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VSRD-TNTJ, Vol. 2 (5), 2011, 249-261

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Assessment of Bearing Fault Detection

Using Vibration Signal Analysis
1

Amit R. Bhende*, 2GK Awari and 3SP Untawale

ABSTRACT
The dynamic performance of bearing is highly influential on performance of any machine. More specifically,
the presence of bearing defects often results in reduced efficiency, or even severe damage of the machine under
consideration. Rolling element bearing find widespread domestic and industrial application. Different methods
are used for detection and diagnosis of the bearing defects. This paper is intended as a tutorial overview of
bearing fault detection using vibration signal analysis. It reviews complete working of the condition monitoring
system. Various signal collecting transducers, selection of transducers according to the applications are
discussed. The signal processing techniques that are being used for the analysis are also discussed.
Keywords : Fault Detection, Vibration Signal, Time Domain, Frequency Domain.

1. INTRODUCTION
Rolling element bearings are a common component in machinery. Therefore, they have received great attention
in the field of condition monitoring. A reliable online machinery condition monitoring system is very useful to a
wide array of industries to recognize an incipient machinery defect so as to prevent machinery performance
degradation, malfunctions, or even catastrophic failures. Fault detection can be conducted based on information
carriers such as the acoustic emission, stress waveform, oil analysis, temperature variation, vibration, etc.
Commonly used technique for fault detection is vibration signature analysis. Vibration monitoring and analysis
in rotating machineries offer very important information about anomalies formed internal structure of the
machinery. The information gained by vibration analysis enables us to plan a maintenance action [1]. Vibration
signature based diagnostics are mainly concerned with the extraction of those features from a diagnostic signal,
which can be related to a good or a defective state of the component. This paper reviews the various bearing
defects present in rolling element bearing and the reasons for the defects. Various fault detection techniques are
studied and compare it with vibration analysis. The complete architecture of the condition monitoring system is
discussed. Various signal collecting transducers, selection of transducers according to the applications are
____________________________
1

Lecturer, 2Principal, 3Professor, 123Department of Mechanical Engineering, Nagpur University, Nagpur, Maharashtra,
INDIA. *Correspondence : amitbhendejobs@yahoo.co.in

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discussed. The signal processing techniques that are being used for the analysis are also discussed.

2. TYPES OF DEFECT
Vibration monitoring is the most popular technique for bearing diagnostics. In a machine under operation,
vibration is always present. The levels of vibration usually increase with deterioration in the condition of the
machine.
Table 1 : Bearing Failure Mechanisms
Failure

Reason for damage

Name of the

Mechanisms

Results

process

Mechanical

Permanent indentation created by

damage

rolling element overload

Crack damage

Manufacturing defect or operating

Brinelling

Nicks or indentation

Crack

stress due to overload

Wear damage

Gradual deterioration or abrasive

Scuffing

particle entrained

scoring

Insufficient

When

lubrication

condition

lubrication

becomes in adequate increases

or

Loss of dimensioning and associate

problem
Accelerate scuffing and scoring increases
bearing temperature

friction
Corrosion

Humid

ambient

subjected

to

Produce rust particles and pits rapid wear

surface oxidation
Fatigue damage

Material

fatigue

after

certain

Formation of minute crack propagated

running time
Plastic

Excessive loading while stationery

Indentation of raceway/localized plastic

deformation

or underlying small movements

deformation

Faulty

Excessive

Radial

installation

misalignment, loose fit, excessive

running

force used in mounting the bearing

difference between inner and outer race

Incorrect

Poor choice of bearing type or size

Low load carrying capacity or low speed

design

for required operation

rating

preloading,

preloading
and

results

increased

in

noisier

temperature

Hence, vibration is an important parameter for the condition monitoring of machines and their elements.
Vibration displacement, velocity and acceleration levels can also be measured. Acceleration is used for high
frequencies and displacement for low frequencies. Vibration velocity is normally measured. Vibration can be
measured using various sensors. This paper deals with the vibration analysis method which now dominates the

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other methods. The defect in the bearing may arise due to improper mounting, improper operation, and
overloading. The defects may be classified into distributed and localized defects. Surface roughness, waviness,
and misaligned races are included into the class of distributed defects. The localized defects include cracks, pits,
and spall caused by fracture on the rolling surface. Some of the reasons for the cause of the defect are discussed
below in table-1.

