Bearing Analyser III TI WL 80-63E 02 04

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Rolling Bearing Diagnosis with theFAG Bearing Analyser III

Technical Information

A Member of the

Schaeffler Group



Unforeseen bearing damage, often

resulting in machine downtimes

and production loss, does not only

cause an enormous cost in paper

mills, oil refineries, steel mills,

chemical plants and power plants.

It also causes an unnecessary re-

pair expenditure even in less com-

plex production plants. Condition-related maintenance helps every

machine operator save enormous

cost. To this end, any damage must

be detected at an early stage, diag-

nosed, and its development moni-

tored. In this way maintenance

work can be scheduled well ahead

and the necessary preparations can

be made. The availability of ma-

chines increases, and the produc-

tion cost is reduced.

Rolling Bearing Diagnosis with the

Portable FAG Bearing Analyser III

The FAG Bearing Analyser II I is an ef-

ficient and reasonably priced multi-

channel vibration analysis tool for

early and reliable damage diagnosis

and troubleshooting in all kinds of

machines. Even complex machines

and plants, such as multistage gears

and rolling stands, can be analysed

in detail with the help of the BearingAnalyser III. The Bearing Analyser III

hardware and software can turn any

standard laptop computer into a

portable, efficient machine diagno-

sis system. The Bearing Analyser III

hardware is simply connected to the

laptop via the enclosed data acqui-

sition card. The signals measured by

the system are transmitted to the

Bearing Analyser III software and

analysed by it. The integrated auto-

matic diagnosis system recognisestypical machine damage patterns in

the vibration signal.

Principle of Envelope Detection

Analysis

The Bearing Analyser III uses the

envelope detection analysis

method to detect bearing damage.

Cycling of discrete damage on a

rolling bearing, e.g. pitting in the

raceways, causes a periodic seriesof individual shocks. These shocks

induce structural resonances in the

bearing or in adjacent machine

parts. The shock frequency is char-

acteristic of the type of rolling

bearing damage and can be calcu-

lated if the bearing geometry and

the speed are known.

Depending on the location of the

damage (outer ring, inner ring,

rolling elements) different shock

frequencies are obtained that are

referred to as kinematic bearing

frequencies. These high-frequency

vibrations are superimposed by

running noise. The original shock

values can be reconstructed for

evaluation by filtering out all sinu-

soidal vibrations and rectifying the

signal. The rolling bearing damage

is characterized by increased am-

State-Of-The-Art, Condition-Related Monitoring of Plantsand Machines

1

plitudes at the corresponding kine-

matic frequencies and by their mul-

tiples and side bands.

Bearing Analyser III Hardware:

• 2 inputs for acceleration sensors

(max. overall sampling rate:

200 kHz)• 2 inputs for the raw signal and

2 inputs for the envelope signal

(low-pass filter: 200 Hz / 1 kHz /

5 kHz / 20 kHz )

• Additional trigger input

(analogue/TTL)

Bearing Analyser III Software:

• Continuous measurement

(data is stored on the hard drive)

• Improved automatic diagnosis

system

• Data administration in the data-

base

• Bearing database and calculator

for other bearing types

• Data viewer (data visualised in

the form of a waterfall diagram)

• E-service function



Key Function –Hierarchic Configuration

The machines to be monitored are

mapped in the new Bearing Analyser

III database in the form of a tre e

structure. The system permits users

to generate individualized configu-

ration files that meet different moni-toring requirements . This is done by

defining different parameters, for

example, the number of channels to

be measured or the configuration of

the low-pass filters (raw signal and

envelope). Alternatively, the user

can make specific definitions, for ex-

ample measurement of a certain

number of samples (max. 65536

samples), continuous measurement

or the use of a trigger signal.

The tree structure shows the current

status of the individual segments.

Depending on the results of the

measurements, the colour of the

icons in the tree changes to indicate

their current alarm status:

• green - no alarm,

• yellow – pre-alarm

• red - main alarm.Moreover, it is possible to add pic-

tures and photos.

