Monitoring of Spindle Bearings During Operation...Page 2 Title: Monitoring of Spindle Bearings...

Monitoring of Spindle Bearings During Operation

Lecturer: Ehad Arifi, Schaeffler Technologies GmbH & Co. KG

Together We Move The World

Title: Monitoring of Spindle Bearings During Operation Lecturer: Ehad Arifi, Schaeffler Technologies GmbH & Co. KGTable of contents

ü Spindle bearing monitoring during operation

ü Targets and approaches

ü Effects of bearing damages

ü Possible monitoring parameters

ü Temperature, Vibration

ü Vibration monitoring strategies

ü Basic principle of vibration monitoring

ü Practical examples

ü Offline and Online vibration monitoring

ü Schaeffler Technologies vibration monitoring products

Condition Monitoring a tool of Condition Based Maintenance

Maintenance strategies:

ü Running until failure

ü Advantage: Effort only in case of failure

ü Disadvantage: No maintenance planning possible

ü Planned maintenance / Preventive maintenance

ü Advantage: Failures can be avoided

ü Disadvantage: In certain cases unnecessary effort

ü Condition based maintenance

ü Advangtage: Optimum performance of components

ü Disadvantage: Information about components necessary

Maintenance:

Ø Avoid unplanned shut downs

Ø Ensure and increase machine availability

Ø Information about machine componentsØ Support for maintenance schedule

and maintenance capacityØ Maintenance without disturbing

normal machine operationØ Reduce of maintenance costsØ Reduce stock of components

Ø Online monitoring of beginningdamages of components

Production:

Ø Avoid disruption of production

Ø Increase productivity

Ø Reduce production costs

Ø Ensure product quality

Condition Monitoring a tool of Condition Based Maintenance

Condition Monitoring

Targets and approaches from point of view….

Cause of spindle bearing failure

Ø Operating life time is limited in most cases dueto wearØ Sealing: Ingress of foreign particlesØ Lubrication: contaminents

Ø Indentation in racewaysØ Plastic deformation as result of static

overloade.g. crash

Ø foreign particle cycling

Ø Material fatigueØ pittingØ crack

Normal raceway

Fatigue, pitting

Indication of bearing damage

Ø Reduction of workpiece quality

Ø Temperature profile

Ø Noise, Vibration

Ø Due to fatigue and racewaydamages











ü Vibration monitoring products of Schaeffler Technologies

Ø Friction Torque

Ø Bearing temperature monitoringØ Change of preload and malfunction

of floating bearing generates typicaltemperature profiles

Ø Vibration monitoring / noiseØ Continuous monitoringØ Periodic monitoring

Ø Characteristic value monitoringØ Frequency analysis

Possible monitoring parameters

Bearing Friction Torque ( coast down )

0

2000

4000

6000

8000

10000

12000

0 10 20 30 40 50 60 70 80Zeit [s]

n [1

/min

]

OK

Temperature Monitoring

Ø Reference Temperature

Ø Contact to the measuringObject

Ø Temperature Developing

0

0,5

1

1,5

2

0 10 20 30 40 50

Temperature [°C ]

Run

tim

e [h

]

Temperature Monitoring

0

0,5

1

1,5

2

0 10 20 30 40 50Temperature [°C ]

Run

tim

e [h

]

XXDamage Limitation

XXCondition basedmaintanance

XStoring of OperatingConditions

XXQuality Assurance

ContinuousPeriodicalOne-Time

Targets - Vibration monitoring strategies

Spindle bearing arrangement in machine toolØ Lathe machineØ Milling machineØ Drilling machineØ Grinding machine

Characteristic of spindle arrangementØ High running accuracyØ High stiffnessØ Low running noise

Ø at high turning speed

è Consequential: Definition of monitoring parameters and strategies

Bearing arrangement of machine tool

Source of noise in bearings

Ø Elastic deformation

Ø Friction, lubrication noise

Ø Surface effects( change of contact surface, local damage, wear )

Ø Surface of rolling elementØ Outer and Inner ring raceway

Cycling of surface effects

Ø Cycling of damages on surfaces generatesimpacts

Ø Impacts leads to looses of qualityand higher running noice

Ø Even little damages may lead to strong qualityproblems

Ø Specified monitoring of bearing defect frequencies

Ø Attention !Progress of damage very fast on high speedapplications

Ø Damage on outer ring

Ø Damage on inner ring

Ø Damage on rolling element

Specified damage bearing frequencies

Offline monitoring of spindles

Ø Offline measuring with Data collector

Ø Measurements on test rig

Ø Create databasemachine information, spindle number, bearing type and documentation spindle condition

