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Vibration monitoring through IIoT is a crucial aspect in condition monitoring of industrial equipment across many facilities, as it allows for the detection of potential mechanical issues before they lead to costly equipment failure.
Traditional vibration monitoring systems require physical cabling, which can be both time-consuming, costly to install and disruptive to existing operations. However, with the advent of wireless vibration monitoring, industrial facilities can now easily and efficiently monitor the health of their machinery.
What is Vibration Monitoring?
Vibration monitoring is a process that involves looking for anomalies and monitoring changes in the established vibration signature of a system. It is used to measure the amplitude, frequency or intensity of vibrations emitted by rotating machinery. By analysing vibration patterns, maintenance teams can detect irregularities such as unbalance, misalignment, loose parts and other potential issues in machines.
Vibration monitoring systems work by using vibration trend analysis to identify changes in vibration signatures that could indicate machine malfunctions. These systems help prevent unexpected downtime, reduce maintenance costs and enhance safety by providing early warnings of potential machine failures.
Vibration sensors, like accelerometers, are commonly used to measure vibrations near bearings and continuously monitor machine conditions. Wireless vibration monitoring systems thus play a crucial role in predictive maintenance strategies by collecting vibration data from important machines 24/7, 365 to detect and diagnose faults early on, preventing excessive wear, safety risks, power consumption issues, unplanned downtime and production loss. Overall, vibration monitoring is essential for optimising the performance and maintenance of industrial equipment by enabling continuous monitoring of machine health and providing insights for timely maintenance interventions.
Advantages of Wireless Vibration Sensor Technology in Vibration Monitoring
1. Easy installation:
Wireless vibration monitoring systems do not require physical cabling (no external power supply), making installation a breeze. This not only saves time and money but also allows for monitoring in hard-to-reach or hazardous areas.
2. Remote vibration monitoring:
With wireless technology, vibration monitoring data can be transmitted in real-time to a remote location, allowing for continuous monitoring and analysis.
3. Cost-effective:
Traditional industrial vibration monitoring systems can be costly, both in terms of installation and maintenance. Wireless systems, on the other hand, are cost-effective and require minimal maintenance.
4. Flexibility:
Wireless vibration monitoring systems can be easily moved and reconfigured, allowing for monitoring of different pieces of equipment as needed.
High-Tech Wireless Vibration Sensors
The key component of a wireless vibration monitoring system is the sensor hardware. These sensors come in a variety of forms, from accelerometers to proximity probes and are designed to detect specific types of vibrations. For example, accelerometers are used to measure linear acceleration, while proximity probes are used for non-contact vibration measurement.
Read more about this revolutionary wireless vibration sensor here.
Smart Vibration Monitoring without Cabling
The latest advancements in wireless vibration monitoring technology have led to the development of smart sensors. These sensors not only detect vibrations but also process and transmit the data to the Cloud, allowing for real-time monitoring and detailed analysis. In addition, smart sensors can be integrated with other systems, such as Predictive Maintenance (PdM) software or similar historian, to provide a comprehensive view of equipment health.
Miniotec provides the world’s only 6-in-1 sensor (integrated triaxial wireless accelerometer, wireless temperature sensor (measures surface temperature), magnetic flux, RPM (speed) 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.
Best-in-Market Wireless Vibration Sensors
When it comes to wireless vibration monitoring, there a number of factors requiring consideration. A best-in-market sensor should possess a range of capabilities across multiple sensors that enable accurate and reliable vibration measurement and analytics.
1. High sensitivity:
A high-sensitive sensor can monitor vibration and detect even the slightest vibrations, providing early warning of potential issues. Temperature sensors that can measure surface temperature data are more relevant to condition monitoring than temperature sensors that only monitor ambient temperatures.
2. Wide frequency range:
A wide frequency range allows for the detection of a broad range of vibrations, from low frequency vibration to high frequency vibration.
3. Robust design:
Industrial environments can be harsh and a robust sensor design is crucial for withstanding extreme temperatures, shock and vibration. IP68 should be the minimum expectation for most applications. Where monitoring is required in Hazardous Environments, sensors that are intrinsically safe is an imperative.
