EP4695596A1 - System and method for monitoring bearing health conditions - Google Patents

System and method for monitoring bearing health conditions

Info

Publication number
EP4695596A1
EP4695596A1 EP24788285.5A EP24788285A EP4695596A1 EP 4695596 A1 EP4695596 A1 EP 4695596A1 EP 24788285 A EP24788285 A EP 24788285A EP 4695596 A1 EP4695596 A1 EP 4695596A1
Authority
EP
European Patent Office
Prior art keywords
rotatory
machine
rotatory machine
motor
detection unit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP24788285.5A
Other languages
German (de)
French (fr)
Inventor
Eva Kühne
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EWA Sensors ApS
Original Assignee
EWA Sensors ApS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EWA Sensors ApS filed Critical EWA Sensors ApS
Publication of EP4695596A1 publication Critical patent/EP4695596A1/en
Pending legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C19/00—Bearings with rolling contact, for exclusively rotary movement
    • F16C19/52—Bearings with rolling contact, for exclusively rotary movement with devices affected by abnormal or undesired conditions
    • F16C19/527—Bearings with rolling contact, for exclusively rotary movement with devices affected by abnormal or undesired conditions related to vibration and noise
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G01M13/04—Bearings
    • G01M13/045—Acoustic or vibration analysis

Definitions

  • the present invention relates to a bearing health condition monitoring system configured to monitor a health condition of one or more bearings of a rotatory machine.
  • the present invention also relates to a method for monitoring a health condition of one or more bearings of a rotatory machine.
  • Motor bearings are important as they support the rotor in a rotary machine. Bearings are, however, wear parts and the actual wear depends on the actual speed, load and temperature from the rotor.
  • Bearings need to be serviced regularly, with service intervals and bearing lifetime normally being calculated as depending on the operation condition. Bearing can, however, be damaged when the machine is not running/operating, due to vibration from surroundings (false brinelling). In this passive configuration, significant load force is distributed over a relatively small surface area inside the bearing and as the machine is in stationary condition, the load force in continuously and on the same surface area.
  • Brinelling occurs when the internal raceways of a bearing have been permanently damaged.
  • the indentations can quickly lead to improper operation, like chattering or excess vibration, which in turn can accelerate other forms of wear.
  • True brinelling is caused by shock or excessive loads due to improper mounting, dropping of machinery during handling, excessive static or impacts loads during the operation cycle.
  • False brinelling is caused by vibrations acting on the bearing while in a non-rotating state. Signs are depressions and wear marks in the bearing raceway along the radial direction. These depressions cause more noise and eventual fatigue.
  • the prior art bearing health condition monitoring system for monitor a health condition of a bearings of a rotatory machine merely take into account the vibration caused by the rotary machine itself.
  • US 20100064814 Al discloses a failure detect device configured to detect the presence of a failure in a peripheral member of a rotary shaft by analyzing a vibration generated in a device provided with the rotary shaft when the rotary shaft is rotated.
  • a vibration detection unit detects the vibration of the device
  • a rotation speed detection unit detects a rotation speed of the rotary shaft.
  • An analysis unit calculates a frequency spectrum of the vibration of the device and determines an actually measured vibration level at each vibration order by dividing a frequency component of the calculated frequency spectrum by the rotation speed of the rotary shaft.
  • a detection unit detects the presence of a failure in the peripheral member on the basis of the actually measured vibration level at each vibration order. This solution, however, is nor suitable for detecting when the surroundings cause impact vibrations.
  • the system according to the invention is a bearing health condition monitoring system configured to monitor a health condition of one or more bearings of a rotatory machine of a machine assembly, wherein the rotatory machine comprises a motor arranged and configured to rotate a shaft of the rotatory machine, wherein the shaft is supported in at least one bearing, wherein the system comprises a detection unit configured to be attached to and hereby detect vibration data representing vibrations of the rotatory machine, wherein the system comprises a processing unit configured to receive and process said vibration data, wherein the system is configured to calculate: a) the active vibration energy associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is running and b) the passive vibration energy associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is not running and c) comparing passive vibration energy and the active vibration energy.
  • the system makes it possible to provide data that influence the expected life-time of the bearing.
  • the system provides a more comprehensive way of monitoring bearings.
  • the system makes it possible to provide service personal with relevant bearing information that is not available today. Accordingly, preventive measures can be taken when needed.
  • the system is configured to quantify the vibration induced stress of the one or more bearings of the rotatory machine of a machine assembly.
  • the level of the vibration induced stress may influence the expected lifetime of one or more bearings of the rotatory machine of a machine assembly.
  • the rotatory machine may be vibrationally connected to other rotatory machines or other sources of vibration.
  • the connection may be established through a floor, piping or a wall by way of example.
  • the rotatory machine comprises a motor arranged and configured to rotate a shaft of the rotatory machine.
  • the motor may be an electrical motor.
  • the shaft of the rotatory machine is supported in at least one bearing.
  • the shaft is typically supported by two spaced apart bearings (a drive end bearing and a non-drive end bearing).
  • the system comprises a detection unit configured to be attached to and hereby detect vibration data of the rotatory machine.
  • the system comprises a processing unit configured to receive and process the vibration data.
  • the system is configured to calculate: a) the active vibration energy associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is running and b) the passive vibration energy associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is not running.
  • the system is configured to compare the passive vibration energy and the active vibration energy.
  • the rotatory machine constitutes a part of a pump.
  • the rotatory machine constitutes a part of a gear.
  • the rotatory machine constitutes a part of a fan.
  • the rotatory machine constitutes a part of a compressor.
  • the rotatory machine constitutes a part of a conveyor belt.
  • the rotatory machine comprises a pump having a shaft mechanically connected to a motor shaft by means of a coupling.
  • the system comprises two bearing health condition monitoring systems configured to be connected to a floor, piping or wall, wherein the system comprises: a) a first rotatory machine configured to be mechanically connected to the floor, piping or wall; b) a second rotatory machine that is placed in a non-zero distanced from the fist rotatory machine and being configured to be mechanically connected to the same floor, piping or wall in such a manner that the bearing of the first rotatory machine is exposed to vibration caused by the second rotatory machine when the motor of the second rotatory machine is running.
  • the detection unit detects vibrations of the first rotatory machine.
  • the vibrations may be generated by the second rotatory machine or other sources of vibration.
  • the vibrations would typically mainly be generated by the first rotatory machine, but the second rotatory machine or other sources of vibration also generate vibrations.
  • the detection unit is attached to the motor.
  • the detection unit is attached to a structure that is attached to the motor.
  • the detection unit is attached to the bearing.
  • the detection unit comprises a communication module configured to wirelessly transmit vibration data.
  • the detection unit comprises a housing, wherein a communication module is provided in the housing.
  • a battery is provided in the housing.
  • a power supply is provided in the housing.
  • a data cable extends from the housing, wherein the data cable is configured to be electrically connected to a rotatory machine of the machine assembly.
  • the system is configured to quantify a parameter based on the total energy the passive vibration energy E P and the active vibration energy EA of the bearing of the rotatory machine. The parameter may influence the expected lifetime of the bearing.
