Quality-Control of Bearings Using Vibration Monitoring: Application Notes

Application Notes
Quality-control of Bearings
Using Vibration Monitoring
The- American N T \ Hearing
Manufacturing Corporation at
Schiller
Park
manufactures
deep-groove ball hearings. T h e
outer diameter of the miter
races is ground on a centreless
urinder. T h e quality of the
hearings depends largely on the
balance of the grinding wheel.
'I'he balance of each machine
was checked at hourK intervals
with a hand-held vibration meter but because the balance of
t he \\ heel could change very
quickly. up to an hour's pro
duct ion of badly ground races
could pass down the produclion line before they were delee led.
I
;
j
J
:
A Type 2. )0"> Multipurpose

Monitor was installed on each
grinder
to
detect
Midden
changes in balance. Since the
installation of the T y p e 2-M)~i.
the scrap rale at the plant has
. been halved.
,
Bearing quality greatly depends upon the quality of the grinding wheel. By
permanently monitoring vibrations from the grinding wheel, a tight check can
be kept on its condition
The American NTN Bearing Manufacturing Corporation,

Schiller Park, Illonois
The American NTN Bearing Manufacturing Corporation is a subsidiary
of the NTN Toyo Bearing Company of
Japan. The plant at Schiller Park
manufactures 40 mm, 52 mm and
62 mm Deep-Groove Ball Bearings.
The bearings are standard items in the
NTN catalogue and most will be used
by the automobile manufacturing industry for car alternators, etc. The
plant has 4 production lines, two of
which produce 40 mm bearings. Each
line consists of several grinding operations followed by assembly and testing.
The outer diameter of the outer
races is ground on a centreless grinder
lder
Opat the beginning of each line. This opBO 0245-11
Fig. 1. One of four centreless grinders used to grind the outside diameter of the outer races at
Schiller Park
eration is largely automatic. The quality of the bearings depends largely on

the balance of the grinding wheel.
Normally the grinding wheel would go
out of balance gradually over a period
of 18 hours. Sometimes, however, the
change would be more sudden. Such
sudden changes would be due to a chip
coming off the wheel or a change in
the density of the coolant.
Balancing the Grinding

Wheels
The balance of each machine was
checked at hourly intervals with a
hand-held vibration meter. The balance of the grinder was unacceptable
if the vibration displacement exceeded
3,5 ^m for the 40 mm bearings or 4 /im
for the 62 mm bearings. The wheel
was then balanced so that the vibration did not exceed 1 jum. Initially, the
rebalancing operation could take 5 or
6 hours. The balancing was done by
trial and error and it took some 5 minutes for the wheel to stop before eachi
adjustment. Larry Hackett, the Electrical Engineer at Schiller Park, reduced the balancing time to 20 minutes by installing a dc brake on each
machine.
The hand-held vibration meter adequately covered the routine case of the3
grinding wheels going out of balance3
2
over a period of time, and the dc
brakes had speeded up the balancingy
operation. The problem of the wheelss
suddenly going out of balance still remained. The problem was made worse3
by the fact that the grinding time dictated the overall rate of production.
The average grinding time was 8 seconds whereas the average assembly/
time was 3 seconds per bearing. The3
mismatch between the grinding time3
and the assembly time meant that the3
newly ground races would often pass3
down the production line immediately. Because the machines were only/
checked periodically, up to an hour's3
production of badly ground races3
could pass down the production line3
before they were detected.
Fig. 2. Diagram of the Type 2505 setup on a centreless grinder
Permanently
ireiiiiaiieiiuy Monitoring
iviuiiiiuriiig the Grinding Wheels
A permanent monitoring system
was needed. The plant already used
Kjser sound level meters
Briiel and Kjaer
and vibration analyzers and so Briiel
and Kjaer were asked to provide a sosoType
lution. Larry Hackett chose the Type
2505 Multipurpose Monitor as the
the
most suitable for the application. The
The
fact that the Type 2505 closes to aa
spfllpH
unit was
was an
nn important
imnnrtant rnnsiHsealed unit
consideration because of the coolant suspended in the air around the grinders.
A permanently-installed "rugged" Industrial Accelerometer Type 8315 was
used for the vibration pick-up. Larry
installed a Type 2505 and 8315 on
each grinder. The alarm level was set
between 2,5 and 3 ^m displacement
depending on the diameter of the race
to be ground. The trip level was set
1 fxra higher. The best position for
measuring vibration had been found
with the hand-held vibration meter.

The 8315 was put in the same position.
The wheels still go out of balance in
18 hours but no longer are there production losses due to sudden changes
of balance. Since the installation of
the Type 2505, the scrap rate at the
plant has been halved.
Fig. 3. The Type 2505 Multipurpose Monitor

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Application Notes

A Type 2. )0"> Multipurpose

The American NTN Bearing Manufacturing Corporation,

eration is largely automatic. The quality of the bearings depends largely on

Balancing the Grinding

Fig. 2. Diagram of the Type 2505 setup on a centreless grinder

with the hand-held vibration meter.

Fig. 3. The Type 2505 Multipurpose Monitor

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