3. FAULT DETECTION TECHNIQUES

There are several techniques that can be employed to predict the condition of bearing, these include: vibration
monitoring, Current Signature Analysis, Tribology, Thermography, etc... Several studies showed that the most
important technique in predictive maintenance is vibration analysis as it gives clear indications regarding the
condition of the machine in question, in addition the level of vibrations and the frequency at which these
vibrations occur can serve in determining the exact location of the defect and possibly severity of such defect.
Tab.2 shows the Comparison of various methods of fault detection
Table 2 : Comparison of Various Methods of Fault Detection
sr. no.

methods of analysis

temp.

press.

Flow

oil analysis

spm meter

vibration-fft

out of balance

Misalignment

bent shaft

ball brg. damage

journal brg. damage

gear damage

mechanical looseness

mechanical rubbing

noise

10

cracking

11

leaking valve seats

X
x

x
x
x

4. THEORY BEHIND VIBRATION ANALYSIS

Each elements of bearing has unique characteristic rotational defect frequency which depends on the kinematics
consideration, this frequency can be calculated knowing the geometry of the bearing and its rotational speed,
usually these frequency lie in the low-frequency range (less than 500Hz). When a certain defect is present on a

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bearing element (example of a rough defect ), an increase in the vibration levels at this frequency can be noticed,
and thats why frequency-domain analysis of vibration reading is usually carried out to determine the condition
of motor bearings.

5. ARCHITECTURE OF FAULT DETECTION SYSTEM

First step of vibrations measurement of the bearing is to collect the signals. The sensing element for collecting
the signals will be accelerometer. The accelerometer gives a voltage reading that corresponds to the level of
vibration. The analog signals given by the accelerometer are then collected by the Data Acquisition Card and
transform them into digital signals so that it can read by

an analyzing interface. The analyzing interface

(computer software) is used to perform and use the analysis methods.

SOURSE OF VIBRATION

VIBRATION MEASUREMENT
DEVICE

DATA ACQUISITION CARD

SIGNAL PROCESSING

COMPUTER DISPLAY

Fig. 1 : Components of Architecture

5.1. Vibration Measurement

A number of transducer types exist for measuring machine vibration, including proximity probe, velocity
transducers, accelerometers etc. The measurement of machine casing acceleration is the most common method
used for bearing fault detection.
This is normally achieved by mounting piezoelectric accelerometer externally on the machine casing, preferably
near or on the bearing housing, or on the portion of the casing where relatively rigid connection exists between
the bearing support and transducer. Piezoelectric sensors are less sensitive to temperature which is important
since most machinery fault results in temperature increase [28]. This will allow the bearing vibration to transmit
readily through the structure to transducer. Accelerometers have the advantage of providing a wide dynamic
range and a wide frequency range for vibration measurement. They have been found to be the most reliable,
versatile and accurate vibration transducer available.

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Velocity transducers are used for measuring the velocity of the machine casing to which they are attached. They
are capable of measuring down to almost DC. Most machines will have a flat velocity frequency response from
near DC to 2 kHz. For slow speed rotating machinery, velocity is often used when a vibration velocity
magnitude measurement is required. They have not found wide acceptance for bearing fault detection as the
wider frequency range available with accelerometers has been found to be better, even for slow speed rotating
machinery. Proximity probes are used for bearing fault detection by mounting directly on the outer race to
measure outer race deflection at each ball pass. A number of probes are used including eddy current, strain
gauge and optic fiber transducers. Whilst giving a very clear image of the ball pass deflection of the outer race
from which diagnostics such as ball speed ratio can be made, it necessitates modification and installation of the
transducer into the bearing housing to provide clear view of the bearing outer race. Whilst this could be readily
achieved in most instances at the manufacturing stage, for a large number of bearing it is not possible after
production. This is seen as a severe limitation on its use as opposed to the external mountings of accelerometer.
Wilson Wang and Ofelia Antonia Jianu [28] have developed a new low cost smart sensing unit for vibration
measurement and signal analysis. The sensing unit uses two ICP accelerometers (e.g., PCB 320 series) with
sensitivity 1.02 mV/(m/s2 ) and measurement range 4900m/s2 peak. Two sensors are mounted perpendicularly
to measure vibrations along x- and y-direction, respectively.