  • the method according to the invention is a method for monitoring a health condition of one or more bearings of a rotatory machine of a machine assembly, wherein the rotatory machine comprises a motor arranged and configured to rotate a shaft of the rotatory machine, wherein the shaft is supported in at least one bearing, wherein the method comprises the step of:
  • the method comprises the following steps: a) determining the active vibration energy E A associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is running and b) determining the passive vibration energy E P associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is not running and c) comparing passive vibration energy E P and the active vibration energy E A .
  • the method makes it possible to enables a more comprehensive way of monitoring bearings.
  • the method makes it possible to provide service personal with relevant bearing information that is not available today. Accordingly, preventive measures can be taken when needed.
  • the rotatory machine is or comprises a pump.
  • the rotatory machine is a pump having a shaft mechanically connect to a motor shaft by means of a coupling.
  • the rotatory machine is or comprises a gear.
  • the rotatory machine is or comprises a conveyor belt.
  • the method comprises the step of applying a system comprising two bearing health condition monitoring systems configured to be connected to a floor or wall, said system comprising: a) a first rotatory machine configured to be mechanically connected to a floor or wall; b) a second rotatory machine that is placed in a non-zero distanced from the fist rotatory machine and configured to be mechanically connected to the same floor or wall in such a manner that the bearing of the first rotatory machine is exposed to vibration caused by the second rotatory machine when the motor of the second rotatory machine is running.
  • the method comprises the step of detecting vibrations of the motor.
  • the step of detecting vibrations of the motor is carried out by means of a detection unit that is attached to the motor.
  • the method comprises the step of detecting vibrations of the bearing. In an embodiment, the method comprises the step of wirelessly transmit vibration data to an external receiver.
  • the step of wirelessly transmit vibration data to an external receiver is carried out by using a detection unit comprising a communication module configured to wirelessly transmit vibration data.
  • the detection unit comprises a housing, wherein a communication module is provided in the housing.
  • a battery is provided in the housing.
  • a power supply is provided in the housing.
  • a data cable extends from the housing, wherein the data cable is configured to be electrically connected to a power source near or at the rotatory machine.
  • the detection unit is electrically powered through a cable electrically connected 24 V power source.
  • the method comprises the step of calculating an expected lifetime of the bearing based on the total energy the passive vibration energy EP and the active vibration energy EA of the bearing of the rotatory machine.
  • the vibration data is collected in a frequency range form 0-1000 Hz.
  • the vibration data is collected with a sampling rate in the range in a frequency range 100-5000 Hz. In an embodiment, the vibration data is collected with a sampling rate in the range in a frequency range 500-4000 Hz.
  • the vibration data is collected with a sampling rate in the range in a frequency range 1000-3000 Hz.
  • the vibration data is collected with a sampling rate of 2000 Hz.
  • vibration data can be detected by using either an analog or a digital measurement technique.
  • Fig. 1 shows a perspective view of two bearing health condition monitoring systems according to the invention
  • Fig. 2A shows an end view of a bearing health condition monitoring system according to the invention
  • Fig. 2B shows a detection unit of a bearing health condition monitoring system according to the invention
  • Fig. 2C shows another detection unit of a bearing health condition monitoring system according to the invention
  • Fig. 3A shows vibrations on a rotatory machine detected by a bearing health condition monitoring system according to the invention
  • Fig. 3B shows the rotational speed of a rotatory machine detected by a bearing health condition monitoring system according to the invention
  • Fig. 3C shows vibrations on a rotatory machine detected during a short time period by a bearing health condition monitoring system according to the invention
  • Fig. 4 shows a flowchart of a method according to the invention
  • Fig. 5A shows a schematic view of a bearing health condition monitoring system according to the invention
  • Fig. 5B shows a schematic view of another bearing health condition monitoring system according to the invention.
  • Fig. 6A shows an exploded view of an electric motor
  • Fig. 6B shows the motor shown in Fig. 6A in an assembled state.
  • a bearing health condition monitoring system 2 of the present invention is illustrated in Fig. 1.
  • Fig. 1 illustrates a perspective view of a first bearing health condition monitoring system 2 and a second bearing health condition monitoring system 2' according to the invention.
  • the first system 2 comprises a machine assembly 26 comprising a rotatory machine 4 that is mechanically connected to a floor 34.
  • the second system 2' comprises a machine assembly 26' comprises a rotatory machine 6 that is mechanically connected to the floor 34. Accordingly, the first rotatory machine 4 and the second rotatory machine 6 are vibrationally connected.
  • the first rotatory machine 4 comprises a motor 8 provided with a motor shaft 22.
  • the motor 8 is arranged and configured to rotate a shaft 14 of a pump 12 that is driven by the motor 8.
  • the second rotatory machine 6 comprises a motor 8' that is provided with a motor shaft 22'.
  • the motor 8' is arranged and configured to ro- tate a shaft 14' of a pump 12' that is driven by the motor 8'.
  • the shaft 14, 14' of each of the pumps 12, 12' is connected to the corresponding motor 8, 8' via a coupling 11, 11'.
  • the first system 2 comprises a first detection unit 24 placed on the motor 8 of the first rotatory machine 4.
  • the second system 2' comprises a second detection unit 24' placed on the motor 8' of the second rotatory machine 6.
  • the first detection unit 24 is configured to be attached to and hereby detect vibration data 28 of the first rotatory machine 4.
  • the second detection unit 24' is configured to be attached to and hereby detect vibration data 28' of the second rotatory machine 6.
  • the systems 2, 2' shown in Fig. 1 comprise a processing unit 32 configured to receive and process said data 28, 28'.
  • the processing unit 32 may be contained in a web-based server accessible via the Internet 30.
  • the processing unit 32 is integrated in the detection unit(s) 24, 24'.
  • the processing unit 32 is integrated in an external device (e.g. a laptop computer or a tablet that is communicatively connected to the detection unit(s) 24, 24').
  • the second rotatory machine 6 is mechanically connected to the floor 34 in such a manner that the bearing 10 of the first rotatory machine 4 is exposed to vibrations caused by the second rotatory machine 6 when the motor 8' of the second rotatory machine 6 is running. Since the first rotatory machine 4 is also mechanically connected to the floor 34, the bearing 10' of the second rotatory machine 6 is exposed to vibrations caused by the first rotatory machine 4 when the motor 8 of the first rotatory machine 4 is running, even though the second rotatory machine 6 is placed in a non-zero distanced from the fist rotatory machine 4.
  • the second rotatory machine 6 is mechanically connected to the floor 34 via a base member 20' placed on the floor 34.
  • the first rotatory machine 4 is mechanically connected to the floor 34 via a base member 20 placed on the floor 34.
  • the first system 2 is configured to monitor the health condition of any bearing provided in the motors 8 of the first rotary machine 4.
  • the second system 2' is configured to monitor the health condition of any bearing provided in the motor 8' of the second rotary machine 6.
