New Approach for Bearing Life Cycle Estimation and Control

Abstract

A new approach for the control of the life cycle of rolling bearings in machine tools is presented. The approach is based on a new simulation tool that has been developed using the well-known ISO 281 standard as a reference. This new tool improves the accuracy of the estimations in two fields: model-based and feature-based prognostics. The tool provides accurate end-of-life estimations, thanks to the determination of more realistic component loads for a defined manufacturing cycle. In addition, it can be embedded in monitoring devices using real machine tool usage data and calculate remaining useful life (RUL) of the analyzed component. Experimental tests confirm that the ISO 281 standard overestimates end-of-life of bearings under controlled conditions and presents vibration analysis as a key tool for an early detection of bearing failure. Indeed, the application of the module for remaining useful life calculation should be combined with vibration-based condition monitoring in order to detect unexpected component degradation.