4. Long battery life:
Wireless sensors rely on battery power and a long battery life (min. two (2) years) ensures continuous operation without the need for frequent battery replacement. We will in time see more ultra low power sensors powered by vibration itself where the sensors turn vibration into power or light itself into power therefore battery longevity will be less of a consideration.
5. Real-time data transmission:
A wireless sensor that can transmit data packets of large sizes and that offer high quality and frequent data collection in real-time are market leading as they enable continuous monitoring and analysis of equipment health.
6. Communication protocols that can transmit large data packets:
A wireless system with sensors having minimal data bandwidth communication protocols such as Zigbee, Bluetooth or LoRa, are not typically the best choice for a wireless vibration monitoring system as these protocols have very limited data transmission packet sizes and bandwidth, which may not be able to support the large amount of data and frequent large data uploads required for predictive maintenance capabilities, compared to sensors that offer LTE or a Wi-Fi wireless protocol.
7. Advanced signal processing:
Advanced signal processing capabilities, such as digital filtering, frequency analysis, high data quality and data compression, enable the sensor to provide detailed vibration information. On-board anomaly detection within a sensor is also an advantage and key differentiator.
8. Remote configuration:
The ability to remotely configure sensor settings over-the-air (OTA), individually or within a cluster, such as measurement range and frequency, allows for easy adaptation to specific monitoring needs and providing necessary firmware updates to keep the devices up to date with the latest Cyber security firmware.
9. Predictive Maintenance capabilities:
Predictive maintenance capabilities, such as built-in algorithms, allow for early detection of potential equipment failure, which may not be fully achievable with limited data transmission packet sizes offered by Zigbee, Bluetooth, or LoRa communication protocols.
10. Cloud compatibility:
Cloud platform compatibility enables easy access to data from anywhere, making it possible to perform analysis, share data and create alarms. Solutions with the capability to also offer intelligent data communication and that can be connected via an API (accessed via HTTPS, MQTT protocol and FTP over TCP connections) should also be regarded highly.
By incorporating these capabilities, a wireless vibration sensor can provide industrial operations with accurate, reliable and real-time vibration monitoring, enabling predictive maintenance and increasing equipment uptime. However, It is important to note that certain communication protocols may have limitations in terms of data transmission packet sizes and may not be able to fully support predictive maintenance capabilities. It is important to consider this when choosing a sensor with a communication protocol.
Read more about how wireless vibration sensors are benefitting the mining industry.
In Summary
Wireless vibration monitoring to collect vibration data with IIoT devices is a game-changer for industrial operations, providing easy installation, remote monitoring, cost-effectiveness and flexibility. With the latest advancements in wireless technology and the development of smart sensors, industrial facilities can now efficiently and effectively monitor the health of their machinery, increasing uptime, reducing maintenance costs and maximising asset performance - with no wires.
It is important to consider the capabilities of the IoT vibration sensor device when choosing a wireless vibration monitoring system. A best-in-market sensor should possess a high sensitivity integrated triaxial accelerometer, a wide frequency range, a robust design, long battery life (low power consumption), real-time data transmission, advanced signal processing, remote configuration and predictive maintenance capabilities. Additionally, it should be compatible with various communication protocols and be able to transmit large data packets, such as LTE (no gateway required) or Wi-Fi, to avoid limitations in data analytics.
When it comes to wireless vibration monitoring, one sensor stands out from the rest. The sensor offered by Miniotec is unique in that it is the only sensor on the market that can connect to the Cloud with no gateways, just like your mobile phone. It also has six sensors in one and is capable of specific fault identification, on-board anomaly detection and excellent fault detection algorithms which places it ahead of other sensors. Each sensor can also be programmable with different monitoring firmware offering the most flexibility to monitor any type of equipment, even equipment that may run intermittently or in batch production. This sensor is a powerful tool for industrial operations, providing accurate, reliable and real-time vibration monitoring, enabling predictive maintenance and increasing equipment uptime.
We are collectively accelerating into even more exciting times and opportunities with Predictive Maintenance and IIoT sensors. Embrace it. Digital matters.
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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.
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