Abstract
On the basis of empirical mode decomposition and teager energy operator, the new approach for rolling bearing fault diagnosis based on phase difference correction method is presented. It focuses on improving the identification precision of characteristic defect frequency of rolling bearing. Firstly, fault vibration signal is decomposed into finite number of intrinsic mode functions by empirical mode decomposition method. Secondly, computing the kurtosis value and correlation coefficient between intrinsic mode functions and original signal, then the reasonable intrinsic mode function is selected to demodulate by teager energy operator through the correlation coefficient and kurtosis value. Finally, the accurate characteristic defect frequency can be estimated by using phase difference correction method to correct the demodulation spectrum. The proposed method is applied in actual fault signals of rolling bearing with inner race damage and outer race damage. The results showed that, compared with the method without spectrum correction, the improved method receives better effect to identify characteristic defect frequency.
Keywords
Introduction
Rolling bearing is the critical and vulnerable component for most rotating machinery. A number of conventional faults in rotating machinery are closely associated with bearing; bearing fault may lead entire system to catastrophic failure. Hence, bearing fault diagnosis (BFD) is very important and the early estimation of bearing faults can significantly prevent the system from damage. Many approaches have been studied throughout these last years, of which a typical research subject is to extract and identify the characteristic defect frequencies (CDF) of rolling bearing. CDF is the low-frequency defects and it is one important feature for BFD. It is well known that the fault types of bearing can be easily determined by CDF. However, CDF is usually difficult to be extracted due to the modulation in fault vibration signal of bearing. Therefore, the key step of BFD is to extract and identify the CDF with high precision.
As a matter of fact, the characteristics of fault vibration signals of rolling bearing are non-linear and non-stationary, thus it is difficult to obtain CDF. In order to effectively extract the CDF of roller bearings, a variety of signal processing techniques have been developed such as wavelet transform (WT), empirical mode decomposition (EMD), etc. These two famous techniques demonstrate the ability to decompose the original vibration signal of bearing into different frequency bands. 1 Many research have successfully applied the wavelet analysis for BFD,2–4 however, WT suffers drawbacks, i.e. border distortion and energy leakage,5,6 more importantly, in the strict sense, WT is not adaptive due to its fixed-scale frequency resolution. 7 Aiming at these drawbacks, Huang et al. proposed the self-adaptive signal decomposition technique for non-linear and non-stationary signal, which is called EMD. 8 The complicated vibration signal can be decomposed into a finite number intrinsic mode functions (IMFs) (intrinsic mode functions) efficiently and adaptively by EMD, the frequency component of each IMF from high to low and changed with the original signal itself. Therefore, EMD is an effective tool for treating vibration signals of rolling bearing. 9 Moreover, some researches have combined the EMD with other techniques applied to BFD, such as Hilbert transform (HT), 10 support vector machine (SVM), 11 wavelet packet transform (WPT). 6 Autoregressive (AR) model, 12 and energy operator (EO). 13
We know that the fault vibration signal of bearing always present the characteristic of modulation. Therefore, fault vibration signal demodulation analysis is necessary for BFD. At present, HT and EO are two common methods for signal demodulation. The performance of these two methods are analyzed and compared in Potamianos and Maragos. 14 From Potamianos and Maragos, 14 the demodulation effect of HT is inferior to EO demodulation and the computation of EO is also simple to perform. The non-linear EO (teager energy operator) valid for mono-component amplitude modulated (AM) signal and the frequency modulated (FM) signal is proposed in Kaiser, 15 which is a fast and simple algorithm for BFD.1,16 However, a majority of bearing fault vibration signals in real cases are all multi-component modulated signals. Therefore, EMD method is usually combined with teager energy operator (TEO) to decompose the multi-component signal into the mono-component signal. Many articles have applied this method to bearing fault detection with good effects.17–19 It shows that the EMD–TEO method is an ideal option for the CDF extraction.
