Condition monitoring in vibration measurement technology
Condition monitoring refers to the continuous monitoring and analysis of machines, plants or systems in order to evaluate their condition and performance. Various parameters such as vibrations, temperatures, pressures or lubricant conditions are recorded through the use of sensors and measuring devices. This data is then analyzed in order to detect signs of wear, malfunctions or other problems at an early stage. Condition monitoring enables preventive maintenance, as potential failures can be predicted. As a result, unplanned downtime can be avoided, the service life of systems extended and efficiency increased.
Continuous condition monitoring of machines
Vibration measurement technology is used for the condition monitoring of rotating machines. Vibration analyses provide conclusions about the condition of the system and help to detect changes at an early stage and schedule maintenance. In this way, faults can be prevented in good time, plant availability increased and maintenance costs reduced. The measurement technology used for condition monitoring differs in terms of its scope of services, its flexibility and the manufacturer's support in adapting it to customer-specific systems.
Avoid downtimes with condition monitoring
Continuous condition monitoring is essential when it comes to maximizing system availability. It detects whether system parts could fail prematurely due to wear or be damaged by vibrations. Vibration analysis enables predictive, plannable maintenance. However, a reliable condition analysis is not trivial for many systems. Rolling bearings, plain bearings and gears need to be monitored and disruptive influences filtered out in a targeted manner. The sensors, vibration measurement technology and evaluation software must be suitable and sufficiently powerful for this. Condition monitoring must also be adapted to the respective system.
Vibration measurement technology monitors system components
The recording and evaluation of vibrations requires powerful measurement technology. The Expert Vibro measuring device was specially developed for condition monitoring tasks on rotating machines and for vibration tasks.
- Self-sufficient local operation: Expert Vibro is very powerful and can be operated purely locally thanks to its internal memory. The sensor signals are recorded via 4, 8, 12 or 16 synchronous measurement channels with sampling rates of up to 50 kHz per channel.
- Analysis and monitoring: The measurement technology records the acceleration values and the shaft distance, compresses the data into meaningful characteristic values and evaluates them online. Set threshold values are monitored in real time and digital outputs can be switched in msec in the event of limit value violations.
- Powerful signal processing: In large systems, different components can be responsible for the unwanted vibrations. With a frequency analysis and phase determination, a more in-depth diagnosis, precise identification of individual components and a differentiated picture of conspicuous vibrations are possible.
- Software for vibration analysis: ProfiSignal is the software for measured value acquisition, analysis, visualization and automation. The additional option "Vibro" provides special visualizations for vibration measurement analyses such as Bode diagram, frequency spectrum (FFT), envelope curve spectrum or the waterfall diagram. With the ProfiSignal 20 software, measurement data can be recorded decentrally and accessed via any end device, regardless of location and platform.
High-quality measurement and testing technology for condition monitoring
- Conveyor belt monitoring: The rollers on the carriers of a baggage transport conveyor system are subject to heavy wear due to the constant loads. However, the wear and failure rate of the rollers varies greatly. To prevent the baggage transport system from coming to a standstill, each carrier is individually monitored by two acceleration sensors. The very large amount of sensor data is first pre-selected and compressed in the measurement technology and then transferred to the controller via OPC UA HA. The evaluation routines were created, tested and implemented on site by Delphin's application development team. Now the wear of the transport rollers is permanently monitored and timely maintenance is possible.
- Fan monitoring: In the production halls of a pharmaceutical company, large fans ensure that specified temperature ranges are maintained. To prevent fan failure and interruptions during operation, the drive bearings of the fans are monitored by acceleration sensors. In this way, the condition is constantly analyzed and the degree of wear is determined. Constant fan monitoring ensures that each bearing can be replaced in advance according to the degree of wear. Limit values are defined for the drive bearings, which trigger a (non-critical) pre-alarm in the event of increased wear. The pre-processed and summarized data is transmitted to the central ERP system via the ODBC interface (Open Database Connectivity). If a serious fault occurs, a main alarm is triggered and operation is stopped automatically to prevent damage to the fan.
Typical areas of application
of condition monitoring
- Monitoring systems for maximum system availability
- Condition monitoring of rolling and plain bearings
- Turbine and generator monitoring
- Pump test stands
- Gearbox test stands
Maximum flexibility for condition monitoring
The Expert Vibro measuring device was developed for the most flexible use possible. Depending on requirements or for in-depth analyses, it can record data from different sensors and combine vibration and process data. In addition to acceleration sensors, temperature, eddy current, structure-borne sound, force, pressure and flow sensors or measuring microphones in accordance with the IEPE standard (Integrated Electronics Piezo Electric) can also be integrated, for example. Thanks to data acquisition with 24-bit resolution and very high sampling rates, vibration and process measurement values can be recorded and evaluated synchronously in one system.
Condition monitoring and IIoT
The Industrial Internet of Things (IIoT) plays a decisive role in the further development of condition monitoring systems. IIoT enables machines and systems to be networked, allowing comprehensive data to be collected and analyzed in real time. By integrating sensors and other devices into the IIoT, condition monitoring systems can continuously collect data on the condition of machines. This data is then transmitted via the internet to a central platform or cloud solution, where it is analyzed and evaluated.