  • the first system 2 is configured to calculate: a) the active vibration energy E A associated to the vibration data 28 of first rotatory machine 4 detected by the detection unit 24 when the motor 8 of the first rotatory machine 4 is running and b) the passive vibration energy E P associated to the vibration data 28 of a first rotatory machine 4 detected by the detection unit 24 when the motor 8 of the first rotatory machine 4 is not running and c) comparing passive vibration energy EP and the active vibration energy E A .
  • the second system 2' is configured to calculate: a) the active vibration energy EA' associated to the vibration data 28' of second rotatory machine 6 detected by the detection unit 24' when the motor 8' of the second rotatory machine 6 is running and b) the passive vibration energy E P ' associated to the vibration data 28' of a second rotatory machine 6 detected by the detection unit 24' when the motor 8' of the second rotatory machine 6 is not running and c) comparing passive vibration energy E P ' and the active vibration energy E A '. It is important to underline that the second system 2' may be omitted.
  • the passive vibration energy E P detected on one rotatory machine is cause by vibrations from the surroundings including the other rotatory machine.
  • the passive vibration energy EP detected on one rotatory machine can, however, also be caused by vibrations from other sources (such as heavy traffic nearby or other machines or devices that creates vibrations).
  • the first pump 12 is connected to and receives a media to be pumped via an inlet pipe 16.
  • the first pump 12 is connected to and pumps the media out through an outlet pipe 18.
  • the rotatory machines 4, 6 may be different from the ones shown in Fig. 1.
  • the rotatory machine(s) are pumps, wherein the motor and the pump are joint (built together or integrated).
  • the rotatory machine(s) are pumps, wherein the motor of the pump is fixed the pump housing of the pump. It is important to notice, that the method and system according to the invention can be used on other type of rotary machines, as compressors, belts, conveyers and fans.
  • the detection units 24, 24' may be attached to any suitable structure of the rotatory machines 4, 6. When attached to a suitable structure of the rotatory machines 4, 6, the detection units 24, 24' provide reliable vibrating data.
  • the attachment may be established by using any suitable mechanical fastening structures including glue, bolts, a hose clamp, or a mounting bracket.
  • Fig. 2A illustrates an end view of a bearing health condition monitoring system 2 according to the invention.
  • the system 2 is configured to monitor a health condition of one or more bearings of a first rotatory machine 4.
  • a second system 2' configured to monitor a health condition of one or more bearings of a second rotatory machine 6 of a machine assembly 26 is shown.
  • the first rotatory machine 4 comprises a first motor 8 and the second rotatory machine 6 comprises a second motor 8'.
  • the first rotatory machine 4 is attached to a first base member 20 that is placed on a floor 34.
  • the second rotatory machine 6 is provided in a distance from the first rotatory machine 4.
  • the second rotatory machine 6 is attached to a second base member 20' that is placed on the floor 34. Accordingly, the rotatory machines 4, 6 are vibrationally connected and that vibration 50 from the motor 8' of the motor 8' of the second rotatory machine 6 is transferred via the base member 20' of the second rotatory machine 6 to the floor 34 and further via the base member 20 of the first rotatory machine 4 to the motor 8 of the first rotatory machine 4.
  • Fig. 2B illustrates a detection unit 24 of a bearing health condition monitoring system according to the invention.
  • the detection unit 24 comprises a housing 40 configured to be attached to a rotatory machine.
  • the detection unit 24 comprises a battery 42 for providing electrical power to the detection unit 24.
  • the detection unit 24 comprises a power supply.
  • the detection unit 24 comprises a printed circuit board 44 provided with a communication module 36.
  • the communication module 36 is configured to communicate wirelessly with an external device (e.g. via a local network).
  • the detection unit 24 comprises a modem configured for sending digital data wirelessly.
  • detection unit 24 comprises a Bluetooth radio module with built-in antenna.
  • the detection unit communicates via a wired fieldbus connection (e.g. a Modbus protocol).
  • the detection unit 24 comprises an accelerometer 38 arranged and con- figured to detect vibrations of the detection unit 24. Accordingly, when the detection unit 24 is attached to a rotatory machine, the accelerometer 38 is capable of detecting the vibrations of the rotatory machine.
  • the accelerometer 38 is a multi-axis accelerometer configured to detect both the magnitude and the direction of the proper acceleration, as a vector quantity.
  • the accelerometer 38 is a two-axis accelerometer.
  • the accelerometer 38 is a three-axis accelerometer.
  • the accelerometer 38 is a single-axis accelerometer 38.
  • the accelerometer 38 is a micromachined microelectromechanical systems (MEMS).
  • MEMS micromachined microelectromechanical systems
  • the detection unit 24 comprises a control unit.
  • the control unit comprises a processing unit.
  • Fig. 2C illustrates another detection unit 24 of a bearing health condition monitoring system according to the invention.
  • the detection unit 24 comprises a housing 40 configured to be attached to a rotatory machine.
  • the detection unit 24 comprises a power supply 46 connected to a power cable 48 protruding from the housing 40.
  • the detection unit 24 comprises a printed circuit board 44 provided with a communication module 36.
  • the communication module 36 is connected to an external device by means of a data cable 52.
  • the data cable 52 may be electronically connected to a control box of rotatory machine (e.g. a pump).
  • the detection unit 24 comprises no communication module but is electrically connected to an external communication module (e.g. built into an external device such as a control box of a pump or a motor).
  • the data cable 52 is use for data communication and for supplying power to the detection unit 24.
  • the data cable 52 is electrically con- nected to a control panel.
  • the detection unit 24 comprises or is connected to a gateway.
  • the gateway may be connected to a cloud server via a wired or wireless connection.
  • the user can display data detected by the detection unit 24 on a screen of a PC via a web interface.
  • the detection unit 24 comprises an accelerometer 38 corresponding to the one shown and explained with reference to Fig. 2B.
  • the detection unit 24 comprises a control unit.
  • the control unit comprises a processing unit.
  • Fig. 3A illustrates curve 54 depicting vibrations on a rotatory machine detected by a bearing health condition monitoring system according to the invention.
  • the curve 54 is shown in a coordinate system, in which the percentages of vibration energy defined as the Secondary Impact Ratio (SIR) (detected by a detection unit attached to a rotatory machine) received by the rotary machine from the surroundings is plotted as function of time T.
  • SIR Secondary Impact Ratio
  • the total vibration energy E detected by a detection unit attached to a pump is defined as the sum :
  • the secondary impact ratio I as the percentages of energy received from the surroundings in relation to the total energy received.
  • the solid curve 54 shows the percentages of vibration energy from the surroundings measured by means of a detection unit attached to a first pump.
  • the time T extends over 11 days (from a first day Di to a day Dn ten days after).
  • the vibration energy from the surroundings for each day corresponds to the average for several measurements carried out that day.
  • Fig. 3B illustrates the rotational speed (revolutions per minute, RPM) of a rotatory machine detected by a detection unit of a bearing health condition monitoring system according to the invention as function of time T.
  • the time period of a single pump cycle extending from 10:40 to 11 :30.
  • the solid curve 58 shows the rotational speed of a first pump.