Ø Combination of parameter monitoring and deep frequency analysis

Ø Measurements at same turning speedand same sensor position

Ø Trending of parameters andamplitudes of specified frequencies

Ø Right setting of monitoringconfiguration


Ø Periodic measurementswith documentation

Ø Trending data and deviation

Ø As a result of frequency analysisbearing damages are detected on time


Damage on bearing racewayMeasurement taken on work piece spindle

– Impacts as a result of damagedbearing are visible in thefrequency spectra

Measurement taken after replacement of spindle bearing arrangement

– The vibration signal doesn‘t consistbearing defect frequencies

Online monitoring of tool spindlesØ Online monitoring of stationary tool

spindles with permanent installed sensors

Ø Monitoring of spindle bearingsØ Monitoring of overall vibration levelØ Frequency analysis

Ø Monitoring of unbalance (1x turning speed)

Ø Data communication via TCP/IP (Network)Ø Alarm informationØ Data transfer

Measuring only during idle position at same speed:

Ø Measuring on idle position:Ø No additional vibration sourcesØ Increased visibility of damage frequenciesØ Detection of incipient damages on bearings

is possibleØ Spindle bearing frequencies can be separated

Ø Measuring on same speed: Ø Reliable data trending and alarm settings

Online monitoring of tool spindles

Start button for measurement

FAG Detector III – Monitoring and balancing with a single device

FAG Detector III

Vibration diagnosis

§ Route planning

§ Integrated bearing database

§ Automatic alarm threshold adjustment

§ Automatic selection of measuring points(RFID technology)

§ Presentation of vibration data trends

§ In-depth diagnosis

§ Customer-specific measurement reports

FAG Detector III – Functions

FAG Detector III – Scope of delivery

FAG Detector III Balancing Kit§ Acceleration sensor with magnetic foot§ Trigger sensor (optical and inductive)§ Weighing balance§ Magnetic holder for trigger sensor§ Extension for magnetic holder§ Cable for trigger sensor (length 10 m)§ Reflex mark for trigger sensor§ Dongle for activation of balancing function§ Case

FAG Detector III Kit*§ Base device with rechargeable battery§ Acceleration sensor with magnetic foot§ Contact-free (infra red) temperature sensor§ Power pack§ PC data cable (serial/USB)§ User manual§ Protective bag with holder for temperature sensor§ PC software Trendline§ RFID tags§ Case

Completediagnosis system

•Available with and without RFID technology-Please note: The RFID functionality is notavailable worldwide.

FAG DTECT X1 s

FAG DTECT X1 s - Advantages

New

All necessary functions in one device:§ Monitoring from up to eight channels plus

two additonal channels§ Integrated rotary frequency input§ Improved overvoltage protection for power,

additional signals and communication, sensor defect identification

§ TCP/IP and serial communication (WiFi option)§ Extended operating temperature from

-20 oC up to +70 oC for device environment§ Analog interfaces to process systems with optional

galvanic isolation to protect control systems§ Protection class IP 67

FAG DTECT X1 s - Advantages

New

Small design: § W: 260 mm x H: 150 mm x D: 90 mm

Standardized connection technology:§ Flexible and easy installation in the field through

M12 connection sockets§ Isolation amplifier as separate modules upgradable

in the field (adjustable: 0 – 10 V, 0 – 20 mA, 4 – 20 mA)

Compatibility to existing installations:§ Firmware and software

Safety through vigilance!The time is ripe: vibration sensors on every machine

FAG SmartCheck – Products and services

permits access to datavia smartphones

e.g. via standard web browser

thanks to status LEDsthanks to monitoringconfiguration template

through easy mountingand little wiring

FAGSmartCheck App

EASY retrieval of measured data

INTUITIVE operation

IMMEDIATELY ready for use

QUICKinstallation


* At the planning stage

Derivation of processcontrol measures

Analysis and diagnosissoftware permitsremote access to FAG SmartCheck

Various machine and process parametersare recorded and correlated withvibration signals

Data exchange OPC UA client server*

Communication and power supply via a single line

Integration intocontrol station

Webinterface:FAG SmartWeb

Gain informationfrom data

Integration intoPLC / OPC

Network capableand Power overEthernet (PoE)

Standard andtailored to ourcustomers‘ needs

● System integrationand adaptation

● Integration relatedconsultation

● Maintenance service

● Preparation of condition reports

● Writtenrecommendations foraction

● Remote servicing(analysis and reporting)

● System maintenance(adjustment of alarmthresholds etc.)

● Definition of measuring points

● Commissioning● Reference

measurements● Measuring rounds● System integration● Investigation of the

cause(s) of problems

Training coursesServices Reconditioning

Condition reportRemotemonitoring

On SITE service


Together We Move The World

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Monitoring of Spindle Bearings During Operation...Page 2 Title: Monitoring of Spindle Bearings...

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