Roller bearing acoustic signature extraction by wavelet packet transform, applications in fault detection and size estimation

Continuous online monitoring of rotating machines is necessary to assess real-time health conditions so as to enable early detection of operation problems and thus reduce the possibility of downtime. Rolling element bearings are crucial parts of many machines and there has been an increasing demand to find effective and reliable health monitoring technique and advanced signal processing to detect and diagnose the size and location of incipient defects. Condition monitoring of rolling element bearings, comprises four main stages which are, statistical analysis, fault diagnostics, defect size calculation, and prognostics. In this paper the effect of defect size, operating speed, and loading conditions on statistical parameters of acoustic emission (AE) signals, using design of experiment method (DOE), have been investigated to select the most sensitive parameters for diagnosing incipient faults and defect growth on rolling element bearings. A modified and effective signal processing algorithm is designed to diagnose localized defects on rolling element bearings components under different operating speeds, loadings, and defect sizes. The algorithm is based on optimizing the ratio of Kurtosis and Shannon entropy to obtain the optimal band pass filter utilizing wavelet packet transform (WPT) and envelope detection. Results show the superiority of the developed algorithm and its effectiveness in extracting bearing characteristic frequencies from the raw acoustic emission signals masked by background noise under different operating conditions. To experimentally measure the defect size on rolling element bearings using acoustic emission technique, the proposed method along with spectrum of squared Hilbert transform are performed under different rotating speeds, loading conditions, and defect sizes to measure the time difference between the double AE impulses. Measurement results show the power of the proposed method for experimentally measuring size of different fault shapes using acoustic emission signals. (c) 2015 Elsevier Ltd. All rights reserved.