5.2. Signal Processing Techniques in Vibration Analysis

Many signal processing techniques have been proposed in literature for machinery fault diagnosis [2], and the
authors research group has also proposed several approaches for fault detection in gearboxes [3][6]. In timedomain analysis, a bearing fault is diagnosed with the help of some statistical indexes (e.g., RMS value, crest
factor, or kurtosis); however, most of these monitoring indexes are sensitive to noise and operating conditions.
Frequency analysis may be the most fundamental approach for bearing fault detection. Bearing health conditions
are assessed by examining the fault-related characteristic frequency components in the spectra [14] or some
associated expressions such as bispectrum and cepstrum maps [15], [16]. Frequency based techniques, however,
are unsuitable for the analysis of non stationary signatures that are usually related to machinery defects. Non
stationary or transient signals can be analyzed using timefrequency domain techniques such as short-time
Fourier transform (STFT) [17], WignerVille distribution [18], or wavelet transform (WT) [3]. In fault
diagnosis, the WT is more suitable than either the WignerVille transform that contains some cross terms or the
short-time FT that has a limited multi resolution solution. According to signal decomposition paradigms, the
WT can be performed by the continuous WT [4], discrete WT [19], [20], wavelet packet analysis [21], and
extended WT with post processing (i.e., using singularity [22], FT [23], [24], and energy density [5], [25]).
Although a wavelet packet map can provide more information, its processing results are usually difficult to
explain especially when the bearing operates under different load/speed operating conditions.

5.2.1.

Time Domain Techniques

One of the simpler detection and diagnostic approaches is to analyze the measured vibration signal in the time
domain. Whilst this can be as simple as visually looking at the vibration signal, other more sophisticated
approaches can be used such as trending time domain statistical parameters. A number of statistical parameters

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can be defined as RMS, peak, crest factor, kurtosis, clearance factor, impulse factor, shape factor and beta
moments based upon the beta distribution.
Time domain statistical parameters have been used as one-off and trend parameters in an attempt to detect the
presence of incipient bearing damage.
(1)

(2)

(3)

(4)
(5)

(6)

(7)

Where

denotes the mean value of the discrete time signal x (t) having N data points. For vibration data

measured from undamaged bearings, the level of kurtosis and crest factor are approximately 3.0 and 3.5
respectively where the vibration data is relatively random. For the vibration data with the inner race bearing
defect, the kurtosis was 4.57 and the crest factor was 6.53.
Other time domain parameters are the clearance factor, impulse factor and shape factor. These three nondimensional vibration amplitude parameters were found to be useful under simulation conditions using a
Gaussian probability density function model of fatigue spalling. The clearance and impulse factors were the
most useful with the clearance factor being the most sensitive and generally robust for detection of incipient
fatigue spalling.
Fabio Immovilli, Marco Cocconcelli, Alberto Bellini and Riccardo Rubini [29] investigated the statistical
properties of machine signals in order to identify in what bandwidth that disturbance is more suitable to appear.
This approach is believed to be more effective for the specific characteristics of generalized-roughness faults.
Then, the energy of the vibration signal computed in the previously defined bandwidth is used as a diagnostic
index to monitor the status of the machine.

5.2.2.

Frequency Domain Technique

The frequency domain refers to the display or analysis of the vibration data based on the frequency. The time
domain vibration signal is typically processed into the frequency domain by the application of Fourier
transform, usually in the form of fast Fourier transform [FFT] algorithm. The principal advantage of the method

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is that the repetitive nature of the vibration signals is clearly displaced as peaks in the frequency spectrum at the
frequency where the repetition takes place.
It is useful to refer to the power spectrum when investigating vibration data in the frequency domain. If a
discrete time signal x (t) represents a sampled periodic function with period T, the Fourier series expansion of x
(t) can be obtained from the Fourier integral
(8)
Where f represents discrete equally spaced frequencies being multiples of the reciprocal of the period T. the
power spectrum P(f)can be defined as the magnitude or power obtained from the Fourier integral and can be
obtained by:
(9)
Where * represents complex conjugation and E [ ] represents the expected value. The FFT provides the fast and
convenient means of computing the discrete Fourier Transform of vibration data and a window function can be
used to force the vibration data to appear periodic, which reduces leakage from one frequency component to
another. A smooth estimate of power spectrum computed from stationary random data can be obtained by
averaging the spectrum obtained by equation over a number of windowed data record and is often referred to as
the Welch method of power spectrum estimation.
One of the main purposes in computing power spectra of vibrating data is to identify major frequency
component which can be found in spectrum and then use these components and their amplitude for the trending
purposes.
Spyridon G. Mouroutsos and Ioannis Chatzisavvas [30] compared the results taken from FFT and envelope
analysis and conclude that FFT is more suitable for finding the fault where as envelope analysis give excellent
results in predicting the damage.

5.2.3.

