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ROLLING-ELEMENT BEARING ANALYSIS (REBA)


TECHNIQUES AND PRACTICES
Dennis H. Shreve
Commtest Inc.

INTRODUCTION
When it comes to diagnosing common machinery problems with the tools offered with vibration
measurements and monitoring, there are typically 5 major areas requiring correction: (1) unbalance, (2)
misalignment, (3) looseness, (4) resonance, and (5) rolling-element bearing faults. This paper will
examine modern-day techniques for early detection of faults in rolling-element bearings.
We will cover the considerations and rules for making measurements. We will then examine several
analysis techniques and discuss field experiences in pinpointing typical problems.
There are certainly lots of product offerings, tools, techniques, and published literature on the topic.
Some technicians have stated that the vast number of choices is a bit overwhelming and intimidating. Our
goal here is to take away some of the mystery surrounding the required measurements and to make the
best of the situation through the tools that are available. We will examine some of the history in making
meaningful measurements, the scientific terminology, and the industry jargon.
BASICS
By definition, a bearing is a load carrying member and is usually a set of round elements placed between
two flat pieces. Relative motion of the two outside pieces causes rolling, with very little resistance or
friction. It actually started way back in history with wooden logs placed on the ground and a stone
(carrying) block on the top. The log at the back came out under movement and was then moved back to
the front, and the sequence continued. Today, the rolling elements are held captive in a circular cage and
do not fall out under a moving load. (At least, that is the concept and the design criteria!) Rolling
elements offer a nice set of trade-offs in terms of cost, size, weight, carrying capacity, durability,
accuracy, and low friction, and the list goes on and on.
FACTS
With an understanding of the concept and the application, we then need to take a look at why bearings fail
and cause machinery downtime. Experience shows that there are typically 5 contributing issues: (1) poor
design, (2) misapplication, (3) poor installation, (4) improper loading, and (5) poor care and maintenance.
From this, we learn that we must first choose the proper bearing for the application. We must be careful
with storage, shipping, and handling. We then must use proper bearing installation techniques. Once
installed on the machine, it is then important to make certain that proper skills are employed to ensure
proper assembly, balancing, alignment, and a variety of other good maintenance tasks. After putting a
selected bearing into operation, it is important to periodically check for proper operation and maintain a
routine lubrication schedule. The bottom line is that everyone involved in the process needs to be trained

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on the value of following good practices for rolling-element bearings and being proactive and taking the
time to do the job right.
Even with all this knowledge and understanding, studies show that less than 10% of all bearings achieve
their design life. 16% fail due to improper handling and installation. 14% fail due to contamination.
36% fail due to inadequate lubrication. 34% fail due to fatigue issues (i.e., excessive loading).
In the L10 life bearing life expectancy equation, the actual load is a cubed function in the denominator.
This means that any excessive loading due to unbalance and misalignment has a major effect. In fact,
10% extra loading cuts life by 1/3. A 20% extra loading cuts life by half!
Now, we need to take a look at factors to consider in calculating L10 life. It is the number of hours to
expect for 90% of the population. A full load life is estimated at 1,000,000 revolutions. While it sounds
impressive, a shaft turning at 3600 RPM would be at this number of revolutions at only 4.6 hours of
operation. Thus we need to implement some conservative design factors. A light load is considered at
<6%. A heavy load is considered at >12%. Thus, normal loading is between 6% and 12%.
OUR GOALS
We wish to have early detection of even the slightest fault appearing in the rolling-element bearing. We
wish to avoid any down time and secondary damage caused by a bearing failure. We wish to pinpoint the
faulty component as quickly as possible through measurements of vibration levels relative to acceptable
standards. We then wish to decide an acceptable course of corrective action, with follow-up
measurements and verification. We typically follow the classical PdM 4-step process of Detection,
Analysis, Correction, and Verification.
There are several acceptable problem detection techniques employed for rolling-element bearings. These
include vibration analysis and acoustic emission, oil and wear particle analysis, and infrared
thermography. Each technology has its place in PdM; and in most cases, they are considered
complementary.
VIBRATION MEASUREMENTS
Concentrating on just one technical area, vibration analysis, we can usually break the measurement into 4
constituent parts: (1) Forced vibration due to unbalance, misalignment, blade and vane pass, gear mesh,
looseness, impact, resonance, etc. (2) Resonance response due to impacts, (3) Stress waves or shock
pulses, and (4) Frictional vibration. Converting the raw time waveform to the frequency domain, we start
to see some distinctive patterns. Harmonics are almost always caused by the time waveform shape.
Sidebands are due to amplitude or frequency modulation. Mounds (or haystacks) are random vibrations
showing up in a frequency range. A raised noise floor is due to while noise or large random events.
All this said, what are we looking for in our vibration measurement? We want to be able to detect the
slightest metal-to-metal contact from impacting components or inadequate lubrication in the bearing. We
are looking for a slight ringing caused by the bearing fault exciting (or resonating) a natural frequency in
the machinery setup. We are looking for the presence of a high-frequency, low-energy vibration.
Sometimes, this is referred to as raising the carpet level in the noise floor in the acceleration spectral

