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Rolling Bearing Diagnosis with theFAG Bearing Analyser III
Technical Information
A Member of the
Schaeffler Group
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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
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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
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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
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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.
Measurement and Program Description
3
The list of applications of the
Bearing Analyser III is virtually un-
limited.
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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.
Measurement and Program Description
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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.
Measurement and Program Description
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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.
Measurement and Program Description
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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.
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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
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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