  • Fig. 3C illustrates vibrations V detected on a rotatory machine detected during the same time as in Fig. 3B by a detection unit of a bearing health condition monitoring system according to the invention.
  • the solid curve 62 shows the vibration V of the rotatory machine while the rotatory machine is running from 10:46 to 10:50. It can be seen that the vibrations 68 caused by the second rotary machineis are significant. These vibrations 68 are detected from ll. :22 to 11 :26.. In fact the vibrations 68 caused by the second rotary machine are almost as large as the vibrations 62 caused by the first rotatory machine itself. Accordingly, the bearings of the first rotatory machine and will fail prematurely and having a shorter lifetime eventually consequential damage to the rotary machine.
  • Fig. 4 illustrates a flowchart of a method according to the invention. Once the method has started, a) the vibration energy of the motor 10 will be measured by a detection unit according to the invention and b) the rotational speed of the motor 10 is measured
  • the accumulated active energy E A is detected by means of a detection unit according to the invention.
  • the accumulated passive energy E P is detected by means of a detection unit according to the invention.
  • Fig. 5A illustrates a schematic view of a bearing health condition monitoring system 2 according to the invention.
  • the system 2 comprises a detection unit 24 is installed to monitor the bearings of a machine assembly 26 comprising a rotary machine 4.
  • the rotary machine 4 comprises a motor 8 that attached to a base member 20 placed on a floor 34. Accordingly, vibrations 50 from a vehicle 70 driving by on a road 72 outside the building, in which the system 2 is installed are transferred via the road 72 through the wall 78 and further via the floor 34 to the base member 20. From the base member 20, the vibrations 50 are transferred to the motor 8 at which the detection unit 24 detects the vibrations 50.
  • the detection unit 24 is attached to the motor 8.
  • Fig. 5B illustrates a schematic view of another bearing health condition monitoring system 2 according to the invention.
  • the system 2 basically corresponds to the system 2 shown in and explained with reference to Fig. 5A.
  • the detection unit 24 is, however, attached to a structure that connects the housing of the motor 8 with the base member 20.
  • Fig. 6A illustrates an exploded view of an electric motor 8.
  • the electric motor 8 comprises a motor housing 74 and a rotor 76 that is attached to a motor shaft 22.
  • the motor shaft 22 is supported by a drive end bearing 9' and a non-drive end bearing 9.
  • a detection unit 24 is attached to the motor housing 74.
  • Fig. 6B illustrates the motor 8 shown in Fig. 6A in an assembled state.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Acoustics & Sound (AREA)
  • General Physics & Mathematics (AREA)
  • Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)

Abstract

A bearing health condition monitoring system (2) is disclosed. The sys- tem (2) is configured to monitor a health condition of one or more bear- ings (10, 10') of one or more rotatory machines (4, 6) of a machine assembly (26). The rotatory machines (4, 6) are vibrationally connected. Each of the rotatory machines (4, 6) comprises a motor (8, 8') arranged and configured to rotate a shaft (14, 14') of the rotatory machine (4, 6). The shaft (14, 14') of each of the rotatory machines is connected to the motor (8, 8') via the bearing (10, 10') of the rotatory machine (4, 6). The system (2) comprises a detection unit (24, 24') configured to be attached to and hereby detect vibration data (28, 28') of at least one of the rotatory machines (4, 6). The system (2) comprises a processing unit (32) configured to receive and process said data (28, 28'). The system (2) is configured to calculate: a) the active vibration energy (EA) associated to the vibration data (28, 28') of a first rotatory machine (4, 6) detected by the detection unit (24, 24') when the motor (8, 8') of the first rotatory machine (4, 6) is running and b) the passive vibration energy (EP) associated to the vibration data (28, 28') of a first rotatory machine (4, 6) detected by the detection unit (24, 24') when the motor (8, 8') of the first rotatory machine (4, 6) is not running and c) comparing passive vibration energy (EP) and the active vibration energy (EA).

Description

System and Method for Monitoring Bearing Health Conditions
Field of invention
The present invention relates to a bearing health condition monitoring system configured to monitor a health condition of one or more bearings of a rotatory machine. The present invention also relates to a method for monitoring a health condition of one or more bearings of a rotatory machine.
Prior art
Motor bearings are important as they support the rotor in a rotary machine. Bearings are, however, wear parts and the actual wear depends on the actual speed, load and temperature from the rotor.
Bearings need to be serviced regularly, with service intervals and bearing lifetime normally being calculated as depending on the operation condition. Bearing can, however, be damaged when the machine is not running/operating, due to vibration from surroundings (false brinelling). In this passive configuration, significant load force is distributed over a relatively small surface area inside the bearing and as the machine is in stationary condition, the load force in continuously and on the same surface area.
Brinelling occurs when the internal raceways of a bearing have been permanently damaged. The indentations can quickly lead to improper operation, like chattering or excess vibration, which in turn can accelerate other forms of wear.
True brinelling is caused by shock or excessive loads due to improper mounting, dropping of machinery during handling, excessive static or impacts loads during the operation cycle. False brinelling is caused by vibrations acting on the bearing while in a non-rotating state. Signs are depressions and wear marks in the bearing raceway along the radial direction. These depressions cause more noise and eventual fatigue.
The prior art bearing health condition monitoring system for monitor a health condition of a bearings of a rotatory machine, however, merely take into account the vibration caused by the rotary machine itself.
US 20100064814 Al discloses a failure detect device configured to detect the presence of a failure in a peripheral member of a rotary shaft by analyzing a vibration generated in a device provided with the rotary shaft when the rotary shaft is rotated. A vibration detection unit detects the vibration of the device, and a rotation speed detection unit detects a rotation speed of the rotary shaft. An analysis unit calculates a frequency spectrum of the vibration of the device and determines an actually measured vibration level at each vibration order by dividing a frequency component of the calculated frequency spectrum by the rotation speed of the rotary shaft. A detection unit detects the presence of a failure in the peripheral member on the basis of the actually measured vibration level at each vibration order. This solution, however, is nor suitable for detecting when the surroundings cause impact vibrations.
Thus, there is a need for a system and method which reduces or even eliminates the above mentioned disadvantages of the prior art.
It is an object of the invention to make an alternative and more accurate system and a more accurate method.
Summary of the invention
The object of the present invention can be achieved by a system as de- fined in claim 1 and by a method as defined in claim 7. Preferred embodiments are defined in the dependent subclaims, explained in the following description and illustrated in the accompanying drawings.
The system according to the invention is a bearing health condition monitoring system configured to monitor a health condition of one or more bearings of a rotatory machine of a machine assembly, wherein the rotatory machine comprises a motor arranged and configured to rotate a shaft of the rotatory machine, wherein the shaft is supported in at least one bearing, wherein the system comprises a detection unit configured to be attached to and hereby detect vibration data representing vibrations of the rotatory machine, wherein the system comprises a processing unit configured to receive and process said vibration data, wherein the system is configured to calculate: a) the active vibration energy associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is running and b) the passive vibration energy associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is not running and c) comparing passive vibration energy and the active vibration energy.