Envelope Analysis

The interaction of the defect in the rolling element bearings produces pulses of very short duration, whereas the
defect strikes the rotation motion of the system. These pulses excite the natural frequency of the bearing
elements, resulting in the increase in the vibration energy at these high frequencies. The resonant frequencies
can be calculated theoretically. Each bearing element has a characteristic rotational frequency. With a defect on
a particular bearing element, an increase in the vibration energy at this element rotational frequency may occur.
This defect frequency can be calculated from the geometry of the bearing and element rotational speed. By using
a method called high frequency resonance technique [HFRT], or envelope technique, these frequencies could be

isolated and demodulated to give an indication of bearing condition [26,27]. The envelope detection process is
the heart of the HFRT diagnostic system. An accelerometer signal entering the envelope detector may be either
attenuated or pre amplified. The resulting signal is then sent through a band pass filter set for an appropriate
carrier frequency. The filtered signal is then rectified and demodulated in order to extract the envelope of the

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modulated carrier frequency signal. This envelope is then analyzed for frequency content using a real-time
frequency spectrum analyzer. The energy levels of amplitude of the defect frequencies, as it appears in the
spectrum, can be used to diagnose the condition of the rolling element bearing.
An alternative to the analogue enveloping technique as outline above is available using digital signal processing
as detailed in number of references and is most readily described in terms of the Hilbert transform and the
analytical signal. An analytical signal is a complex time signal whose imaginary component is the Hilbert
transform of the real part. Thus if a (t) represents the time signal,
(10)
And H is the Hilbert transform, then the analytic signal is defined as,
(11)
Yuan Yunlong, Zhang Zhenxiang [32] used Hilbert Transform for analysis of the demodulation and spectral
refining of the signal. S. A. McInerny and Y. Dai [31] presented a laboratory module on fault detection in
rolling element bearings. The shortcomings of conventional vibration spectral analysis for the detection of
bearing faults is examined in the context of a synthetic vibration signal that students generate in MATLAB. This
signal shares several key features of vibration signatures measured on bearing housings. Envelope analysis and
the connection between bearing fault signatures and amplitude modulation/demodulation is explained. Finally, a
graphically driven software utility (a set of MATLAB m-files) is introduced.

5.2.4.

Ceptrum Analysis

It is a technique for processing seismological data for separating out the influence of echoes from data. The
ceptrum was originally defined as power spectrum of the logarithmic power spectrum, but a number of
variation have also been developed. The most general definition is given as :
(12)
Where the original frequency spectrum F(x(t)) can be either a power spectrum or a complex spectrum. The
principal use of the ceptrum for beraing fault detection is in detecting periodicities in the frequency spectrum
corresponding to bearing frequency harmonics and associated sideband patterns.

5.2.5.

Time Frequency Analysis

A number of time frequency have been developed which show potential for detecting bearing problems in some
of the more complex classes of rotating machines where the signal to noise ratio is low and a large number of
frequency components are present. These techniques include the short time Fourier transform (STFT), wingerville distribution (and variance) and the wavelet transform.
Wilson Wang and Ofelia Antonia Jianu [28] proposed a new signal processing technique (i.e., wavelet energy
spectrum) and implemented for bearing fault detection. Bearing resonance signatures are first demodulated by
using wavelet analysis, then the resulting wavelet energy functions are integrated to enhance feature

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characteristics, and finally, a correlation spectrum is employed to highlight bearing-fault-related feature

characteristics.
Yuan Yunlong, Zhang Zhenxiang [32] presented time-frequency analysis technique, combined with kurtosis
method and wavelet analysis for the detection and diagnosis of the faults based on the unstable vibration signals
from the rolling bearings. With this method, the signals were decomposed and reconstructed by the wavelet
analysis, followed by the analysis of demodulation and spectral refining by using Hilbert transformation. The
experiment results show that the fault information of the rolling bearings can be detected and diagnosed
effectively, which favor the quick determination of the detailed faulty type within the bearings.
Claudio Bianchini, Fabio Immovilli, Marco Cocconcelli, Riccardo Rubini and Alberto Bellini

[33] applied

various signal processing techniques were applied to the vibration signal (STFT, Welch periodogram, cepstrum
and envelope analysis). Even the scalar quantities (crest factor, kurtosis) were not determinant in the
identification of the faulted bearing. The obtained results proved that it is very hard to find a single characteristic
quantity that states the health condition of the bearing. Indeed the results obtained by the FFT alone and simple
envelope analysis were the most relevant ones and then they were reported in the paper.
Induction motor vibrations, caused by bearing defects, result in the modulation of the stator current. Jafar Zarei,
Javad Poshtan [34] detected bearing defect using the stator current analysis via Meyer wavelet in the wavelet
packet structure, with energy comparison as the fault index. The advantage of this method is in the detection of
incipient faults. The presented method is evaluated using experimental signals.

