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As technology advances, so do the ways in which we can monitor and maintain our equipment. One such innovation is through wireless vibration, a vibration measurement solution that utilises sensors and wireless communications to provide real-time data on the condition of equipment – allowing your ‘dumb’ machines to talk.
Wireless IIoT sensors offer a range of benefits over traditional wired solutions or traditional manual inspection approaches using handheld loggers, including increased uptime, improved safety for workers and cost savings through improved maintenance as we discuss in this article.
Firstly, What are Wireless Vibration Sensors?
Wireless vibration sensors are devices that are easily installed on equipment to monitor and transmit data about its performance and condition. They are often little, battery powered gadgets that are simple to install and transfer between various pieces of equipment. They provide real-time remote monitoring and analysis of equipment performance by transmitting data via wireless communication to a central monitoring system. The best sensors, in terms of communication, use cellular (LTE) and Wi-Fi protocols since they can transmit the large data packets with the high bandwidth required for true predictive maintenance analytics.
Wireless Vibration Sensors: A Predictive Maintenance Solution
One of the most exciting aspects of Industrial IoT wireless vibration monitoring systems is their ability to deliver a predictive maintenance solution through vibration analysis and continuous vibration monitoring.
With powerful machine learning algorithms that process raw data from machine vibration and provide advanced failure detection, diagnosis and remaining useful life calculations, the best systems can catch faults as they develop, very early after a fault is initiated per the P-F curve to avoid unscheduled downtime.
This allows engineers and technicians more time to focus on corrective actions and address root causes to make more informed decisions, rather than use their time collecting and analysing data.
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Real-Time Monitoring for Increased Uptime
A major benefit of wireless vibration monitoring is the ability to monitor equipment in real-time – 24/7 – all-year-round, especially in hard-to-reach assets. This allows engineering teams the increased ability to detect and address issues before they become serious problems, leading to increased uptime and reduced downtime.
By providing real-time data, a wireless vibration monitoring solution also enables teams to proactively schedule maintenance, further reducing downtime and the costs associated with asset management.
Read more on the true cost of deferred maintenance here.
ISO 10816 Standards for Vibration Monitoring
One of the key components of any trustworthy vibration monitoring system is adherence to ISO 10816 criteria. These standards provide recommendations on how vibration in machinery should be measured and evaluated. The criteria are used by engineers and maintenance crews to assess the equipment’s condition and identify any potential issues. The data provided by a wireless vibration monitoring solution that adheres to ISO 10816 requirements is assured to be accurate and reliable.
More Data = More Analytical Capability: The Next Evolution of Sensors
The implementation of a predictive maintenance strategy, which can help to prevent failures and reduce maintenance costs, requires a wireless vibration monitoring system that has frequent data collection and gathers a full spectrum of data, not just simple threshold data or single point RMS acceleration values. A system should also be combined with special analytics algorithms to fully analyse the data very early as faults develop.
One of the most innovative wireless vibration monitoring solutions is the compact wireless MEMS-based IIoT Vibration technology.
The unique sensor technology delivers the world’s only 6-in-1 sensor (the sensor combines integrated triaxial accelerometer (X, Y and Z axes), surface temperature sensor, magnetic flux, RPM extraction, acoustic (inaudible range) and humidity) with fully automated anomaly detection, failure mode classification and remaining useful life determination (RUL) using sophisticated machine learning and signal processing algorithms.
Intrinsically safe and rated IP68 (can withstand dusty environments even in high temperatures), the sensor measures tri-axial vibration, acoustic emissions, magnetic flux, equipment surface temperature, humidity and RPM with built-in cybersecurity and Wi-Fi, LTE Cellular (with No wireless gateway) or LoRaWAN connectivity.
This technology uses machine learning algorithms to process raw data, providing advanced failure detection, diagnosis and a remaining useful life assessment. These capabilities allow engineers and technicians to catch faults as they develop and address them before they become serious problems. By catching faults early, predictive maintenance can help to prevent major damage, costly downtime and increase the overall uptime of the equipment.