Hereby, it is possible to determine how much impact vibrations from the surroundings of a rotatory machine have on the bearing of the rotatory machine. Accordingly, it is possible to determine the negative effect of all the vibrations the bearing is exposed to. Therefore, the system makes it possible to provide data that influence the expected life-time of the bearing. The system provides a more comprehensive way of monitoring bearings. The system makes it possible to provide service personal with relevant bearing information that is not available today. Accordingly, preventive measures can be taken when needed.
In an embodiment, the system is configured to quantify the vibration induced stress of the one or more bearings of the rotatory machine of a machine assembly. The level of the vibration induced stress may influence the expected lifetime of one or more bearings of the rotatory machine of a machine assembly.
The rotatory machine may be vibrationally connected to other rotatory machines or other sources of vibration. The connection may be established through a floor, piping or a wall by way of example.
The rotatory machine comprises a motor arranged and configured to rotate a shaft of the rotatory machine. The motor may be an electrical motor.
The shaft of the rotatory machine is supported in at least one bearing. The shaft is typically supported by two spaced apart bearings (a drive end bearing and a non-drive end bearing).
The system comprises a detection unit configured to be attached to and hereby detect vibration data of the rotatory machine.
The system comprises a processing unit configured to receive and process the vibration data.
The system is configured to calculate: a) the active vibration energy associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is running and b) the passive vibration energy associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is not running. In an embodiment, the system is configured to compare the passive vibration energy and the active vibration energy.
In an embodiment, the rotatory machine constitutes a part of a pump.
In an embodiment, the rotatory machine constitutes a part of a gear.
In an embodiment, the rotatory machine constitutes a part of a fan.
In an embodiment, the rotatory machine constitutes a part of a compressor.
In an embodiment, the rotatory machine constitutes a part of a conveyor belt.
In an embodiment, the rotatory machine comprises a pump having a shaft mechanically connected to a motor shaft by means of a coupling.
In an embodiment, the system comprises two bearing health condition monitoring systems configured to be connected to a floor, piping or wall, wherein the system comprises: a) a first rotatory machine configured to be mechanically connected to the floor, piping or wall; b) a second rotatory machine that is placed in a non-zero distanced from the fist rotatory machine and being configured to be mechanically connected to the same floor, piping or wall in such a manner that the bearing of the first rotatory machine is exposed to vibration caused by the second rotatory machine when the motor of the second rotatory machine is running.
In this embodiment, the detection unit detects vibrations of the first rotatory machine. When the first rotatory machine is not running, the vibrations may be generated by the second rotatory machine or other sources of vibration. When the first rotatory machine is running, the vibrations would typically mainly be generated by the first rotatory machine, but the second rotatory machine or other sources of vibration also generate vibrations.
In this embodiment, it would be possible to apply: a) a first detection unit attached to detect vibration of the first rotatory machine and b) a second detection unit attached to detect vibration of the second rotatory machine.
In an embodiment, the detection unit is attached to the motor.
In an embodiment, the detection unit is attached to a structure that is attached to the motor.
In one embodiment, the detection unit is attached to the bearing.
In one embodiment, the detection unit comprises a communication module configured to wirelessly transmit vibration data.
In one embodiment, the detection unit comprises a housing, wherein a communication module is provided in the housing.
In an embodiment, a battery is provided in the housing.
In an embodiment, a power supply is provided in the housing.
In an embodiment, a data cable extends from the housing, wherein the data cable is configured to be electrically connected to a rotatory machine of the machine assembly. In an embodiment, the system is configured to quantify a parameter based on the total energy the passive vibration energy EP and the active vibration energy EA of the bearing of the rotatory machine. The parameter may influence the expected lifetime of the bearing.
The method according to the invention is a method for monitoring a health condition of one or more bearings of a rotatory machine of a machine assembly, wherein the rotatory machine comprises a motor arranged and configured to rotate a shaft of the rotatory machine, wherein the shaft is supported in at least one bearing, wherein the method comprises the step of:
- detecting vibration data of the rotatory machine and
- processing said vibration data, wherein the method comprises the following steps: a) determining the active vibration energy EA associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is running and b) determining the passive vibration energy EP associated to the vibration data of the rotatory machine detected by the detection unit when the motor of the rotatory machine is not running and c) comparing passive vibration energy EP and the active vibration energy EA.
Hereby, it is possible to determine how much impact vibrations from the surroundings of a rotatory machine have on the bearing of the rotatory machine. Accordingly, it is possible to determine the negative effect of all the vibrations the bearing is exposed to. Therefore, the method makes it possible to enables a more comprehensive way of monitoring bearings. The method makes it possible to provide service personal with relevant bearing information that is not available today. Accordingly, preventive measures can be taken when needed.
In an embodiment, the rotatory machine is or comprises a pump.
In an embodiment, the rotatory machine is a pump having a shaft mechanically connect to a motor shaft by means of a coupling.
In an embodiment, the rotatory machine is or comprises a gear.
In an embodiment, the rotatory machine is or comprises a conveyor belt.
In an embodiment, the method comprises the step of applying a system comprising two bearing health condition monitoring systems configured to be connected to a floor or wall, said system comprising: a) a first rotatory machine configured to be mechanically connected to a floor or wall; b) a second rotatory machine that is placed in a non-zero distanced from the fist rotatory machine and configured to be mechanically connected to the same floor or wall in such a manner that the bearing of the first rotatory machine is exposed to vibration caused by the second rotatory machine when the motor of the second rotatory machine is running.
In an embodiment, the method comprises the step of detecting vibrations of the motor.
In an embodiment, the step of detecting vibrations of the motor is carried out by means of a detection unit that is attached to the motor.
In an embodiment, the method comprises the step of detecting vibrations of the bearing. In an embodiment, the method comprises the step of wirelessly transmit vibration data to an external receiver.
In an embodiment, the step of wirelessly transmit vibration data to an external receiver is carried out by using a detection unit comprising a communication module configured to wirelessly transmit vibration data.
In an embodiment, the detection unit comprises a housing, wherein a communication module is provided in the housing.
In an embodiment, a battery is provided in the housing.
In an embodiment, a power supply is provided in the housing.
In an embodiment, a data cable extends from the housing, wherein the data cable is configured to be electrically connected to a power source near or at the rotatory machine.
In an embodiment, the detection unit is electrically powered through a cable electrically connected 24 V power source.
In an embodiment, the method comprises the step of calculating an expected lifetime of the bearing based on the total energy the passive vibration energy EP and the active vibration energy EA of the bearing of the rotatory machine.
In an embodiment, the vibration data is collected in a frequency range form 0-1000 Hz.
In an embodiment, the vibration data is collected with a sampling rate in the range in a frequency range 100-5000 Hz. In an embodiment, the vibration data is collected with a sampling rate in the range in a frequency range 500-4000 Hz.
In an embodiment, the vibration data is collected with a sampling rate in the range in a frequency range 1000-3000 Hz.
In an embodiment, the vibration data is collected with a sampling rate of 2000 Hz.
It is important to underline that the vibration data can be detected by using either an analog or a digital measurement technique.
