A New Condition Diagnosis Method for Ball Bearings Using Ultrasonic Visualization and Light CNN

Early fault diagnosis of ball bearings is essential for maintaining the reliability of rotating machinery and preventing unexpected downtime. This study proposes a fault diagnosis framework that combines non-contact ultrasonic visualization with a lightweight convolutional neural network (Light CNN). Seven bearing conditions, including ferrous particle contamination and grease starvation, were investigated using ultrasonic, vibration, and acoustic emission (AE) sensors under identical experimental conditions. Sa-liency-map extraction and two-dimensional histogram analysis were applied to ultrasonic RGB images to generate compact feature representations, which were compressed into 20 × 20 feature maps and used as inputs to a three-layer Light CNN. The proposed method achieved an average classification accuracy of 99.98% and an F1-score of 99.98%. In addition, an average inference throughput of 11.47 IPS was obtained, representing approximately ten times higher computational efficiency than vibration- and AE-based approach-es. Stable diagnostic performance was also maintained under a low-speed operating condition of 500 rpm. These results demonstrate the effectiveness of combining ultrasonic visualization and a lightweight CNN for accurate and computationally efficient bearing fault diagnosis.