The advantages of IIoT for condition monitoring are manifold. On the one hand, it enables comprehensive monitoring of large systems or machine parks, as data from different locations can be collected and analyzed centrally. This allows potential problems to be identified at an early stage and maintenance measures to be planned in a targeted manner.
In addition, the IIoT enables the integration of advanced analysis techniques such as machine learning or artificial intelligence. These technologies can process large amounts of data and identify patterns or anomalies that would be difficult for human analysts to recognize. This further improves the efficiency and accuracy of condition monitoring.
Another advantage of IIoT is the possibility of remote monitoring. By networking machines, status data can be monitored in real time, regardless of location or time zone. This enables a faster response to problems and more effective planning of maintenance measures.
Overall, the IIoT is making a significant contribution to the further development of condition monitoring systems by enabling comprehensive data collection, advanced analysis techniques and remote monitoring. This enables companies to operate their systems more efficiently, reduce downtime and extend the service life of their machines.
Adapt vibration measurement technology to the system
Depending on the application, very different adaptations may be required to monitor the condition of a machine or system. In practice, this often involves plant-specific sensors, connection to an existing database system and connection to the plant control system.
The measurement technology from Delphin provides the interfaces for this, such as OPC UA, Modbus RTU, Modbus TCP, PROFIBUS or CAN. OPC UA (HA) and ODBC are supported on the software side. If required, Delphin's application development team provides support to ensure that the measurement technology can be adapted to the respective system as quickly and easily as possible.
Powerful and compact measurement technology
Condition monitoring with vibration measurement technology requires particularly powerful measuring equipment. In addition to data acquisition, this involves fast processing of very large amounts of data, online pre-processing, characteristic value calculations, special analysis methods such as phase angle determination, evaluation of high-resolution frequency spectra (FFT) and real-time alarm processing when limit and threshold values are exceeded. Thanks to very compact dimensions, as with the Expert Vibro measuring device (217 x 88 x 128 mm), no additional control cabinet is usually required.
Hardware and software for your measurement and testing solution
Compact data logger
Universal small-channel data logger for industrial use | Cost-effective setup of decentralized measurement networks without channel overhead | High reliability and durability thanks to industrial-grade components | Avoidance of ground loops thanks to galvanic isolation and differential inputs
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Data acquisition and analysis
Display and monitor measurement data live | Intuitive operation and easy handling without programming knowledge | Versatile diagram and analysis functions for various measurement data | Ready for data acquisition and analysis in just a few minutes
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Universal data acquisition
Simultaneously record and analyze various measured variables | Flexible adaptation to different requirements | Continuous process monitoring to detect deviations | Increase plant availability and efficiency system availability and increased efficiency
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Operating and monitoring
Reliably record and save measurement data | Clearly display and evaluate measured values | Quickly set up and operate projects without programming effort | Ideal for individual measuring stations up to small measuring systems
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Modular data acquisition
Precise adaptation to the application thanks to various I/0 modules | Expandability possible with additional modules and slave devices | Durability thanks to the use of high-quality components and parts | Cost efficiency thanks to modularity
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Automate and control
Monitor measurement data and control processes directly | Create automations simply by dragging and dropping | Suitable for complex test benches and automation tasks | Implement and adapt projects without programming knowledge
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Modern vibration specialist
Precise monitoring to detect potential failures at an early stage | Cost reduction through optimization of maintenance intervals | Increased machine availability and reduction of downtimes, for more productivity and efficiency | Quality improvements through data analysis and optimization of processes
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Data acquisition and saving
Display and monitor signals and processes in real time | Easy handling with no training required | Access to measurement data from PC, tablet or smartphone | Ready for many measurement and analysis tasks in just a few minutes
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Synchronous fault specialist
Recording and evaluation of transient signals over a certain period of time | Autonomous operation with long-term memory | Low energy consumption ensures cost-effective operation
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Visualisation and operation
Easily create your own visualizations for measurement data | Conveniently evaluate and log measurement and process data | Intuitive interface for efficient work without programming knowledge | Ideal for individual measuring stations through to complex monitoring solutions
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Modular measurement and control technology
Adapts modularly to measurement and automation tasks | Regulates and controls processes directly - without additional hardware | Maintenance-free continuous operation in industry and laboratories | Seamless integration into existing systems and networks
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Central measurement data management
Central storage of operating, maintenance and process data | Cross-site real-time monitoring of machine and process statuses | Modular structure makes it easy to adapt to growing plant and process environments
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PC-supported data acquisition
Plug-and-play for fast measurement data acquisition directly on the PC | Acquires analog and digital signals with high resolution and speed | Ideal for laboratory, test bench and mobile applications | Easy measurement and analysis with measurement software and other applications
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Mobile measurement data laboratory
Easy and space-saving laboratory measurements | Plug-and-play - ready for immediate use without complex set-up | High-resolution acquisition of measurement signals for laboratory and training | Intuitive operation, simple visualization and analysis with measurement technology software
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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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