The wireless vibration sensor system delivers significant capability and can detect a broad range of failure modes, including unbalance, misalignment, bearing faults, rotor bar faults, impeller problems, looseness, cavitation, winding faults, blade/vane faults, gear problems, phase related problems and more. This allows for early detection of issues such as component fatigue, excessive friction and defects, improving equipment reliability and preventing costly downtimes.
Another unique feature of the sensor is the ability for each sensor's wireless accelerometer to be configured differently depending on the equipment it is monitoring. Whether the equipment is slow speed or equipment that is operated infrequently or in batch processes, the firmware of each sensor can be modified and adjusted remotely if desired or needed to provide flexibility in monitoring that is unparalleled by any other similar wireless vibration sensor in the market.
Predictive Maintenance with NO Wires and NO Gateways - Easier Implementation and Fast Results
A vibration monitoring device should be simple to install, offer efficient but straightforward data transfer with high data quality sensor data, wide sample rate / frequency range and consistent battery life. The best way to do this is with wireless sensors, which do not require cables.
The wireless sensor offered also removes the need for a Gateway, making deployment and condition monitoring the quickest and simplest of all competitive sensors. All other available vibration sensor products today require a gateway of some kind in order to access and send data from the equipment and then send it to the cloud platform.
Similar to how your smartphone connects to a cellular network, a version of the vibration sensor can connect directly to the nearby cellular or LTE network. So it only takes 5 to 10 minutes to find a solution for predictive maintenance!
The sensor also makes it simple to monitor vibration and temperature data on equipment that is hard to reach and/or that is located in congested plant areas (even in harsh environments), which is typical in most industrial or manufacturing applications where gateways are hampered in their capacity to receive data from sensors, which is a restriction in some wireless solutions.
The solution also offers intelligent data communication via an API (accessed via HTTPS, MQTT protocol and FTP over TCP connections), making it simple to interface with already-existing systems, data platforms and historians, giving you more control of your data. It also supports current plant monitoring systems with other liberated data streams, making data analysis and visualisation simple.
Using Wireless IIoT Sensors for Energy Tracking and Carbon Footprint Reduction
Wireless IIoT sensors can help businesses and organisations track their energy consumption and reduce their carbon footprint. The wireless vibration sensor, for example, can integrate its enclosed high-quality magnetic flux data with machine health to calculate changes in power usage and identify which assets are consuming more energy. This allows maintenance teams to address inefficiencies and improve energy efficiency. Additionally, by understanding the cost of energy lost across the facility, businesses can estimate extra CO2 emissions released by poorly operating equipment and take steps to reduce their GHG emissions and carbon footprint. The sensor also allows for regular monitoring of power consumption and CO2 emissions to understand the holistic health of equipment and take corrective steps. Furthermore, the underlying advanced AI algorithms can help companies track the monetary value of lost energy and make informed decisions to reduce energy waste and costs. Some more information regarding how IIoT sensors can support the Energy Transition can be read here: https://www.miniotec.com/post/iiot-and-the-energy-transition.
Maximising ROI and Minimising Maintenance Costs with Wireless Monitoring
Implementing a wireless IoT system that offers multiple sensors in a predictive maintenance program for your industrial equipment can have a significant impact on a business's bottom line. The return on investment (ROI) of wireless sensors can be immense, with the potential to save businesses thousands, if not millions of dollars.
One way to calculate the ROI of wireless sensors is to consider the cost savings from reduced downtime. When equipment is regularly monitored and maintained, breakdowns can be prevented and downtime can be reduced. This results in increased productivity and therefore, increased revenue.
Another way to calculate the ROI is to consider the cost savings from prolonging the lifespan of equipment. By regularly monitoring equipment and identifying potential issues, maintenance teams can address problems before they result in breakdowns, prolonging the lifespan of equipment. This can result in significant savings, as the cost of replacement of some equipment can be costly.