5.2.6.

Other Techniques

Antoniadis and G. Glossiotis [38] proposed an alternative framework for analyzing bearing vibration signals,
based on cyclostationary analysis. Traditionally, the signal processing is done by the methods, which assume
statistically stationary signal features. This framework, being able to model, additionally, signals with
periodically varying statistics, is better able to exhibit the underlying physical concepts of the modulation
mechanism present in the vibration response of bearings.
Fabio Immovilli, Alberto Bellini, Riccardo Rubini and Carla Tassoni [35] This paper compares the use of the
vibration and current signals for bearing faults detection, in order to check advantages and drawbacks of the two
approaches in the different situations.
A novel method to diagnose the bearing fault is presented by B. Muruganatham, M.A. Sanjith, B. Krishna
Kumar, S.A.V. Satya Murty, and P.Swaminathan [36]. The proposed method is based on the analysis of the
bearing vibration signals using Singular Spectrum Analysis (SSA). SSA is a non-parametric technique of time
series analysis that decomposes the acquired bearing vibration signals into an additive set of time series to
extract information correlated with the condition of the bearing.

6. SOFTWARES FOR VIBRATION ANALYSIS

Radoslav Tomovic, Vojislav Miltenovic, Milan Banic, Aleksandar Miltenovic [37] investigated the influence of
internal radial clearance value and number of rolling elements influence on rigid rotor vibrations in unloaded

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rolling element bearing. The results over time were processed by FFT analysis using the MATLAB functions for
digital signal processingSignal Processing Toolbox.
Changting Wang and Robert X. Gao [39] presented the design and implementation of a LabVIEW-based virtual
instrument (VI) as part of an integrated bearing condition monitoring system. The VI is capable of performing
various test and measurement functions including data acquisition, time and frequency domain analysis, data
enveloping, archiving, and management. Furthermore, the VI enables an efficient and user-friendly interface for
comprehensive on-line bearing working parameter display, which is of critical importance to bearing health
monitoring and diagnosis.
D.Ganeshkumar, T. Manigandan, S. Palaniswami [40] present the development of an intelligent and low-cost
vibration monitoring and fault diagnostic system using Virtual Instrumentation technique. Intelligent System is
built with the aid of LabVIEW software (version 7.1) and DAQ (Data Acquisition) card PCI-6042E for testing
the bearings with reference to the standard bearing. Both the bearings are connected to the common shaft of
vibrating segment and vibration analysis is carefully carried out using a piezo-electric sensor with advanced
charge amplifier. The vibration signals from standard and bearing under test, are signal conditioned and
connected to the Terminal block (BNC-2120) at two different channels. Analysis is done with LabVIEW based
software program for Time and Frequency domain study. Comparison between standard and test bearing is
studied based on the Fundamental and multi tones of the signal from its random behavior in frequency domain.
Result and recommendations are displayed according to the condition of the bearing with an allowable
tolerance.

7. CONCLUSION
This paper has attempted to review fundamentals and practical applications of the vibration signature analysis
used for bearing fault detection. A review of publications on bearing fault detection or diagnosis based on
vibration signature analysis reveals the following ironic facts.
In general there are two methods which can be used for machine condition monitoring, one shot analysis and
trending. It can be concluded that trending should always be used wherever possible. In absence of trend data
however, one shot analysis can be effective. A number of techniques can be used for trending as detailed above.
These include the time domain statistics, frequency domain parameters, envelope analysis parameters, ceptrum
amplitudes. The majority of these parameters will require detailed knowledge of the bearing defect frequency to
correctly diagnose bearing failure. The one shot techniques which have been demonstrated to be useful include
some of the time domain statistics such as periodic ad transient features as well as the probability density
distribution.
Time frequency analysis is more popular to investigate transient features such as impact exciting resonances.
Localized fatigue damage of the bearing raceways and rolling elements will be easiest failure mode to detect
because the characteristic bearing defect frequencies are well understood. Wear and geometric form errors of the
raceways can also give rise to periodic vibrations. For the majority of other failure modes such as lubrication
starvation, corrosion, excessive looseness or faulty installation, definitive vibration characteristics are not well
understood and the use of comprehensive trending and/or the application of advanced signal processing will be

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required.

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