Measurement and Program Description

2



Key Function – ContinuousMeasurements

The Bearing Analyser III can also be

used to measure a machine’s vibra-

tion data continuously over a previ-

ously specified period of time and

store it directly on the hard dri ve of

the laptop.

This means that it is also p ossible

to measure, analyse and store ma-

chine run-up and run-out data. Lat-

er, individual measurement phases

can be analysed separately or the

entire process can be visualised in

the form of a waterfall diagram.

This function enables users to de-

termine the natural resonanceranges of a machine.


3

The list of applications of the

Bearing Analyser III is virtually un-

limited.



Key Function – AutomaticDiagnosis System

The new BA III software includes an

automatic bearing damage diagno-

sis system. The user only has to s e-

lect the bearing type from the inte-

grated bearing database and enter

the speed of the shaft.The measured data is then auto-

matically analysed by the software.

The diagnosis system, which was

significantly improved over its

predecessor version, can detect not

only bearing-specific but also ma-

chine-specific damage frequencies

with a high degree of reliability.

The data viewer which is integrated

into the software offers users use-

ful tools for a more detailed data

analysis, for example a harmonic

cursor, a sideband cursor, various

zoom functions, mathematical

functions etc.


4



Key Function – Trend Curve and Report

Moreover, the Bearing Analyser III software offers use rs

the option to visualise the trend of the measured d ata

to document a development over a previously specified

period of time.

The integrated report function enables users to summa-

rize and print all important diagnosis results.

Key Function – E-service

If users need assistance in analysing their data, t hey

can use the new, integrated e-ser vice function: By sim-

ply clicking on the e-service button and selecting the

data area to be analysed, all the req uired data is ex-

ported, compressed and attached to an e-mail mes-

sage. This message will then be sent a utomatically to a

diagnosis expert who was specified in advance, e.g. to

the company’s own diagnosis centre or the F’IS diagno-

sis centre. In this way the assistance of experts can beenlisted for difficult analyses.


5



Combination of Bearing Analyser III and Detector II

A Bearing Analyser III can be com-

bined with a Detector II data collec-

tor to create a vibration monitoring

system for virtually every need: The

handheld, easy to operate Detector

II is used to collect measurementdata on regular inspection rounds.

The data can then be analysed us-

ing the Bearing Analyser III soft-

ware. In-depth analysis options and

the automatic diagnosis system of

the Bearing Analyser III software

make it considerably simpler to di-

agnose the measurement data from

the Detector II.

If the measurements performed

with the Detector II reveal a defect

or unusual data, the Bearing

Analyser III can be used to conduct

a detailed in-depth diagnosis and

troubleshoot the problem right on

the spot.

Combination of Bearing Analyser III and Top-Laser INLINE

A Bearing Analyser III can also be

combined with the FA G Top-Laser INLINE system that is laptop-based

as well. This shaft alignment sys-

tem can be used either alone or as

an add-on to the Bearing Analyser

III and enables users to align ma-

chines in a simple manner.


6



Other Features of the “FAGBearing Analyser” Soft-ware

• Simultaneous measurement of

raw signal and envelope signal

• Automatic frequency analysis by a

fuzzy-based expert system• Monitoring of the envelope carpet

level and of the carpet level ratio

of envelope signal to raw signal

• Monitoring of freely definable fre-

quencies in the envelope spec-

trum

• Integrated database system for

more than 4200 standard FAG

rolling bearings as well as for

rolling bearings made by other

manufacturers

• Integrated “bearing calculator”

for easy input of not yet defined

bearings

Installation

Installation starts automatically

when the enclosed CD is inserted in

the drive. Both the actual Bearing

Analyser III software and the driv-

ers for the DAQ-Card are installed.

The software is compatible with the

following operating systems: Win-dows 98SE, Windows NT 4.0, Win-

dows 2000 and Windows XP.