A very good article that can be used as a reference can be read here: (https://www.miniotec.com/post/roi-calculations), which provides a comprehensive overview of the approach to ROI calculations for wireless sensors in predictive maintenance. The article includes considerations of the cost savings from reduced downtime and prolonged equipment lifespan associated with implementing a wireless sensor program.
Read about a successful case study with client recognised ROI here.
Increased Worker Safety and Risk Reduction
Wireless vibration monitoring devices can improve worker safety in addition to increasing equipment uptime and output. The danger of accidents can be decreased and equipment breakdowns can be avoided by maintenance teams through identifying and treating problems before they become serious ones.
Additionally, installing wireless sensors enables equipment to be monitored continuously, year-round, in any place, even in risky or challenging-to-access circumstances. Therefore, dangers and safety concerns can be decreased, if not completely mitigated, by deploying wireless vibration sensors in your maintenance programmes since workers do not need to be put in the line of fire of operating equipment or be required to access difficult asset areas to collect data for analysis.
Artificial Intelligence That Can Monitor and Predict Specific Fault Modes Automatically
Artificial Intelligence (AI) is being used to take predictive maintenance to the next level. With the ability to monitor and predict specific fault modes, AI can improve the efficiency and accuracy of maintenance efforts.
This wireless vibration sensor, for example, uses AI algorithms to analyse data from the sensor and detect specific fault modes in various types of equipment. The AI algorithms used by the sensor are able to recognise patterns and anomalies in the data compared to the physical properties and problem harmonics of the bearings the sensors are monitoring, allowing for the identification of specific fault modes in equipment such as gearboxes, pumps and motors with automated alarms / alerts issued. These algorithms can also be customised to detect specific fault modes in different types of equipment, making the sensor versatile and applicable to a wide range of industries.
One example provided by Miniotec is the detection of bearing failures in gearboxes. The sensor's AI algorithms can analyse vibration data and identify specific patterns that indicate a bearing failure, allowing for early detection and preventative maintenance. Another example is the detection of cavitation in pumps. The sensor's AI algorithms can analyse vibration data and detect specific patterns that indicate cavitation, allowing for early detection and preventative maintenance.
By utilising AI, this wireless vibration sensor is able to go beyond just monitoring thresholds as many other vibration solutions typically offer and provide specific fault mode identification. This leads to more accurate and efficient maintenance, reducing downtime and prolonging the lifespan of equipment.
Highest Level of Data Security
A wireless vibration sensor solution should provide the highest level of data security, ensuring that sensitive data is transmitted securely and only accessible by authorised personnel.
With the Cellular / LTE wireless protocols, the likelihood of cyber hacking through the solution is effectively removed as this solution does not require local Gateways which other similar sensors experience where they are connected through an organisation’s IT network.
Some more information on Cyber Security and IIoT devices can be found in this article: https://www.miniotec.com/post/cyber-security-iiot
User-Friendly System and Customisable
A wireless vibration monitoring system should be user-friendly and customisable to meet the specific needs of the organisation. This allows engineering teams to easily set-up and configure the system and to access and analyse data in a way that is meaningful to them. Dashboard software and reports providing the end-user the ability to view data in a way that is most relevant to the organisation, whether that be by machine, by location, or by other criteria, is important.
Case Study: Wireless Vibration Sensor Implementation
Wireless vibration sensors were successfully implemented at a mining facility, which faced frequent breakdowns and unplanned downtime, eliminating lost productivity and high maintenance costs. The device's wireless accelerometer and wireless temperature sensors helped detect 'unbalance' problems and heat increases in two (2) of their main conveyors before they could cause breakdowns, reducing downtime by 25% and cutting potential maintenance costs by almost 20%, resulting in a 20X return on investment within 3 months. Other case studies can be found here: https://www.miniotec.com/case-studies-proof-of-success
Summary
The implementation of a Wireless Vibration Monitoring System utilising ISO 10816 standards in equipment maintenance can greatly benefit engineering teams by reducing failures before major damage occurs, preventing costly downtimes and increasing uptime.
