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Study of a predictive maintenance system based on vibratory analysis for the

monitoring of rotating machines

Conference Paper · May 2017

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International Conference on Civil Engineering and Materials (ICCEM'2017)
11-12 May 2017, Al Hoceima, Morocco

Study and development of a predictive maintenance system based on

vibratory analysis for the monitoring of rotating machines

B. Abou elanouar*, M. Elamrani, B. Elkihel, F. Delaunois

Laboratoire Electronique et Systèmes, Faculté des sciences Université Mohamed Premier, Oujda, Maroc
Laboratoire génie industriel, maintenance et production mécanique ENSAO, Oujda, Maroc

*For correspondence: Email: b.abouelanouar@ump.ac.ma

Abstract

Investing in the reliability, maintainability and availability of modern production equipment significantly
increases their durability. Concretely, the anticipated gains from the implementation of a simple system of
management in preventive maintenance improve the product quality, productivity, and profitability of
manufacturing and production plants. Indeed, predictive maintenance is a philosophy or attitude that uses the
actual operating condition of plant equipment and systems to improve overall effectiveness of manufacturing and
production plants. A comprehensive predictive maintenance management program uses the most cost effective
tools (vibration monitoring, thermography, tribology) to obtain the actual operating condition of critical plant
systems and based on this actual data schedules all maintenance activities on an as-needed basis. Thus, a
predictive maintenance program based on vibration analysis deals with potential vibration problems by using
electronic hardware and software to monitor vibration, and to distinguish between normal vibration signals and
those that indicate problems in equipment operation. The aims of this study were: (1) to provide an overview of
vibration monitoring as a predictive maintenance tool for faulty rotating machines, (2) to outline the steps to
implement a vibration analysis program and (3) to give an experimental results of vibration analysis of different
rotating machines such as: bearings, gears and electric motors. It was found that the vibration monitoring is an
essential tool of any good predictive maintenance program for the early detection and diagnosis of machinery
defects.

Keywords: Preventive maintenance, Predictive maintenance, Vibration monitoring, Rotating machine, Defects

1. Introduction
Advances in the design and manufacture of rotating machines have given rise to more and more efficient
machines. As their mass power is constantly increasing, they have to cross several critical speeds in climbing
speed and slowing down. The inevitable machining and mounting faults then cause considerable vibratory
problems. Manufacturers and operators seek to eliminate them in order to increase the service life of the
machines, to optimize their efficiency and to ensure their regularity of operation [1].

An effective predictive maintenance program will depend on several factors, the largest of which is program
management. Two major factors in creating a successful program are to acquire the correct equipment and to train
the personnel that will administer the program. Fortunately most companies that sell vibration monitoring
equipment offer free seminars on the use of their equipment. Starting a predictive maintenance program is a large
task that demands a structured approach. Predictive maintenance should be gradually integrated into the current
maintenance program in five steps [2]:
International Conference on Civil Engineering and Materials (ICCEM'2017)
11-12 May 2017, Al Hoceima, Morocco

1. Choosing personnel
2. Selecting a program type
3. Purchasing the equipment
4. Providing office space
5. Choosing a route.

A predictive maintenance program uses vibrational analysis to deal with potential vibration problems by
using electronic hardware and software to monitor vibration, and to distinguish between normal vibration signals
and those that indicate problems in equipment operation. Vibrational analysis is rapidly becoming standard
practice in most industrial predictive maintenance programs. Many industries have found that there are significant
advantages including cost savings in using this method to predict component failure in rotating machinery. Since
vibrational analysis is a tool that predicts component failure, those parts identified as needing corrective action
can be scheduled for repair or replacement during planned equipment shutdowns, rather than during costly
emergency downtime due to equipment failure [3].
Bearing and gear failures are the most common failure modes in rotating machines. Indeed, the
optimization of shapes and materials from conception, various techniques has been developed to control the
vibratory behavior of rotating machines. This communication presents a monitoring of the gears and the bearings
by the techniques of vibratory analysis in the time and frequency domains. In order to do this, various tests are
carried out on gear reducers comprising wear uniformly distributed over the toothing [4].

