Vibration data acquired on a small helical gearbox with three shafts supported by tapered roller bearings indicated symptoms consistent with bearing failure. Vibration pattern that helped identify the problem as lubrication-related is discussed in this article. Lower-order harmonics dominated the spectrum, and their magnitudes suggested bearing fault in an advanced stage.
Vibration data acquired on a small helical gearbox with three shafts supported by tapered roller bearings indicated symptoms consistent with bearing failure. Vibration pattern that helped identify the problem as lubrication-related is discussed in this article. Lower-order harmonics dominated the spectrum, and their magnitudes suggested bearing fault in an advanced stage.
Vibration data acquired on a small helical gearbox with three shafts supported by tapered roller bearings indicated symptoms consistent with bearing failure. Vibration pattern that helped identify the problem as lubrication-related is discussed in this article. Lower-order harmonics dominated the spectrum, and their magnitudes suggested bearing fault in an advanced stage.
Tags: gear lubrication, case study The vibration data acquired on a small helical gearbox with three shafts supported by tapered roller bearings indicated symptoms consistent with impending bearing failure The vibration pattern that helped to identify the problem as lubrication- related is discussed in this article Fault Frequencies !oth inner and outer race bearing faults were present in the spectrum "#igures $ and %& 'andom impacting of high magnitude was indicated in the time waveform "not shown& (n alarm showed that lower-order harmonics dominated the spectrum, and their magnitudes suggested bearing fault in an advanced stage Figure 1. Harmonics of inner race bearing defect frequency M=BPFI. Figure 2. Harmonics of outer race bearing defect frequency L=BPFO. Figure 3. oise modu!ating by bearing cage frequency "=F#F. The modulation of a random signal by the cage frequency was also observed in the )ea*+ue data "#igure ,& It has been theorized that due to dry operation, both the inner and outer races wore out to a point that the round geometry of the races had been compromised In addition, insufficient lubrication caused increased friction between the rollers and the cage !ecause of being sub-ected to modulation by the cage, friction became apparent in the )ea*+ue data (fter removing the gearbox from operation and disassembling it, the entire space in the gearbox filled with grease, used mainly in open gears, but the lubricant was completely washed out from the bearing areas "#igure .& Figure $. %rease &as been 'as&ed out from t&e bearing areas. Bearing outer races are une(en!y 'orn out. Results of Metal Wear The diagnosis was confirmed by observing the damage sustained by the input shaft bearing /xtensive wear was present in the outer race "#igure 0& ( rough surface was not the only result of the metal wear ( groove up to 11$0-inch deep also developed in the path of the rollers Figure ). * groo(e u+ to ,.,1)-inc& dee+ is +resent in t&e outer race. The inner race exhibited a similar pattern "#igure 2& 3o pitting or spalling was observed on the surface The cage was also excessively worn out and bro*e off in several locations This, along with the smaller inner-race diameter, compromised the separation of the rollers "#igure 4& Figure .. /orn surface on t&e inner race. * groo(e de(e!o+ed in t&e +at& of t&e ro!!ers. Figure 0. 1age is damaged. o !ubricant is +resent. (n observant reader may as* why grease was used in a gearbox instead of oil 5onsider this wintertime scenario6 In attempting to warm up the room, you turn up the thermostat instead of shutting the door to retain the heat Dealing with a symptom instead of the root cause is still a common approach to solving problems In this case, the lubrication scheme was designed as an oil splash-type, but over time, the shaft seal started to lea* To prevent oil from escaping, lubricant flow properties have been ad-usted for the lea*ing seal by draining the oil and filling the entire space of the gearbox with grease 7hile there was some grease still left in the bearing area, it operated almost satisfactorily, possibly slightly hotter, than normal !ut once the initial charge was depleted, the lubricant could not be delivered, even with the excess grease in the gear casing The same is true for the lubrication of the gears 8a*ing lubrication modifications without considering the lubrication scheme could be detrimental to you and your equipment
About the author: David Gluzman is a 5ertified 'eliability /ngineer "5'/& with Temple-Inland 5orporation, a manufacturing company focused on corrugated pac*aging and building products Gluzman also holds 8achine 9ubrication Technician 9evel I and 9evel II certifications through the International 5ouncil for 8achinery 9ubrication