Miniotec offers a compact wireless MEMS-based IIoT Vibration technology that does not require gateways for connectivity. With the ability to deploy in minutes and utilising the Cellular/LTE wireless communication protocol, this system offers a simple data transmission and easy implementation for both complex and simple machines and balance of plant (BoP) equipment, removes the need for cabling and mitigates risks in monitoring difficult to access equipment.
The solution's analytic capabilities, powered by machine learning algorithms, provide advanced failure detection, diagnosis and remaining useful life assessments, making it a powerful predictive maintenance solution. With the ability to detect and classify a broad range of failure modes in various types of equipment, this wireless vibration monitoring system offers comprehensive plant monitoring.
The comprehensive solution Miniotec offers ensures that equipment is always operating at its best, providing a significant return on investment very timely. For more information, please contact us.
Frequently Asked Questions
Q1: How does a wireless vibration sensor work?
A. Wireless vibration and temperature sensors typically uses an accelerometer to measure vibrations (typically velocity and acceleration and displacement) in different axes (such as X, Y, and Z) and a temperature sensor to measure temperature. They are typically epoxied (or use a stud mount) to the equipment where they then collect vibration data, which can then be analysed to detect any anomalies or potential issues with the equipment, including potential machine failures, well ahead of time.
Q2: What other sensors do wireless vibration sensors include?
A. In addition to vibration sensors, the best wireless vibration sensors may include other measuring parameters such as temperature sensors and acoustic sensors. This allows for simultaneous monitoring of both vibration, temperature and sound, providing a more comprehensive monitoring system. The sensor also includes magnetic flux and humidity, as well as the ability to extract RPM details ensuring it is suitable for fixed speed and variable speed drive (VSD) applications.
Q3: What is the battery life of wireless vibration sensors?
A. The battery life of a wireless system can vary depending on various factors, such as the frequency of data transmission, environmental conditions, signal strength and the sensor's power consumption. However, modern wireless vibration sensors generally have a battery life that can range from twelve months to a few years. Using a wireless vibration sensor has many advantages over fixed wired sensors, particularly because of their simple installation.
Q4: How do wireless vibration sensors transmit data?
A. Wireless vibration sensors typically use wireless communication protocols. The lesser quality sensors in Predictive Maintenance applications use Bluetooth, LoRaWAN, Zigbee, Wireless mesh, SigFOX which have limitations on data packet sizes that can be transmitted. Also mesh networks can sometimes suffer latency connectivity issues. The higher quality sensors use Wi-Fi and LTE to transmit data. These communication protocols allow a full data spectrum to be collected more quickly and more frequently and analysed remotely on the cloud.
Q5: How can multiple sensors be used in a wireless vibration monitoring system?
A. In a wireless vibration monitoring system, multiple sensors can be strategically placed on different equipment or locations to collect data simultaneously. The wireless sensors can be used for comprehensive monitoring and comparison of vibration levels across various assets as they are easy to install.
For a comprehensive FAQ on Wireless Vibration Sensors, please refer to this page.
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About Miniotec:
Miniotec is a digital consulting and technology solutions provider, dedicated to supporting companies in their digital transformation journeys. Established by a group of experienced engineers, we emphasise the harmonious integration of people, processes and technology. Our team has a rich history of working across various sectors, from energy and resources to infrastructure and industry. We are trusted by the world's largest miners, oil and gas giants, utility companies and even budding start-ups and believe in the transformative power of the Industrial Internet of Things (IIoT) and its role in unlocking valuable data insights. Through IIoT, we aim to facilitate better decision-making, enhance operational activities and promote safer work environments. At Miniotec, our goal is to guide and support, ensuring every digital step is a step forward.