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Spare Vibration Monitoring

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Sumset International Trading Co.,Ltd is located in Xiamen Fujian China which is one of the beautiful coastal tourism city in China Southeast region.

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We specialize in PLC modules, DCS control cards, ESD control cards, turbine supervisory, vibration monitoring and asset protection system.

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Our sales team are professional engineers who can help system architecture proposal, part number selection, system test and after sales services.

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Our products are widely used in CNC machinery and metallurgy, oil and gas, petrochemical, chemical, paper printing, textile printing and dyeing, machinery, electronics manufacturing, automobile manufacturing, tobacco, plastic machinery, electricity, water conservancy, water treatment / environmental protection, municipal engineering, Heating, energy, transmission and distribution industries.

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XMV16 620-003-001-116 扩展振动监测卡一对

 

What is Vibration Monitoring

A vibration monitoring system is a tool that looks for irregularities and other anomalies in a machine's health by measuring its vibration levels. It helps to protect the facility, the process and the people. If you want to know the specifications and prices of TMR System, please contact us!

 

Advantages of Vibration Monitoring

 

 

Wide Range of Applications
Due to their many advantages, piezo transducers have an extensive range of applications. In addition to those mentioned above, piezo transducers are also used in record players, accelerometers, electronic watches, microphones, seat belts, kitchen stove igniters, infertility treatment, printers, smartphones, and automatic doors.


Small Electronic Circuit Is Accessible for Almost Any Device
Piezo transducers are very small and can output precise measurements over a wide range. As such, they're very forgiving overall and often can be readily incorporated into preexisting designs with minimal modifications.


High-Frequency Response
One key feature of piezo transducers is frequency response and accuracy. Even slower piezo transducers have a near-instantaneous response to pressure changes, making them perfect for sensitive applications that require accuracy down to fractions of a millisecond. When used to generate vibrations, rather than convert vibrations into electricity, the delay between the electric pulse and the piezo beginning to vibrate is usually just tenths of a millisecond. As a result, piezo transducers are a popular choice for systems that require haptic feedback.


Flexible Design Requirements and Options
In addition to their small size, piezo transducers can perform well when fashioned into nearly any shape, and a wide variety of models are available to suit your exact needs. Piezoelectric transducers also don't require a power source when used to convert vibrations into electrical energy. Many applications of piezo transducers require a single transducer and a single wire, leading from the transducer to a device that measures its signal. However, when using a transducer as an actuator, you'll need a piezo driver to amplify the incoming signal and generate vibration.

 

Types of Vibration Monitoring
MPC4 200-510-070-113 机械保护卡
CA202 144-202-000-105 压电加速度计
RPS6U 200-582-200-021 机架电源
CE620 444-620-000-011-A1-B100-C01 压电加速度计

Piezo Vibration Sensors
Piezoelectric vibration sensors (also called piezo vibration sensors) capture changes in physical parameters or forces. The applied force generates an electrical charge, which is then converted into measurable electrical signals.
Piezo vibration sensors capture highly accurate and dependable data, and they are robust and rugged enough to withstand harsh environments. Those qualities have made an extremely popular choice for industrial vibration sensors. For example, they can handle a wide range of temperatures.
And while piezo vibration sensors' sensitivity and small size make them ideal for many industrial applications, one drawback is that they can consume more power than some other types of vibration sensors.


Accelerometer Vibration Sensors
Accelerometer vibration sensors are another extremely common type of vibration sensor. An accelerometer measures the acceleration forces acting on an object. Static forces, such as gravity, are constantly acting on objects. Dynamic forces, such as vibration, are those applied to objects at varying rates. Accelerometers produce electrical signals proportional to forces that they are measuring.
There are also different types of accelerometers, with varying strengths and recommended applications. For example, triaxial accelerometers measure acceleration in three orthogonal directions (that is, three axes). Because of this, triaxial accelerometers can measure all of the vibration components affecting an object.


Eddy-Current Vibration Sensors
Eddy-current sensors are versatile non-contact devices that measure displacement using the principles of eddy currents. Eddy currents are loops of electrical current within conductors caused by placing the conductor in a changing magnetic field. Eddy-current vibration sensors are commonly used to measure shaft displacement. This type of misalignment is one of the key mechanical issues that vibration monitoring can detect. Eddy-current sensors are ideal for high-resolution, high-speed vibration measurements.
If using more than one eddy-current vibration sensor, pay close attention to their proximity. If they are too close together, their electromagnetic fields can interfere with one another and reduce the accuracy of any measurements. It is possible to shield sensors.