Description of the Drawings
The invention will become more fully understood from the detailed description given herein below. The accompanying drawings are given by way of illustration only, and thus, they are not limitative of the present invention. In the accompanying drawings:
Fig. 1 shows a perspective view of two bearing health condition monitoring systems according to the invention;
Fig. 2A shows an end view of a bearing health condition monitoring system according to the invention;
Fig. 2B shows a detection unit of a bearing health condition monitoring system according to the invention;
Fig. 2C shows another detection unit of a bearing health condition monitoring system according to the invention;
Fig. 3A shows vibrations on a rotatory machine detected by a bearing health condition monitoring system according to the invention;
Fig. 3B shows the rotational speed of a rotatory machine detected by a bearing health condition monitoring system according to the invention; Fig. 3C shows vibrations on a rotatory machine detected during a short time period by a bearing health condition monitoring system according to the invention;
Fig. 4 shows a flowchart of a method according to the invention;
Fig. 5A shows a schematic view of a bearing health condition monitoring system according to the invention;
Fig. 5B shows a schematic view of another bearing health condition monitoring system according to the invention;
Fig. 6A shows an exploded view of an electric motor and
Fig. 6B shows the motor shown in Fig. 6A in an assembled state.
Detailed description of the invention
Referring now in detail to the drawings for the purpose of illustrating preferred embodiments of the present invention, a bearing health condition monitoring system 2 of the present invention is illustrated in Fig. 1.
Fig. 1 illustrates a perspective view of a first bearing health condition monitoring system 2 and a second bearing health condition monitoring system 2' according to the invention. The first system 2 comprises a machine assembly 26 comprising a rotatory machine 4 that is mechanically connected to a floor 34. The second system 2' comprises a machine assembly 26' comprises a rotatory machine 6 that is mechanically connected to the floor 34. Accordingly, the first rotatory machine 4 and the second rotatory machine 6 are vibrationally connected.
The first rotatory machine 4 comprises a motor 8 provided with a motor shaft 22. The motor 8 is arranged and configured to rotate a shaft 14 of a pump 12 that is driven by the motor 8.
The second rotatory machine 6 comprises a motor 8' that is provided with a motor shaft 22'. The motor 8' is arranged and configured to ro- tate a shaft 14' of a pump 12' that is driven by the motor 8'.
The shaft 14, 14' of each of the pumps 12, 12' is connected to the corresponding motor 8, 8' via a coupling 11, 11'.
The first system 2 comprises a first detection unit 24 placed on the motor 8 of the first rotatory machine 4. Similarly, the second system 2' comprises a second detection unit 24' placed on the motor 8' of the second rotatory machine 6.
The first detection unit 24 is configured to be attached to and hereby detect vibration data 28 of the first rotatory machine 4. The second detection unit 24' is configured to be attached to and hereby detect vibration data 28' of the second rotatory machine 6.
The systems 2, 2' shown in Fig. 1 comprise a processing unit 32 configured to receive and process said data 28, 28'. The processing unit 32 may be contained in a web-based server accessible via the Internet 30. In an embodiment, the processing unit 32 is integrated in the detection unit(s) 24, 24'. In an embodiment, the processing unit 32 is integrated in an external device (e.g. a laptop computer or a tablet that is communicatively connected to the detection unit(s) 24, 24').
The second rotatory machine 6 is mechanically connected to the floor 34 in such a manner that the bearing 10 of the first rotatory machine 4 is exposed to vibrations caused by the second rotatory machine 6 when the motor 8' of the second rotatory machine 6 is running. Since the first rotatory machine 4 is also mechanically connected to the floor 34, the bearing 10' of the second rotatory machine 6 is exposed to vibrations caused by the first rotatory machine 4 when the motor 8 of the first rotatory machine 4 is running, even though the second rotatory machine 6 is placed in a non-zero distanced from the fist rotatory machine 4. The second rotatory machine 6 is mechanically connected to the floor 34 via a base member 20' placed on the floor 34. Similarly, the first rotatory machine 4 is mechanically connected to the floor 34 via a base member 20 placed on the floor 34.
The first system 2 is configured to monitor the health condition of any bearing provided in the motors 8 of the first rotary machine 4. The second system 2' is configured to monitor the health condition of any bearing provided in the motor 8' of the second rotary machine 6.
The first system 2 is configured to calculate: a) the active vibration energy EA associated to the vibration data 28 of first rotatory machine 4 detected by the detection unit 24 when the motor 8 of the first rotatory machine 4 is running and b) the passive vibration energy EP associated to the vibration data 28 of a first rotatory machine 4 detected by the detection unit 24 when the motor 8 of the first rotatory machine 4 is not running and c) comparing passive vibration energy EP and the active vibration energy EA.
Likewise, the second system 2' is configured to calculate: a) the active vibration energy EA' associated to the vibration data 28' of second rotatory machine 6 detected by the detection unit 24' when the motor 8' of the second rotatory machine 6 is running and b) the passive vibration energy EP' associated to the vibration data 28' of a second rotatory machine 6 detected by the detection unit 24' when the motor 8' of the second rotatory machine 6 is not running and c) comparing passive vibration energy EP' and the active vibration energy EA'. It is important to underline that the second system 2' may be omitted.
The passive vibration energy EP detected on one rotatory machine is cause by vibrations from the surroundings including the other rotatory machine. The passive vibration energy EP detected on one rotatory machine can, however, also be caused by vibrations from other sources (such as heavy traffic nearby or other machines or devices that creates vibrations).
The first pump 12 is connected to and receives a media to be pumped via an inlet pipe 16. The first pump 12 is connected to and pumps the media out through an outlet pipe 18.
It is important to underline that the rotatory machines 4, 6 may be different from the ones shown in Fig. 1. In an embodiment, the rotatory machine(s) are pumps, wherein the motor and the pump are joint (built together or integrated). In an embodiment, the rotatory machine(s) are pumps, wherein the motor of the pump is fixed the pump housing of the pump. It is important to notice, that the method and system according to the invention can be used on other type of rotary machines, as compressors, belts, conveyers and fans.
The detection units 24, 24' may be attached to any suitable structure of the rotatory machines 4, 6. When attached to a suitable structure of the rotatory machines 4, 6, the detection units 24, 24' provide reliable vibrating data. The attachment may be established by using any suitable mechanical fastening structures including glue, bolts, a hose clamp, or a mounting bracket.
Fig. 2A illustrates an end view of a bearing health condition monitoring system 2 according to the invention. The system 2 is configured to monitor a health condition of one or more bearings of a first rotatory machine 4. A second system 2' configured to monitor a health condition of one or more bearings of a second rotatory machine 6 of a machine assembly 26 is shown.
The first rotatory machine 4 comprises a first motor 8 and the second rotatory machine 6 comprises a second motor 8'. The first rotatory machine 4 is attached to a first base member 20 that is placed on a floor 34. The second rotatory machine 6 is provided in a distance from the first rotatory machine 4. The second rotatory machine 6 is attached to a second base member 20' that is placed on the floor 34. Accordingly, the rotatory machines 4, 6 are vibrationally connected and that vibration 50 from the motor 8' of the motor 8' of the second rotatory machine 6 is transferred via the base member 20' of the second rotatory machine 6 to the floor 34 and further via the base member 20 of the first rotatory machine 4 to the motor 8 of the first rotatory machine 4.