2. Experimental
2.1. Instrumentation
The equipment for collecting the vibratory data is shown in the figure 1. This is a vibrotest 60 equipped with an
AS_056 accelerometer with a sensitivity of 100mv / g.

Figure 1: vibrotest 60

2.2 Defects studied

In this experimental work, we study the most common defects in gears and bearings. In fact, failures detected at
the gears are mainly located in the teeth: these are the most stressed parts. For bearings, the most common fault is
that of the outer ring.

2.2.1 Gear defect

As shown in the figure 2, the defect studied was caused artificially on the wheel by making wear of a tooth of the
input pinion.
 International Conference on Civil Engineering and Materials (ICCEM'2017)
11-12 May 2017, Al Hoceima, Morocco

Figure 2: Failure mode studied for gears

2.2.2 Bearing defect

The bearing defect studied (~ 11mm) was artificially induced on the outer ring as shown in the Figure 3.

Figure 3: Failure mode studied for bearing

3. Results and discussion
3.1. Gear defect analysis
3.1.1 In the time domain
In this domain, we study the evolution of the RMS and Crest Factor indicators in the three directions (vertical,
axial and radial) as a function of the rotation speed.

RMS Values for healthy Gear RMS Values for Defective Gear
0.2
0.15
0.15
RMS mm/s
RMS mm/s

0.1
0.1 Radiale
Radiale
0.05 Axiale
Axiale 0.05
verticale
Verticale
0 0
600 900 1400 sec 900 1400
Frequency rd/mn Frequency rd/mn

ertical directions
International Conference on Civil Engineering and Materials (ICCEM'2017)
11-12 May 2017, Al Hoceima, Morocco

Crest factor Values for healthy Gear Crest factor Values for Defective Gear

2.5
2
2 Radiale
1.5 RadialE 1.5 Axiale

FC
CF

1 Axiale
1
Verticale Verticale
0.5 0.5
0 0
600 900 1400 600 900 1400
Frequency rd/mn Frequency rd/mn

Figure 5: Crest factor Values in radial, axial and vertical directions

The study presented in this section concerns the detection and diagnosis of gear failures. To do this, we have
chosen the most widespread and effective method: vibratory analysis. In the first place, an overall analysis of the
failure of wear of a gear tooth has been initiated. From the trend curves illustrated in the Figures 4 and 5, it can be
seen that the RMS indicator causes a misinterpretation because it increases with the speed of rotation. Whereas
the crest factor appears to be the most appropriate indicator for the detection of shock-type defects, particularly
those of gears. Moreover, it remains sensitive to the frequency band of the signal but not as much as the RMS.
Therefore, it is more significant to use the crest factor or the Kurtosis to characterize the vibrational signal of a
gear.

3.1.2 In the frequency domain

In this domain, a wear defect of a tooth is visualized at a peak corresponding to the meshing frequency
Fe = F1 * Z1.
F1: frequency of rotation of the input gear;
Z1: number of teeth of the pinion.
In addition to this peak it is necessary to visualize a peak at the frequency F1 and a peak on each side of Fe distant
from F1.

Figure 6: Vibration measurements in different frequencies

For the frequency domain, the analysis of the vibratory signals coming from different rotation frequencies (Figure
6) proves the efficiency of this method. Indeed, the frequency analysis of tooth wear-type gear defects is more
suitable for medium frequencies (easy visualization of the meshing frequency and its harmonics). However, by
changing the frequency band of the rotational speed, the vibrational manifestation of the fault has lost its pace and
the frequency of engagement has become difficult to detect.
 International Conference on Civil Engineering and Materials (ICCEM'2017)
11-12 May 2017, Al Hoceima, Morocco

3.2. Bearing defect analysis

3.2.1 In the time domain
In this study, we focus on the study of the evolution of indicators RMS and FC in both directions (axial and
radial) depending on the rotational speed.