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readings especially at the high end of the frequency scale. We desire the capability to detect incipient
bearing failures with senses that transcend normal human abilities of sight, sound, touch, smell, etc.
Knowing the physical make-up of the bearing geometry, calculations can be made on 4 inherent fault
frequencies: (1) FTF (cage), (2) BSF (ball spin), (3) BPFI (inner race), and BPFO (outer race).
Fortunately, numbers have all been worked out in supplier handbooks and computer-based lookup tables.
Sometimes, if only the number of elements is known, estimates can be made to get into the right
ballpark. One crucial element, however, to any meaningful rolling-element bearing analysis is to know
the exact turning speed of the shaft. Bearing fault frequencies will be asynchronous.
STAGES OF FAILURE
There are usually 4 distinct stages of progressive failures of rolling-element bearings. In Stage 1, there
will be the presence of ultrasonic frequencies (typically well above 5 KHz) that are barely detectable in
the data. There will be only amplitudes appearing in the acceleration measurement. Bearing life at this
point is at 10-20%. At Stage 2, we will notice more ringing; and there will be more frequencies
appearing, most likely between 500 Hz and 5 KHz. Fault frequencies may show up now with modulated
sidebands. The time waveform will now show some impacting, with flat-topping or notching. Bearing
like is now down to 5-10%. At Stage 3, the energy begins moving down the frequency scale. Defect
frequencies begin to be more prominent. More harmonics and sidebands show up. The wear pattern
tends to flatten out peaks and patterns. The bearing will now get a bit hot to the touch. It is time to order
parts and schedule a change-out. Bearing life is now less than 5%. Stage 4 is best to avoid. The 1X
energy begins to increase dramatically as clearance is quite noticeable. Broadband spectral noise
increases, as evident by a raised noise floor. Failure is eminent! At best, there is only about 1% bearing
life remaining. Several experts in the field have published pattern recognition charts to help identify the
stage of rolling-element bearing failure.
EARLY DETECTION
Understanding the indications and stages of failure, it is our goal now to measure and detect the potential
problem as early as possible. We need to understand the vibration energy. We stated earlier that it
emanates from contact between two metal surfaces. There is a shock (or pressure) wave created. An
analogy is the wave that is set up by an earthquake and the tsunami. You can also see the effect by
tossing a pebble into a pond. The signal resulting from a bearing defect propagates its way through the
metal surfaces when there are no air gaps to filter it. (The measurement signal depends upon good metalto-metal contact, as it is high frequency in nature.)
Special instrumentation and detection circuits have been designed to identify these tell-tale small spikes.
Spikes are short in duration and cause ringing characteristics of natural system resonances. By using the
proper instrumentation, an accelerometer, and good measurement practices, these small signals can be
detected in the presence of lots of noise and higher amplitudes.
Processing of these tell-tale signals and presenting them in an easy-to-understand format has been the
challenge faced by instrument suppliers since the early 1970s. We will attempt to list a few of the
trademarked names here - gSE, Spike Energy, Spike Energy Spectrum, ESP (Envelope Signal