Wired and Wireless Vibration Sensor
Each type of vibration sensor offers different benefits. Wired vibration sensors can record and transmit vibration measurements continuously. In contrast, wireless vibration sensors typically transmit at frequent intervals. In some situations, this distinction makes a difference. Wired sensors can be slightly more expensive to install, in part because of the cabling required. And cable damage can render wired sensors unresponsive. However, there's also much more data available for vibration analysis.
Wireless vibration sensors, paired with cloud-based software, make it possible to access vibration data from any internet-connected device. Data transfer speeds can vary based on connectivity, location, and other factors. Wireless vibration sensors are comparatively inexpensive to install and highly scalable. Wireless sensors can be placed wherever needed without running cables through walls, floors, and ceilings. Wired sensors are more limited in where they can be placed.
The benefits and drawbacks of both types of vibration sensors can be effectively balanced by using wired and wireless industrial vibration sensors together. Many maintenance software systems make it possible to integrate different types of vibration sensors, even those from different OEMs, into one centralized system.

 

Rules for Mounting of Piezoelectric Force Transducers
 

Is An Initial Stress Required?
The CFW force washers are significantly flatter in design and are not pre-stressed. Pre-stressing is required when mounting. These transducers must be calibrated when in a mounting condition. The pre-stressing of the force washer is necessary to ensure the linea­rity and structural durability of the transducer. This pre-stressing means that another mechanical element is mounted parallel to the force transducer. We recommend that the force washer is pre-stressed to at least 10% of its nominal (rated) force. The force washer itself can be used to determine the initial stress. A part of the measuring force is now shunted through the pre-stressing element. Pre-stress and force shunt are determined by the installation situation. It is therefore necessary to calibrate the force washers after mounting is complete, i.e. to compare the output signal of the transducer with a known force. The accuracy of the measure­ment results depends here mainly on the accuracy of the calibration.

 

Increase the Quality of Your Output Signal
The charge output by a piezoelectric transducer is converted into a directly proportional voltage by means of a charge amplifier.
Piezoelectric sensors are ideally suited for dynamic, i.e. non-zero point-related measurements. The drift generated by piezoelectric measure­ment chains is so low that it does not affect accuracy even with high requirements.
The drift is an effect of the charge amplifier. The transducers themsel­ves do not display drift if mounting and connection are implemented correctly. The maximum drift of a measurement chain is 0.1 pC/s or 25 mN/s if quartz is used as sensor material and 13 mN/s for the sensor material gallium phosphate.

 

Clean Contaminated Sockets
If however, despite all care, sockets are contaminated, they can be cleaned as follows:
First of all, unscrew the socket
Dry wipe the white surfaces of the socket with a cleaning pad (e.g. HBM Order number 1-8402.0026)
Spray the socket with pure isopropanol (e.g.: IPA200 from RS Components)
Clean again with a new cleaning pad
The cable plugs cannot be cleaned, i.e. if the cable is contaminated , it must be replaced. The cleaning agent RMS1, which is used for cleaning strain gauge installation points, is not suitable for cleaning piezoelectric sensors.

 

Optimize the Environment for the Force Measurement
Influence of transducer temperature on the characteristic curve: The influence of temperature on the sensitivity of the transducer is very low with 0.2% / 10K and is negligible for most applications. Temperature changes lead to thermal stresses. In addition, the E modu­lus of the pre-stressing elements is temperature dependent.
It is important that the output signal only changes in the case of a temperature modification. In stationary states, a charge is not generated and there is no influence of the temperature changes on the measure­ment. The temperature effects can be minimized if it is ensured that
The transducer is stored for sufficient time at the application temperature
The transducer is not touched shortly before measurement as hand heat can warm up the sensors unevenly
A reset is implemented before every measurement cycle.
The influence of drift and temperature changes are extremely low, par­ticularly with measurement times up into the minute range and larger forces, and therefore do not lead to relevant inaccuracies in measure­ment.

 

Note the Load Limits
In piezoelectric force transducers, the crystal lies in the direct force flow. The measuring elements (quartz or GaPO4) are designed for each transducer at the maximum occurring normal force. Applied bending moments can lead to a overload of the transducer as the crystal is more strongly loaded on one side and, in contrast, the load is relieved on the other side. The maximum mechanical stress is calculated from the addition of the stresses caused by the bending moment in the crystal and the load stresses of the axial forces to be measured. The maximum permitted surface pressure must not be exceeded under any circumstances. As the output signal is not dependent on the nominal (rated) force of the sensor in piezoelectric transducers, it is possible to select transdu­cers with a higher nominal force in order to avoid an overload in such cases. The following diagram shows the maximum permissible bending moment, dependent on the process force. The highest permissible bending moment can be accepted by the force washer with 50% load stress. If the bending moment is generated by a force from the side, a lateral force is also produced reducing the maximum values. The measurement error caused by the bending moment is low, as the higher material stresses on the one side of the crystal are compensated for by the lower stress on the other side.

 

 
Frequently Asked Questions
 
 

Q: Why is vibration monitoring important?

A: Vibration monitoring is important because it provides early warning signs of equipment problems, allowing for preventive maintenance, reducing downtime, improving reliability, and extending the lifespan of machinery. It is a key part of predictive maintenance programs in industrial settings.

Q: What types of equipment benefit from vibration monitoring?

