Carrier Frequency

Frequency
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Theres more to Enveloping If we apply a Digital Low Pass Filter as the upper end of the Envelope, we can then extract the modulating frequencies from the impact waveform
Digital Low Pass Filter (FMAX)

Amplitude

Frequency

The Key Question: What frequencies are left?

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Bearing Fault Frequencies! Ball Pass of the Inner Race (BPIR) Ball Pass of the Outer Race (BPOR) Ball Spin Frequency (BSF)

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Any Questions? Remember, this was a practical overview!

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