Fig. 2B illustrates a detection unit 24 of a bearing health condition monitoring system according to the invention. The detection unit 24 comprises a housing 40 configured to be attached to a rotatory machine. The detection unit 24 comprises a battery 42 for providing electrical power to the detection unit 24. In an embodiment, the detection unit 24 comprises a power supply. The detection unit 24 comprises a printed circuit board 44 provided with a communication module 36. The communication module 36 is configured to communicate wirelessly with an external device (e.g. via a local network). In an embodiment, the detection unit 24 comprises a modem configured for sending digital data wirelessly. In an embodiment, detection unit 24 comprises a Bluetooth radio module with built-in antenna. In an embodiment, the detection unit communicates via a wired fieldbus connection (e.g. a Modbus protocol).
The detection unit 24 comprises an accelerometer 38 arranged and con- figured to detect vibrations of the detection unit 24. Accordingly, when the detection unit 24 is attached to a rotatory machine, the accelerometer 38 is capable of detecting the vibrations of the rotatory machine. In an embodiment, the accelerometer 38 is a multi-axis accelerometer configured to detect both the magnitude and the direction of the proper acceleration, as a vector quantity. In an embodiment, the accelerometer 38 is a two-axis accelerometer. In an embodiment, the accelerometer 38 is a three-axis accelerometer. In an embodiment, the accelerometer 38 is a single-axis accelerometer 38.
In an embodiment, the accelerometer 38 is a micromachined microelectromechanical systems (MEMS).
In an embodiment, the detection unit 24 comprises a control unit. In an embodiment, the control unit comprises a processing unit.
Fig. 2C illustrates another detection unit 24 of a bearing health condition monitoring system according to the invention. The detection unit 24 comprises a housing 40 configured to be attached to a rotatory machine. The detection unit 24 comprises a power supply 46 connected to a power cable 48 protruding from the housing 40.
The detection unit 24 comprises a printed circuit board 44 provided with a communication module 36. The communication module 36 is connected to an external device by means of a data cable 52. The data cable 52 may be electronically connected to a control box of rotatory machine (e.g. a pump). In an embodiment, the detection unit 24 comprises no communication module but is electrically connected to an external communication module (e.g. built into an external device such as a control box of a pump or a motor). In another embodiment, the data cable 52 is use for data communication and for supplying power to the detection unit 24. In an embodiment, the data cable 52 is electrically con- nected to a control panel.
In an embodiment, the detection unit 24 comprises or is connected to a gateway. The gateway may be connected to a cloud server via a wired or wireless connection. Hereby, the user can display data detected by the detection unit 24 on a screen of a PC via a web interface.
The detection unit 24 comprises an accelerometer 38 corresponding to the one shown and explained with reference to Fig. 2B. In an embodiment, the detection unit 24 comprises a control unit. In an embodiment, the control unit comprises a processing unit.
Fig. 3A illustrates curve 54 depicting vibrations on a rotatory machine detected by a bearing health condition monitoring system according to the invention. The curve 54 is shown in a coordinate system, in which the percentages of vibration energy defined as the Secondary Impact Ratio (SIR) (detected by a detection unit attached to a rotatory machine) received by the rotary machine from the surroundings is plotted as function of time T.
The total vibration energy E detected by a detection unit attached to a pump is defined as the sum :
The active vibration energy EA (when the motor of the rotary machine is running) and the passive vibration energy Ep (when the motor of the rotary machine is not running). This can be expressed by equation (1):
(1) E = EA + EP
As the total vibration energy E is defined to be 100%, we define the secondary impact ratio I as the percentages of energy received from the surroundings in relation to the total energy received.
(2) SIR. = (100 %)-EP/E
The solid curve 54 shows the percentages of vibration energy from the surroundings measured by means of a detection unit attached to a first pump.
On the x-axis, the time T extends over 11 days (from a first day Di to a day Dn ten days after). The vibration energy from the surroundings for each day corresponds to the average for several measurements carried out that day.
Fig. 3B illustrates the rotational speed (revolutions per minute, RPM) of a rotatory machine detected by a detection unit of a bearing health condition monitoring system according to the invention as function of time T. The time period of a single pump cycle extending from 10:40 to 11 :30. The solid curve 58 shows the rotational speed of a first pump.
Fig. 3C illustrates vibrations V detected on a rotatory machine detected during the same time as in Fig. 3B by a detection unit of a bearing health condition monitoring system according to the invention.
The solid curve 62 shows the vibration V of the rotatory machine while the rotatory machine is running from 10:46 to 10:50. It can be seen that the vibrations 68 caused by the second rotary machineis are significant. These vibrations 68 are detected from ll. :22 to 11 :26.. In fact the vibrations 68 caused by the second rotary machine are almost as large as the vibrations 62 caused by the first rotatory machine itself. Accordingly, the bearings of the first rotatory machine and will fail prematurely and having a shorter lifetime eventually consequential damage to the rotary machine. Fig. 4 illustrates a flowchart of a method according to the invention. Once the method has started, a) the vibration energy of the motor 10 will be measured by a detection unit according to the invention and b) the rotational speed of the motor 10 is measured
If the rotational speed co of the motor 10 is larger than zero, the accumulated active energy EA is detected by means of a detection unit according to the invention.
If the rotational speed co of the motor is zero, the accumulated passive energy EP is detected by means of a detection unit according to the invention.
Now the actual level of false brinelling is calculated as the SIR.: EP/(EA + EP) 100%
Fig. 5A illustrates a schematic view of a bearing health condition monitoring system 2 according to the invention. The system 2 comprises a detection unit 24 is installed to monitor the bearings of a machine assembly 26 comprising a rotary machine 4. The rotary machine 4 comprises a motor 8 that attached to a base member 20 placed on a floor 34. Accordingly, vibrations 50 from a vehicle 70 driving by on a road 72 outside the building, in which the system 2 is installed are transferred via the road 72 through the wall 78 and further via the floor 34 to the base member 20. From the base member 20, the vibrations 50 are transferred to the motor 8 at which the detection unit 24 detects the vibrations 50. The detection unit 24 is attached to the motor 8.
Fig. 5B illustrates a schematic view of another bearing health condition monitoring system 2 according to the invention. The system 2 basically corresponds to the system 2 shown in and explained with reference to Fig. 5A. The detection unit 24 is, however, attached to a structure that connects the housing of the motor 8 with the base member 20. Fig. 6A illustrates an exploded view of an electric motor 8. The electric motor 8 comprises a motor housing 74 and a rotor 76 that is attached to a motor shaft 22. The motor shaft 22 is supported by a drive end bearing 9' and a non-drive end bearing 9. A detection unit 24 is attached to the motor housing 74.
Fig. 6B illustrates the motor 8 shown in Fig. 6A in an assembled state.