1.5 RMSRadial values 3 RMSAxial values

2.5
1 2
RMS

RMS
1.5
0.5 1
0.5
0 0
300 500 600 900 1000 1200 1400 300 500 600 900 1000 1200 1400
Frequency (rpm) Frequency (rpm)

Figure 7: RMS Values in radial and axial directions: defective bearing and healthy bearing

5 Crest factorAxial Values

3 Crest factor radial values
Crest facctor 4
crest factor

2 3

2
1
1

0 0
300 500 600 900 1000 1200 1400 300 500 600 900 1000 1200 1400
frequency (rpm) Frequency (rpm)

Figure 8: Crest factor Values in radial and axial directions: defective bearing and healthy bearing

As shown in Figures 3 and 4, the RMS factor increases as a function of speed. The Crest Factor responds well
in the frequency range of 500 rpm to 1200 rpm. For low and high speeds, it decreases because the signal is less
pronounced and less amplified by default.

3.2.2 In the frequency domain

In the frequency domain, a fault is quantified by measuring the amplitude of the vibration velocity signal raised to
the bearing defect frequencies (FTF, BPFO, BPFI or BSF) or their harmonics [5]. The evolution of the
degradation a bearing degradation failure cause not only increasing the amplitude of the vibration at the
frequencies of bearings, but also generates vibration harmonics of these frequencies [6].
The bearings used in this test are tapered roller bearings (TIMKEN, 6005-2Z / C3) whose frequency
characteristics are listed in Table 1.

Rotation FTF BSF BPFO BPFI

frequency

Order 1 Order 0.42 Order 5.81 Order 6.7 Order 9.3

Table 1: Bearing frequencies TIMKEN, 6005-2Z / C3

International Conference on Civil Engineering and Materials (ICCEM'2017)
11-12 May 2017, Al Hoceima, Morocco

The acceleration signals for a healthy bearing and a defective bearing, acquired at a speed of 600 rpm, are shown
in Figure 9(A). We observe that the ‘healthy’ bearing generates a white noise random vibration. For the defective
bearing, we can perfectly distinguish the BPFO frequency and its harmonics, which is significant of a fault on the
outer ring. We turned up the shaft speed to 1200 rpm and 1500 rpm, the Figure 9(B) shows the vibration
spectrum of healthy and defective bearing at 1200 rpm. At this speed, we can notice that the vibration
level increased and we may distinguish the BPFO frequency with remarkable amplitude. However, we
could not see exactly the BPFO frequency harmonics in the spectrum of defective bearing. Figure 9(C)
represents the vibration spectrum of both healthy and defective bearing acquired at 1500 rpm. At this
speed, it was difficult to detect the bearing defect.

A B C

Figure 8: Vibration measurements in different frequencies

Conclusions
For predictive maintenance to be effective, accurate and reliable measurements of machine condition are required.
Vibration analysis is a means used to monitor the health of rotating machines in operation. If the vibration
increase of the machine detects a fault, the analysis of the vibration characteristics of the machine makes it
possible to identify the cause. The delay can then be accurately deduced before it becomes critical.
This article has been devoted to the application of vibration analysis techniques including global analysis and
spectral analysis for the diagnosis of both of the gear and bearing defects.
On the experimental tests which have been carried out, this method first enabled the detection of the defect using
statistical indicators: RMS and crest factor. Moreover, the results obtained are interesting and have made it
possible to understand the evolution of the sensitivity of these scalar indicators as a function of the frequency of
rotation. This made it possible to situate the contribution and the limits of each of them.
Then, the changeover to the frequency domain allowed the diagnosis of the fault. Indeed, the signals coming from
different rotational frequencies have proved the presence of the fault and its location.

Acknowledgments-The authors are pleased to acknowledge the team of the technological platform P.F.T.2M, ENSAO-Oujda.

References
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 International Conference on Civil Engineering and Materials (ICCEM'2017)
11-12 May 2017, Al Hoceima, Morocco

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2011 ISBN 2-921145-32-4, pp 361-88,
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(2017); http://www.iccem2017.com/

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