A multi-function integrated PVDF transducer for fault detection and speed measurement of cylindrical roller bearings

Abstract

Monitoring the condition of bearings in rotating machinery is crucial to ensure reliability, safety, and efficiency. Recently, integrated sensors have become more popular than traditional accelerometers in bearing condition monitoring because of their compact design, cost-effectiveness, and improved efficiency in fault detection through a short transmission path. This study presents a new approach to bearing condition monitoring by developing a bearing with an integrated Polyvinylidene Fluoride transducer. This polymer-based transducer, known as PVDF, has a piezoelectric effect which generates electric charge in response to mechanical excitation. The PVDF transducer was selected for its high sensitivity, flexibility, and thin structure. The developed bearing with the integrated PVDF transducer can detect faults under constant and variable speeds, and the damage size can be estimated with an accuracy of 10%. It outperformed a commercial accelerometer in noisy environments with artificial impacts from an air motor, making it a highly reliable option for bearing condition monitoring in noisy industrial settings. The PVDF transducer can also be used as a low-cost speed sensor with an accuracy of 5.2%, offering a versatile solution for machine monitoring. By simultaneously recording rotational speed and vibration, the developed integrated transducer provides a comprehensive view of machine health and performance as a multi-function transducer, enabling more accurate and efficient maintenance scheduling.