Vibration Monitoring (VM) has been around for quite a long time and has been used to monitor the health of a machine, equipment, or a structure. The vibration data collected via dedicated sensors during the operation of a machine is monitored and analyzed in real-time. The main goal of vibration monitoring is to reduce the risk of fatal damages and potential line-down situations which leads to final operational cost control and reduction. The vibration data from a vibration sensor can be used as a stand- alone input or be combined with other sensor data depending on the operational requirements. For example, in a factory automation application, the vibration data can be combined with: ■ Temperature ■ Smoke
The collected data are fed into dedicated algorithms, including the emerging artificial intelligence (AI) algorithms, to develop a model that can predict potential future failure. The model prediction information can then be used to build knowledge for making decisions on whether any immediate actions need to be taken to avoid productivity loss. A new trend in factory automation is the emergence of AI algorithms which can be trained based on sensor data to predict which tasks should be performed. This lessens the burden on individual operators who previously had to make critically
The capability of a vibration sensor to capture high-frequency signals enables more accurate frequency analysis of the vibration. The latest MEMS vibration sensor offers a bandwidth of over 6 kHz which will be discussed later. A MEMS-based vibration sensor has many use cases and Figure 1 provides a list of some major applications. Motor vibration monitoring is an essential building block of successful factory automation. Vibration monitoring in railways can help avoid catastrophic train accidents. Home appliances such as washing machines have been equipped with vibration monitoring since the inception of MEMS sensors in industrial applications. The structural monitoring application has gained momentum since the emergence of MEMS sensors at an affordable cost. For example, municipalities bear the responsibility to monitor bridge vibration to ensure that structures are in good health and sound condition. The bridge vibration data, particularly during peak traffic hours, can provide valuable information on any abnormality that may cause the collapse of the bridge.
difficult and time-consuming decisions. An autonomously
automated factory takes away the responsibility of individual operators and reacts automatically to any changing operating conditions.
Vibration sensor
■ Humidity ■ Pressure ■ Sound
A key component in a vibration monitoring application is a vibration sensor. The latest vibration sensors are based on MEMS technology using the same concept of acceleration detection in an accelerometer. The main difference is in the bandwidth of the sensor. A MEMS accelerometer has a typical bandwidth of 3 kHz, however, a vibration sensor is capable of detecting the vibration at significantly higher bandwidth.
This combination generates a complete system that will provide a more robust and reliable solution. In some other use cases such as structural monitoring, the vibration data can be combined with the tilt position data that is collected via an inclinometer to determine the health of the structure.
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