List of reference numerals
2, 2' System
4 Rotary machine
6 Rotary machine
8, 8' Motor
9, 9' Bearing
10, 10' Bearing
11, 11' Coupling
12, 12' Pump
14, 14' Shaft
16 Inlet pipe
18 Outlet pipe
20, 20' Base member
22, 22' Motor shaft
24, 24' Detection unit
26 Machine assembly
28, 28' Data (e.g. sent as wireless signals)
30 Internet
32 Processing unit
34 Floor or wall
36 Communication module
38 Accelerometer
40 Housing
42 Battery
44 Printed circuit board
46 Power supply
48 Power cable
50 Vibration
52 Data cable
54 Curve
58 Curve 62 Curve
66 Vibration
70 Vehicle
72 Road
74 Motor housing
76 Rotor
78 Wall
V Vibration
T Time
SIR Secondary impact ratio
EA, EA' Active vibration energy (when the motor is running)
EP, EP' Passive vibration energy (when the motor is turned off)

Claims

Claims
1. A bearing health condition monitoring system (2, 2') configured to monitor a health condition of one or more bearings (10, 10') of a rotatory machine (4, 6) of a machine assembly (26, 26), wherein the rotatory machine (4, 6) comprises a motor (8, 8') arranged and configured to rotate a shaft (22, 22') of the rotatory machine (4, 6), wherein the shaft (22, 22') is supported in at least one bearing (10, 10'), wherein the system (2, 2') comprises a detection unit (24, 24') configured to be attached to and hereby detect vibration data (28, 28') representing vibrations of the rotatory machine (4, 6), wherein the system (2, 2') comprises a processing unit (32) configured to receive and process said vibration data (28, 28'), characterised in that the system (2, 2') is configured to calculate: a) the active vibration energy (EA) associated to the vibration data (28, 28') of the rotatory machine (4, 6) detected by the detection unit (24, 24') when the motor (8, 8') of the rotatory machine (4, 6) is running and b) the passive vibration energy (EP) associated to the vibration data (28, 28') of the rotatory machine (4, 6) detected by the detection unit (24, 24') when the motor (8, 8') of the rotatory machine (4, 6) is not running and c) comparing passive vibration energy (EP) and the active vibration energy (EA).
2. System (2, 2') according to claim 1, wherein the rotatory machine (4, 6) is or comprises a pump (12, 12').
3. System (2, 2') comprising two bearing health condition monitoring systems (2, 2') according to claim 1 or 2 configured to be connected to a floor, piping or wall (34), wherein the system (2, 2') comprises: a) a first rotatory machine (4) configured to be mechanically connected to the floor, piping or wall (34); b) a second rotatory machine (6) that is placed in a non-zero distanced from the fist rotatory machine (4) and being configured to be mechanically connected to the same floor, piping or wall (34) in such a manner that the bearing (10) of the first rotatory machine (4) is exposed to vibration caused by the second rotatory machine (6) when the motor (8') of the second rotatory machine (6) is running.
4. System (2, 2') according to one of the preceding claims, wherein the detection unit (24, 24') is attached to the motor (8, 8') or to a structure attached to the motor (8, 8').
5. System (2, 2') according to one of the preceding claims, wherein the detection unit (24, 24') comprises a communication module (36) configured to wirelessly transmit vibration data (28, 28').
6. System (2, 2') according to one of the preceding claims, wherein the detection unit (24, 24') comprises a housing (40), wherein a communication module (36) is provided in the housing (40).
7. Method for monitoring a health condition of one or more bearings (10, 10') of a rotatory machine (4, 6) of a machine assembly (26), wherein the rotatory machine (4, 6) comprises a motor (8, 8') arranged and configured to rotate a shaft (22,22') of the rotatory machine (4, 6), wherein the shaft (22, 22') is supported in at least one bearing (10, 10'), wherein the method comprises the step of:
- detecting vibration data (28, 28') of the rotatory machine (4, 6) and
- processing said vibration data (28, 28'), characterised in that the method comprises the following steps: a) determining the active vibration energy (EA) associated to the vibra- tion data (28, 28') of the rotatory machine (4, 6) detected by the detection unit (24, 24') when the motor (8, 8') of the rotatory machine (4, 6) is running and b) determining the passive vibration energy (EP) associated to the vibration data (28, 28') of the rotatory machine (4, 6) detected by the detection unit (24, 24') when the motor (8, 8') of the rotatory machine (4, 6) is not running and c) comparing passive vibration energy (EP) and the active vibration energy (EA).
8. A method according to claim 7, wherein the method is carried out by using a system (2, 2') comprising two bearing health condition monitoring systems (2, 2') configured to be connected to a floor or wall (36), said system (2, 2') comprising: a) a first rotatory machine (4) configured to be mechanically connected to a floor or wall (34); b) a second rotatory machine (6) that is placed in a non-zero distanced from the fist rotatory machine (4) and configured to be mechanically connected to the same floor or wall (34) in such a manner that the bearing (10) of the first rotatory machine (4) is exposed to vibration caused by the second rotatory machine (6) when the motor (8') of the second rotatory machine (6) is running.
9. A method according to claim 7 or 8, wherein the method comprises the step of detecting vibrations of the motor (8, 8').
10. A method according to claim 7 or 8, wherein the method comprises the step of detecting vibrations of the bearing (10, 10').
11. A method according to one of the claims 7-10, wherein the method comprises the step of wirelessly transmit vibration data (28, 28') to an external receiver (30, 32).
EP24788285.5A 2023-04-12 2024-04-09 System and method for monitoring bearing health conditions Pending EP4695596A1 (en)

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PCT/DK2024/050084 WO2024213215A1 (en) 2023-04-12 2024-04-09 System and method for monitoring bearing health conditions

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JP3551033B2 (en) * 1998-08-28 2004-08-04 日本精工株式会社 Apparatus and method for evaluating bearing stiffness
JP4253104B2 (en) * 2000-05-19 2009-04-08 東京電力株式会社 Abnormal diagnosis method for rotating machinery
US9618037B2 (en) * 2008-08-01 2017-04-11 Honeywell International Inc. Apparatus and method for identifying health indicators for rolling element bearings
JP4560110B2 (en) * 2008-09-17 2010-10-13 ジヤトコ株式会社 Abnormality diagnosis apparatus and abnormality diagnosis method
US9857272B2 (en) * 2015-02-02 2018-01-02 Goodrich Corporation Systems and methods for detecting wheel bearing wear with mounted accelerometers
US9964467B2 (en) * 2015-10-09 2018-05-08 United Technologies Corporation Methods and systems for estimating residual useful life of a rolling element bearing
US11105712B2 (en) * 2018-04-06 2021-08-31 Raytheon Technologies Corporation Integrated vibe/ODM fusion and trending analysis for prognostic health management of engine bearing
EP4368959A4 (en) * 2021-07-07 2024-11-13 NSK Ltd. STATE MONITORING APPARATUS FOR MECHANICAL APPARATUS, WIND POWER GENERATION APPARATUS, STATE MONITORING METHOD, AND PROGRAM

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