A: Equipment such as motors, pumps, compressors, fans, turbines, generators, gearboxes, and other rotating machinery benefit from vibration monitoring. Any equipment with moving parts that are prone to wear or misalignment can be monitored for vibration to prevent breakdowns.

Q: How does vibration monitoring work?

A: Vibration monitoring works by placing sensors on machinery to measure vibration levels. The sensors send the data to a monitoring system, which analyzes the vibration patterns. Changes in these patterns can indicate mechanical issues, such as misalignment, imbalance, or bearing failures.

Q: What types of sensors are used in vibration monitoring?

A: Common sensors used in vibration monitoring include accelerometers, velocity sensors, and displacement sensors. Accelerometers are the most widely used and measure the acceleration of vibrations, providing detailed data for analysis.

Q: What is the role of an accelerometer in vibration monitoring?

A: An accelerometer measures the acceleration forces caused by vibrations in a machine. These forces are proportional to the vibration's intensity and can be used to detect mechanical problems. Accelerometers are essential in capturing high-frequency vibrations for detailed analysis.

Q: What is the difference between online and offline vibration monitoring?

A: Online vibration monitoring continuously monitors equipment in real-time, providing instant data and alerts for any abnormalities. Offline vibration monitoring involves periodic data collection, where measurements are taken at specific intervals, often as part of a routine maintenance schedule.

Q: What are common causes of excessive vibration in machinery?

A: Excessive vibration in machinery can be caused by imbalance, misalignment, loose components, bearing failures, gear issues, structural resonance, and electrical faults in motors. Monitoring these vibrations helps identify the root cause before it leads to equipment damage.

Q: What is vibration analysis?

A: Vibration analysis is the process of examining vibration data collected from sensors to determine the condition of machinery. By analyzing vibration patterns, frequency, and amplitude, technicians can diagnose issues like unbalance, misalignment, or bearing wear.

Q: How often should vibration monitoring be conducted?

A: The frequency of vibration monitoring depends on the criticality of the equipment and the operational conditions. High-risk or critical machines may require continuous online monitoring, while less critical machinery might be monitored periodically (e.g., weekly or monthly).

Q: What is a vibration spectrum?

A: A vibration spectrum is a graphical representation of the vibration levels of a machine across different frequencies. It shows the amplitude of vibration at various frequency points, helping to identify specific issues such as imbalance, misalignment, or bearing defects.

Q: What is the role of frequency analysis in vibration monitoring?

A: Frequency analysis breaks down the vibration signal into its individual frequency components. Each type of machine fault has a characteristic frequency pattern, so by analyzing these frequencies, technicians can pinpoint the source of a problem, such as imbalance or misalignment.

Q: What are the benefits of vibration monitoring in predictive maintenance?

A: Vibration monitoring in predictive maintenance allows for the early detection of potential failures, enabling repairs to be scheduled before a breakdown occurs. This minimizes unplanned downtime, reduces maintenance costs, and improves the overall reliability of equipment.

Q: Can vibration monitoring prevent equipment failure?

A: Yes, vibration monitoring can prevent equipment failure by detecting abnormal vibrations early, allowing maintenance teams to address the issue before it worsens. This proactive approach helps avoid costly repairs and unplanned downtime due to catastrophic failures.

Q: What is the difference between velocity and acceleration in vibration monitoring?

A: Velocity measures the speed at which an object is vibrating and is useful for detecting medium-frequency vibrations. Acceleration measures the rate of change of velocity and is more sensitive to high-frequency vibrations, making it ideal for detecting early-stage faults like bearing wear.

Q: What is a vibration severity chart?

A: A vibration severity chart is a tool used to classify vibration levels according to their severity, ranging from acceptable to critical. It helps maintenance personnel determine whether the vibration levels in machinery are within acceptable limits or if immediate action is needed.

Q: What is condition monitoring in relation to vibration monitoring?

A: Condition monitoring refers to the continuous or periodic measurement of various machine parameters, including vibration, to assess the health of equipment. Vibration monitoring is a key component of condition monitoring, providing real-time or scheduled insights into machine performance.

Q: Can vibration monitoring be used in hazardous environments?

A: Yes, vibration monitoring systems can be designed for hazardous environments, such as in oil and gas, mining, or chemical processing plants. Specialized sensors with certifications like ATEX or IECEx can safely operate in explosive atmospheres or extreme conditions.

Q: What are vibration monitoring thresholds?

A: Vibration monitoring thresholds are predefined limits that indicate acceptable and unacceptable vibration levels. If the vibration exceeds these thresholds, the monitoring system triggers an alarm, allowing operators to investigate and address the issue.

Q: What is machine unbalance, and how is it detected through vibration monitoring?

A: Machine unbalance occurs when the mass distribution of rotating components is uneven, causing excessive vibration. Vibration monitoring can detect unbalance by measuring the vibration amplitude at the rotational frequency of the machine.

As one of the leading spare vibration monitoring manufacturers and suppliers, we warmly welcome you to buy discount spare vibration monitoring from our factory. All our products are with high quality and competitive price.

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