Most of existing researches are only concerning about how to effectively extract the CDF, thus far, few works have been reported on the precision of CDF. So far, the precision of CDF is not good as we expected, especially for shorter data length. Recently, discrete spectrum correction (DSC) methods have been widely applied to signal processing for improving estimation accuracy of signal parameters. Therefore, the goal of this paper is to improve the precision of CDF by using DSC methods. The phase difference correction (PDC) method is a kind of DSC which has the good anti-noise property and is easy to be implemented. 20 It was first proposed by McMahon and Barrett, 21 hitherto, three types of PDC methods can be described as: time shifting (TS),22,23 window length changing(WLC),24,25 and correction method based on asymmetrical windows (AW).26,27 TS method needs to choose an appropriate parameter L of time delay. And the AW method has presented very satisfactory computational accuracy, however, it needs the extra iterations. The WLC PDC method has the advantages of low computational effort and relatively high accuracy.
It is generally known that the fault vibration signal of bearing with low signal-to-noise ratios (SNR) and CDF is always overwhelmed by heavy noise. Based on the characteristics of vibration signals of rolling bearing, taking advantage of WLC, this study use WLC method for vibration signal analysis after being preprocessed by EMD-TEO and combine with kurtosis, correlation coefficients to select an appropriate IMF. The remainder of the paper is organized as follows: the principle of method is presented in “Basic principle” sections. Application of the improved method in the vibration analysis of rolling bearing with inner race (IR) damage and outer race (OR) damage are presented in “Simulation and experimental results” section. Finally, the conclusions are drawn in “Conclusion” section.
Basic principle
EMD method
The vibration signal can be decomposed into a finite number IMFs by EMD method, which is
developed for non-stationary and non-linear signal analysis. Each IMF must satisfy the
definition is mentioned in Huang et al.
8
According to the definition, any signal
can be decomposed as follows
The above discussion shows that the signal can be decomposed into different IMFs by EMD
method, however, EMD method faces the problem of how to select a reasonable IMF for fault
diagnosis of rolling bearing. Therefore, kurtosis metric is introduced to assist with
making reasonable analysis, and select the optimum IMF. Kurtosis is a statistical
parameter, which is sensitive to the shock signal and the value is described as28,29
Meanwhile, in the case of the kurtosis value K > 3, correlation
coefficient is introduced as another metric to remove pseudocomponents of IMFs. As is
known from the property of autocorrelation function (ACF), the ACF of periodic function is
the periodic function with the same period of itself. An important aspect of vibration
signals of rolling bearing is its periodical, therefore, ACF can be fully used to
highlight the periodical of vibration signals and IMFs. As well as the pseudocomponents of
IMFs can be effectively removed. The ACF of each IMF and the original signal defined as
Then, the ACF is normalized to get the correlation coefficients between IMF ACF and
original signal ACF
Teager energy operator
In order to effectively extract the CDF, the optimum IMF of vibration signal need to be
demodulated. The TEO was proposed by Kaiser to measure the energy of the mechanical
process that generated a single time-varying signal, which offers valuable signal
processing tools for demodulating amplitude and frequency from AM–FM signal. The TEO for
discrete time signal x(n) is
15
From equation (5), we can see the output of TEO is in direct proportion to the square of amplitude A and frequency ω. Thus TEO is able to enhance the transient characteristic of vibration signal very effectively, moreover, since the output of TEO is obtained by only calculating the three adjacent sample points, the entire computation can be simplified. Therefore, the TEO implementation is simple and efficient for signal demodulating.
WLC PDC method
The WLC is a kind of PDC method, which is nearly applicable for all classical window
functions and has relatively high accuracy, good anti-noise property. Without loss of
generality, consider a single-frequency signal in the following formula
Make discrete Fourier transform (DFT) on weighted signal
yw(t) = y(t)wT(t)
with the different length of time-shifted Hanning window (N and
N/2). In DFT, we assume that the number of acquired samples is
N and the sampling frequency is fs, then
the phase of the two spectral peaks
(k1,k2) can be written in the
following form
From equation (9) we can obtain
The corrected frequency is
Then, the accurate CDF can be worked out by equation (11)
Diagnosis approach for rolling bearings based on WLC PDC method
The proposal can be summarized as follows Perform the EMD to decompose the vibration signals into different IMF components as
c1…cn. Obtain the kurtosis value and correlation coefficient according to equation (2) and
equation (4), then choose the optimum IMF component from above IMF components
according to kurtosis value and correlation coefficient. Compute the output of optimum IMF component by TEO. Apply WLC phase difference method to the output of IMF component based on
Hanning-windowed. Finally, we get accurate corrected CDF.
