Wear fault diagnosis of an emulsion pump crank bearing

The total load on a crank bearing was calculated by performing a load analysis of the crank connecting rod mechanism. The Reynolds equation for hydrodynamic lubrication of the crank bearing was established at the Reynolds boundary condition and was then solved using the Holland method. From this the regular track of the bearing axis was obtained. As the crank bearing gradually wears the eccentricity ratio corresponding to the minimum oil film thickness increases gradually. The oil-bound film eventually breaks down, which allows friction and collision between the metal surfaces of the crank pin and the bearing. The rigid impact leads to excitation of high frequency vibrations at the natural frequencies of the connecting rod. The experiments show that the wear condition of the crank bearing can be identified correctly through the vibration signature at the natural frequencies of the connecting rod. The degree of wear can be predicted accurately through the energy content of the high frequency bands.