Best practice for air gap measurement using air gap sensors
Air gap measurement is a method of measuring the distance between two surfaces using air as the medium. Air gap measurement with air gap sensors is a very effective system monitoring method for rotating machines, generators, turbines or electric motors. Seamless monitoring records the system status and provides important data for maintenance.
Special air gap sensors are used to monitor rotating machines for changes in synchronization. It is important that the air gap is measured evenly and precisely, as small deviations can lead to malfunctions or quality problems. The distance (air gap) between the rotating rotor and stationary stators is measured in very short measuring cycles. Thanks to the high sampling rates of up to 50k samples per second and channel, even the smallest changes are reliably detected. Extremely short response times are maintained to protect the systems. This means that vibrations and imbalances can be detected immediately, the causes diagnosed quickly and damage to the system detected at an early stage, thus preventing breakdowns and downtimes. Regular inspection of the measuring devices and careful calibration are also important to ensure high measurement accuracy in air gap measurement.
Many years of experience for effective air gap measurement
- Maximum system safety: Depending on the system, different capacitive or inductive air gap sensors are used.
- Flexible sensor data: A wide range of system data such as air gap, temperature, flow rate and vibrations can be recorded centrally for reliable diagnostics. The measurement can also be triggered via different speeds.
- High data resolution: For comprehensive system monitoring, the measurement data is recorded synchronously by up to 16 sensors with sampling rates of up to 50 KHz per channel.
- Reliable root cause analysis: For reliable evaluation of the measured values, the individual sensor data must be recorded synchronously to 100%.
- Extremely fast response times: Data evaluation takes place in parallel to data acquisition directly in the measurement technology using powerful computing channels with FFT spectra, generation of characteristic values and automated alarming in real time to system control, process control systems or higher-level safety technology.
The development of a complete system-specific solution for air gap measurement
- Measurement technology and monitoring solution: Complete solutions from a single source have become established for air gap measurement. This allows measured value acquisition and monitoring to be carried out in a single system, as with the Expert Vibro device and integrate them into the existing infrastructure with the help of standardized interfaces.
- Full engineering: Pre-engineering with application development utilizes the experience gained from a large number of projects. Clear dashboards and a variety of visualizations are available for monitoring. The service includes, for example, an annual calibration service.
- Automated reporting functions: Regular reports document the system status with meaningful key figures, limit value monitoring and selected process data.
- Predictive maintenance: The continuous air gap measurement can be extended to predictive maintenance with prediction of the system condition and wear progression.
Hardware and software for your measurement and testing solution
Flexible, scalable and expandable solution for seamless data acquisition and monitoring
The Loggito device is a compact data logger system designed for the acquisition and recording of measurement data. It has a variety of analog and digital inputs to connect different sensors and signals. The device records the data with high accuracy and stores it on an internal memory or external storage media such as SD cards.
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Data acquisition and analysis
With ProfiSignal Go you can display online data from the Message and Expert hardware in diagram form. Numerous analysis functions, such as zoom, cursor, movable axes, flags, ASCII export and calculation channels, enable fast display of measured values and post-processing.
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Precisely record, autonomously store, automatically transmit and evaluate measured values.
The FPGA-based Expert Logger device is particularly powerful and enables the processing of up to 46 analogue input channels, both at low and high sampling rates. Measured values can be precisely recorded, autonomously stored and automatically transferred to the internet or PC via USB, LAN or WLAN and evaluated.
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Operating and monitoring
ProfiSignal Basic combines the functions of ProfiSignal Go with operating and monitoring elements of process visualisations, e.g. digital and analogue displays, switches, buttons and signal lamps. With Basic, you can create everything from simple visualisation diagrams to complex visualisation systems.
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Modular measuring, monitoring and automation in one device.
The ProfiMessage D device is a state-of-the-art data logger system that has been specially developed for industrial data acquisition and analysis. It offers a wide range of functions such as the recording and storage of measurement data, monitoring of process parameters and alarms in the event of deviations.
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Automate and control
ProfiSignal Klicks supplements ProfiSignal Basic with functions for process automation. Structural diagrams for mapping the process as well as a script language (completely operable with the mouse) enable even the non-informatician to create complex test stand and automation applications with automatic report generation.
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State-of-the-art processor technology and extreme precision for vibration measurement.
The Expert Vibro device is a powerful vibration analysis device that has been specially developed for monitoring and analyzing machine and system conditions. It enables vibration data to be recorded and evaluated in order to detect potential problems or signs of wear at an early stage.
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Fast project planning and analysis of measurement data
With ProfiSignal 20 Go you can visualise your measurement data in just a few steps, both online and offline, in various diagram types, monitor, analyse, archive as a measurement file or export directly in the appropriate file format.
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Intelligent data recorder for synchronous recording of transient and periodic events.
The Expert Transient device enables the recording and evaluation of transient signals over a certain period of time and provides important information for the optimization of processes and systems. The device is characterized by its high accuracy, fast sampling rate and simple operation.
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Visualisation and operation
With ProfiSignal 20 Basic you can create individual diagrams using a wide range of operating and monitoring elements. Both continuous processes (e.g. production data acquisition) and discontinuous measurement tasks (e.g. test measurements) can be visualised, operated and monitored without any programming effort. You can create the operating and monitoring diagrams by assembling and configuring the prefabricated elements.
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Modular system for use as a measuring, control and monitoring device.
The ProfiMessage devices are a modular, expandable and easy-to-use system for measurement data acquisition, monitoring and automation of machines, systems or test benches. ProfiMessage can be used wherever measured values need to be recorded quickly, precisely and electrically isolated, as well as intelligently pre-processed or monitored.
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Central measurement data management
The Delphin Data Center is the solution used for the worldwide measurement networking and control of plants, machines and test stands.
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PC-supported data acquisition and test stand
The Expert Key device is a measuring and control device that can be used in various applications. It enables the acquisition and evaluation of measurement data as well as the control of processes. The device has various interfaces and can be connected to a wide range of sensors and actuators. It is often used in automation technology, mechanical engineering and research.
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Compact and flexible measurement data laboratory with precision measurement technology.
The LoggitoLab device is ideal for use in laboratory environments, research projects, quality control and other applications where precise data acquisition and analysis is required. It offers a reliable and user-friendly solution for monitoring and recording measurement data.
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Test stand for measurements with potential using an internal data memory.
The LogMessage device is a powerful data logger system designed for the reliable acquisition and recording of measurement data. It offers a variety of analog and digital inputs to connect different sensors and signals. The device records the data with high accuracy and saves it to an internal memory or external storage media.
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