Methods and systems for estimating residual useful life of a rolling element bearing

1. A method for estimating residual useful life of a rolling element bearing in an operating gas turbine engine, the method comprising:

receiving, by a processor, a vibration signal from a vibration sensor, the vibration signal including a vibratory response of the rolling element bearing;

detecting, by the processor, a vibratory pattern of the rolling element bearing from the vibration signal;

comparing, by the processor, the vibratory pattern to a reference vibratory pattern, the reference vibratory pattern having a plurality of successive failure propagation stages with respective vibratory specific patterns;

identifying, by the processor, a failure propagation stage of the plurality of successive failure propagation stages in which the vibratory pattern substantially matches a respective vibratory specific pattern of the failure propagation stage;

correlating, by the processor, the failure propagation stage to the residual useful life remaining in the rolling element bearing; and

generating, by the processor, an output signal representing the residual useful life remaining in the rolling element bearing.

2. The method of claim 1 , wherein detecting the vibratory pattern comprises measuring a vibration frequency and vibration amplitude to obtain a measured vibration frequency and measured vibration amplitude.

3. The method of claim 2 , wherein detecting the vibratory pattern comprises detecting a change in the vibratory pattern.

4. The method of claim 3 , wherein the vibratory pattern comprises a vibration frequency range and a vibration amplitude range and detecting the change in the vibratory pattern comprises detecting a shift in the vibration frequency range and a diminution in the vibration amplitude.

5. The method of claim 2 , wherein the vibratory specific patterns comprise a reference vibration frequency range and a reference vibration amplitude range, wherein comparing the vibratory pattern to the vibratory specific patterns comprise comparing the measured vibration frequency against the reference vibration frequency range and the measured vibration amplitude against the reference vibration amplitude in the failure propagation stage.

6. The method of claim 5 , wherein comparing the vibratory pattern comprises comparing a spectral diagram of the vibratory pattern against a spectral diagram of the reference vibratory pattern in the failure propagation stage.

7. The method of claim 1 , further comprising assigning a health score range to the rolling element bearing within each failure propagation stage.

8. The method of claim 7 , wherein assigning a health score range comprises determining a percentage of the vibration frequency and the vibration amplitude within the vibratory pattern.

9. A method for estimating residual useful life of a rolling element bearing of a rotor bearing system in an operating gas turbine engine, the method comprising:

receiving by a processor, a vibration signal from a vibration sensor of the rotor bearing system, the vibration signal including a vibratory response associated with a vibratory pattern of the rolling element bearing;

determining, by the processor, relative contributions of an impulse response and an imbalance response in the vibratory response, the relative contributions defining a vibratory pattern;

comparing the vibratory pattern to a reference vibratory pattern in a failure propagation stage of a plurality of successive failure propagation stages with respective vibratory specific patterns;

identifying a failure propagation stage of the plurality of successive failure propagation stages in which the vibratory pattern substantially matches a respective vibratory specific pattern of the failure propagation stage; and

correlating, by the processor, the failure propagation stage to the residual useful life remaining in the rolling element bearing.

10. The method of claim 9 , wherein determining, by the processor, the relative contributions of the impulse response and the imbalance response in the vibratory response comprises determining a vibration frequency and a vibration amplitude.

11. The method of claim 10 , wherein determining the vibration frequency and the vibration magnitude comprises determining a measured vibration frequency and a measured vibration amplitude.

12. The method of claim 9 , wherein the vibratory specific patterns comprise a reference vibration frequency range and a reference vibration amplitude range, wherein comparing the vibratory pattern to the vibratory specific patterns comprise comparing a measured vibration frequency against the reference vibration frequency range and a measured vibration amplitude against the reference vibration amplitude in the failure propagation stage.

13. The method of claim 9 , wherein comparing the vibratory pattern comprises comparing a spectral diagram of the vibratory pattern against a spectral diagram of the reference vibratory pattern in the failure propagation stage.

14. The method of claim 9 , further comprising assigning a health score range to the rolling element bearing within each failure propagation stage.