1 Bearing Analyser III docking sta-

tion for connecting the sensor

and for signal processing; power

supply via notebook and PC cardcable

Order code:

FIS.BAIII.DOCK

1 BA III acceleration sensor

with a 1.5 m cable and a magnetic

base

Order code:

FIS.BAIII.SENSOR.ACC

1 multifunctional carrying case:

FIS.BAIII.SUITCASE

1 adapter cable for connecting the

data acquisition card:

FIS.BAIII.CABLE.TO.CARD

1 adapter cable for connecting the

acceleration sensor:

FIS.BAIII.CABLE.TO.SENSOR

Features · Installation · Scope of Delivery

7

1 installation CD,

BA III software as described

above

Order code:FIS.BAIII.SOFT

1 BA III data acquisition card

DAQ-Card 6024,

Order code:

FIS.BAIII.CARD

1 User manual

Order code:

FIS.BAIII.MANUAL.ENG.GER

Standard Scope of Delivery:

Order code (complete system): FIS.BAIII.SET.001

The FAG Bearing Analyser III comes ready to use, with the following accessories:

Accessories in bold print can also be ordere d individually as replacement

parts.



Designation FAG Bearing Analyser III · Order code (complete system): FIS.BAIII.SET.001

Dimensions (docking station) 290 mm wide, 230 mm long, 35 mm high

Mass (docking station) ca. 1.5 kg

Power supply Via notebook

Operating time 1.5 to 3 h, depending on the notebook’s type of battery

Temperature range 0 to 50 °C (working temperature)

Operation Windows-based softwareTouchpad or mouse

Data recording capacity Continuous sampling on hard drive for all channels512 –65536 “samples“ or continuously

Entries 2 Lemosa sockets, 4-pole, for acceleration pickup (4 mA ICP power source, 24 V)or voltage input1 additional input for speed data (analogue 0–10 V/ digital (TTL), BNC socket, high-pass < 2Hz))

Voltage ranges ± 5 mV to ± 5 V (peak-peak)± 15 V max. input voltageSoftware issues warning if input sensitivity is exceeded.

Frequency ranges Simultaneous measurement of general vibration signal and envelope signal on both channels

Band width: 200 Hz / 1 kHz / 5 kHz / 20 kHz

Triggering Automatic, pre-programmed externally

Process window Hanning

Filters Antialiasing filter, switchable: 200 kHz, 1 kHz, 5 kHz, 20 kHzHigh-pass filter, switchable for demodulation: 750 Hz/2 kHz with envelope detection

Interfaces ECP/EPP parallel, serial, external VGA,(depending on not ebook) P S/2 k eyboard/mous e/keypad,

PCMCIA interfaces (2 x type II or 1 x type I, PC card)Serial infrared interfaceDAQ-Card-700 or DAQ-Card-6024

Standard scope of delivery Data acquisition card (with adapter cable) FIS.BAIII.CARD

FIS.BAIII.SET.001 Acceleration sensor (with adapter cable) FIS.BAIII.SENSOR.ACCMultifunctional carrying case FIS.BAIII.SUITCASESoftware, on CD-ROM FIS.BAIII.SOFT Docking station FIS.BAIII.DOCK User manual FIS.BAIII.MANUAL.ENG.GER

Damage diagnosis Carpet level analysis for general vibration and envelope signalThreshold value monitoring of the amplitudes within the configured frequency bandsAutomatic frequency analysis with fuzzy-/neuro-based expert system

PC Software BA III Released for Windows 98/NT 4.0 SP 6/2000/XP• Hierarchic plant and measuring point manager • Integrated database for measurement values• Graphic presentation of the measurement values also in the form of a trend curve• Visualisation of the stored time signals and their spectra• Automatic generation of reports on measurement values and alarms

• Waterfall diagram• Averaging (linear / peak hold)• German / English

Technical Data

8



FAG Kugelfischer AG

Postfach 1260

D-97419 Schweinfurt

Georg-Schäfer-Straße 30

D-97421 Schweinfurt

Service hotline:

Phone: +49 2407 914999

E-mail: [email protected]

www.fis-services.de

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Every care has been taken to ensure the

correctness of the information contained

in this publication but no liability can

be accepted for any errors or omissions.

We reserve the right to make changes in

the interest of technical progress.

© by FAG 2004.

This publication or parts thereof may

not be reproduced without our permis-

sion.

TI No. WL 80-63 E

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Bearing Analyser III TI WL 80-63E 02 04

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