Simulation and experimental results
In this section, we apply the proposed method (PM) to vibration data of real deep groove ball bearing, the IR fault and OR fault are discussed, respectively.
Database
The bearing vibration data from the Case Western Reserve University bearing data center 31 are used in the experiment. The data were collected from accelerometer, which was placed at the drive-end bearing of the motor housing and the sample frequency is fs = 12 kHz. The IR fault and OR fault were recorded with motor loads of 0–3 horsepower and test bearing with fault diameters of 0.007 in. and 0.021 in. The test bearing is 6205-2RS JEM SKF deep groove ball bearing, pitch diameter Pd = 1.537 in., ball diameter Bd = 0.3126 in., the number of balls Z = 9, and contact angle a = 0°.
Inner race
Figure 1 illustrates the time
domain waveform of IR with fault diameter 0.007 in. and the motor speed is 1797 r/min; the
data length 1–2048. The CDF of the IR can be calculated by Time domain waveform of the inner race fault signal. The kurtosis and correlation coefficients. IMFs: intrinsic mode functions.
Figure 2 shows the demodulated
CDF and corrected CDF of c1. The CDF is obtained by WLE method
(fC = 162.033267 Hz and double
2fC = 324.127852 Hz) which is close to the calculated value
by equation (12) compared with TEO demodulation (fT = 164.0625 Hz
and double 2fT = 322.265625 Hz). According to the value of
CDF, we can determine that the roller bearing has the IR fault. Demodulation spectrum of c1 and corrected value.
It is worth noting that the kurtosis value of c2 is also
greater than 3. It is considered the consequences of ignoring some fault information if
only just c1 is selected for demodulation, Figure 3 shows the demodulation
spectrum and corrected value of c2. As shown in the figure,
although the peak at the frequency fc = 161.994473 Hz, which
is similar to the CDF of IR: 162.185973 Hz. Nevertheless, the amplitude of CDF is very
small, therefore, c2 lays little effect on faults diagnosis,
which can be ignored. Demodulation spectrum of c2 and corrected value.
In order to evaluate applicability of the proposed algorithm, we investigate two fault
diameters (0.007 in. and 0.021 in.) with different motor speeds. We use the root mean
square error (RMSE) as a quantitative indicator of 80 random samples from bearing
vibration data, and the data length of each sample is 2048. We define the corrected
frequency error and demodulated frequency error as:
fec = fC − fir
and fet = fT − fir,
respectively. The RMSE of fec and
fet is given by RMSE for 80 random samples (0.007 in., N = 2048). RMSE: root mean
square error. RMSE for 80 random samples (0.021 in., N = 2048). RMSE: root mean
square error.


The RMSE of fec for 50 random samples are shown in Figures 6 and 7, and the data length of each sample is 4096.
Firstly, the accuracy of both fec and
fet increase with the growth of data length. Secondly, Figure 6 (1721 r/min) and Figure 7 (1752 r/min) illustrate the
same situation as Figure 5. In
general, by observing the simulation results, it is concluded that in most cases the
proposed algorithm has higher precision than TEO demodulation. RMSE for 50 random samples (0.007 in., N = 4096). RMSE: root mean
square error. RMSE for 50 random samples (0.021 in., N = 4096). RMSE: root mean
square error.

Outer race
For localized defects of OR, we mainly consider the defects are located at different
positions with same fault diameter. The localized defects of OR are located at
3:00 o'clock (directly in the load zone) and at 6:00 o'clock (orthogonal to the load
zone), respectively, then the CDF of the OR can be calculated by
The RMSE of fec for 80 random samples with fault diameters
(0.007 in.) at different location (3:00 o'clock, 6:00 o'clock) are shown in Figures 8 and 9, respectively, the data length of each sample is
2048. RMSE for 80 random samples (0.007 in., N = 2048, 3:00 o'clock).
RMSE: root mean square error. RMSE for 80 random samples (0.007 in., N = 2048, 6:00 o'clock).
RMSE: root mean square error.