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Processing), HFD (High Frequency Detection), SEE (Spectral Emitted Energy). PeakVue, Shock Pulse,
Stress Waves, Enveloping, Demodulation, Cepstrum to name a few.
There is a common thread to all these, and we will now discuss the fundamental and underlying concept.
Inherent to all machine structures, there are minute tell-tale signals that show the presence of repetitive
impacts that indicate possible bearing faults, gear damage, looseness, cavitations, and similar faults. One
just has to examine closely with the proper instrumentation and know what to look for. A machine
component, bearing housing, or sensor resonance condition is excited by these impacts similar to
striking a bell. These repetitive fault frequencies can be identified with special signal processing
techniques, including filtering, peak detection, and frequency determination. Careful measurement and
collection methods are essential to enable this technique. Advanced signal processing technology and
instrumentation afforded today make this a proven analysis tool in routine data collection in most
predictive maintenance programs.
For this technique to work, we fist need to see the spikes created from the impacts. We also need to see
the ringing caused by the excitation of natural frequencies. We then need to apply a method to determine
or see the repeated fault frequency. (Sometimes, this method for stripping off the content in a carrier
frequency is called demodulation. It is similar to how a typical AM radio works. A carrier frequency is
broadcast with program content added through amplitude modulation (AM). The radio is tuned to the
carrier frequency - like 620 KHz on the band - and the program information is stripped off through
demodulation.) The frequency of the repeated fault frequency is then determined and compared to
possibilities to help isolate the fault itself.
MEASUREMENT REQUIREMENTS
While the concept may sound simple enough, there are some very strict requirements in order to make it
work. First of all, the sensor of choice, typically an accelerometer, must have the capability of measuring
high frequencies and be very solidly mounted. For trending data, it should be mounted on a target
location with the orientation maintained. To get the best transmission, it should be mounted in the load
zone of the bearing housing. (Remember, our goal is to get the best possible mechanical interface to
permit the transmission of low-level, high frequency energy.) Once, we have the means for making the
measurement, we then need a high-frequency energy detection method. We are attempting to detect a
repeated fault and ringing condition. We wish to strip out any low frequency content that is associated
with actual running speed. We need the ability to demodulate (sometimes called enveloping) the signal
peaks that are the characteristic repetitive fault. We then need to determine the repetition fault frequency,
show it in an FFT display, and compare its pattern to that of published fault-frequency data. Thus, the
method is really a 4-step process: (1) we first high-pass the measurement to eliminate any low frequencies
associated with running speed, (2) we then detect the repetitive peaks showing up in the time waveform,
(3) we low-pass that signal to strip off the resonance carrier, and finally, (4) we present the FFT to
compare patterns to published data.
DEMODULATION
Demodulation (or enveloping) is a typical means for getting at the tell-tale fault frequency. As mentioned
earlier, the technique is analogous to stripping out the program information from an AM radio broadcast.
We first incorporate some band-pass filtering of the composite raw signal from the accelerometer to
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purposely strip out any normal running speed components. We are looking for small ultrasonic frequency
components and eliminating any high amplitude signals associated with 1X and multiples up to about
10X. Our primary goal is to include only the fault frequencies that are exciting inherent resonance in the
machine structure. We wish to intensify and draw out repetitive components of the fault itself. Once this
signal has been deciphered in time, converting it to frequency allows the display of a pattern that can be
compared to published fault-frequency data. If problems exist, the demodulated FFT presentation will
show up as a distinctive saw tooth or comb harmonic pattern of the actual bearing fault, such as a
BPFI or BPFO.
While we are typically only looking for the presence of fault frequencies, and there are no published
standards for acceptable amplitudes for the demodulated data, we can set up trending on a machine.
However, for these records to have much meaning, we have to ensure the following conditions: same
hardware, same exact measuring location, solid mounting and good transmission path, and the same
conditions.
PRE-REQUISITES AND PROCEDURE
While we have gone into a little detail of one proven concept for early detection of rolling-element
bearing faults, all available methods have a common thread. In order to achieve success in the program,
however, it is imperative that the installed bearing part number be known along with its characteristic
fault frequencies. These data need to be preloaded into any diagnostic software programs. It is also
imperative that the machine running speed be accurately recorded during the measurement. (Remember
that bearing fault frequencies are asynchronous in nature and will only be present in a displayed
frequency spectrum when there is an impending problem.) The bearing faults will tend to cause impacts
that excite natural resonances in the machine components or transducer. The fault frequency will be
recurring throughout the captured data. A demodulation or enveloping technique as described in this
paper will strip out the repetition rate in time. The actual fault frequency will then be displayed in an FFT
display along with the actual bearing data overlays for pinpointing the root cause of the problem.

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SUMMARY REMARKS
Data collectors and PdM programs have incorporated methods for detecting incipient rolling-element
bearing defects since the early 1970s. It has been proven that machinery vibration measurements in time
waveform and spectrum can indeed provide early (tell-tale) signs of rolling-element bearing problems.
Special signal processing techniques have been incorporated in most portable instruments to detect
impacting spikes and pinpoint specific fault frequencies. Comparing the resulting pattern in an FFT
display to published fault frequencies can determine the root cause of the problem. Field experiences
have shown the concepts to be quite accurate, dependable, and reliable. Considerable cost savings in
maintenance and production are afforded by the effective application of these techniques and practices.
AUTHOR CONTACT INFORMATION
Dennis H. Shreve, CMRP, VA III
Channel Support Engineer
Commtest, Inc.
6700 Baum Drive, Suite 12
Knoxville, TN 37919
Phone 1-865-862-6671
e-mail: dshreve@commtest.com

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