As shown in Figures 8 and 9, we can clearly see that the maximum RMSE of fet is nearly equal to 2.4, and fet are still so large in most cases compared with the fec except in Figure 8 (RMSEfec(1774r/min) = 0.521114 and RMSEfet(1774r/min) = 0.451514) and Figure 9 (RMSEfec(1773r/min) = 0.376766 and RMSEfet(1773r/min) = 0.461368) due to the same reason as Figure 5.
Figures 10 and 11 show the simulation results for
each sample with 4096 sample points. Generally, RMSE decrease as the data length increase
and the trend of the fec is relatively stable with different
motor speeds. In general, the proposal gives satisfactory results for fault detection with
different locations of localized defects and different motor speeds, which can completely
meet the requirement of the fault diagnosis. RMSE for 50 random samples (0.007 in., N = 4096, 3:00 o'clock).
RMSE: root mean square error. RMSE for 50 random samples (0.007 in., N = 4096, 6:00 o'clock).
RMSE: root mean square error.

Compare and influence of window
In addition to PDC method, windowed interpolated DFT (WIpDFT) algorithm is another
popular method of DSC. It was first proposed by Jain et al.
32
and has been widely used in harmonic
analysis. Figure 12 shows the
RMSE of CDF for PM and WIpDFT
33
based on Hanning window with different data length and different
defects location. RMSE of PM and WIpDFT. (a) RMSE for 80 random samples IR007
N = 2048; (b) RMSE for 80 random samples IR021
N = 2048; (c) RMSE for 50 random samples OR007 at 3:00 o'clock
N = 4096; (d) RMSE for 50 random samples OR007 at 6:00 o'clock
N = 4096. RMSE: root mean square error; WIpDFT: windowed
interpolated discrete Fourier transform.
From Figure 12 it can be observed that the accuracy of both method is quite high to identify the CDF of bearing and WIpDFT is even slightly better than PM in some cases. Both of these methods can meet the precision expectations of BFD. However, the process of WIpDFT always needs polynomial approximation if there is no analytical formulas for estimating the parameters of signal. In other words, WIpDFT therefore relies heavily on window with poor applicability. Being different from WIpDFT, WLC can be applied to all classical windows and without iteration, that is the reason why the WLC is chosen for PM. Although the accuracy of WLC is inferior to WIpDFT in some cases, it is good enough to precisely identify the CDF. In order to illustrate the accuracy of CDF influenced by window selection and to highlight the applicability of WLC, the proposed algorithm is used in four classic windows: Blackman, Blackman–Harris (B–H) window and Rife–Vincent (I)-5 (5-RV(I)), there are classical 3–5 term cosine window.
As shown in Figure 13(a),
firstly, although shorter data for analysis (N = 1024), PM with different
windows still presents satisfactory results, which shows a good generality of WLC.
Secondly, the precision level decreases as term of window increases, and the precision of
CDF based Hanning window (2-term window) is greatest because it gives relatively narrow
main-lobe width. From Figure
13(b), it is clear that the Hanning window with the narrowest main-lobe width,
which brings good frequency resolution of Hanning window. Performance of different windows. (a) RMSE for 100 samples
(N = 1024,IR007); (b) normalized logarithm spectrum of windows.
RMSE: root mean square error.
Conclusion
According to the characteristics of TEO and vibration signal of rolling bearing, TEO
can effectively identify the CDF by demodulating the vibration signal. However, this
method receives good effects only when the data length of sample with more data point,
so the accuracy of demodulating is dependent largely on the number of sampling
points. The improved algorithm based on the WLC PDC is proposed in this paper, which
effectively enhances the identification accuracy of the CDF and is easy to be
implemented, therefore it is very suitable for the application of embedded system. The simulation results from vibration signals with IR and OR faults indicate that
combining the TEO demodulating with the WLC PDC technique can effectively improve the
precision of CDF identification with fewer sampling points in most cases. The identification accuracy of CDF is influenced by the main-lobe width, and narrow
main-lobe width may obtain better effects.
Footnotes
Acknowledgements
The authors want to thank the anonymous reviewers for their helpful comments, which significantly improved the quality of the paper.
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.
Funding
The author(s) disclosed receipt of the following financial support for the research, authorship, and/or publication of this article: the Chongqing Municipal Education Commission (Grant No. KJ1600428).
