Predictive Maintenance and Condition Monitoring

Vibration Monitoring for Predictive Maintenance

Monitor machine health utilizing predictive maintenance by continuously monitoring for vibration and temperature changes. Watch the video to learn how.

Maintenance Based on Data from the Machine Itself


Predictive maintenance is becoming essential to the smart factory.  Predictive maintenance enables users to more accurately anticipate when machine maintenance will be needed based on real-time data from the machines themselves. 

The ability to accurately track machine performance and anticipate failures before they occur is helping manufacturers improve productivity and reduce wasted time and costs.


What is Predictive Maintenance?

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Predictive Maintenance

What It Is and Why It Matters

Predictive maintenance is the process of tracking the performance of crucial machine components, such as motors, to minimize downtime needed for repairs. Predictive maintenance enables users to more accurately anticipate when machine maintenance will be needed based on real-time data from the machines themselves.

Traditionally, plant managers relied on preventative maintenance schedules provided by a machine’s manufacturer, including regularly replacing machine components on a suggested timeline. However, these timelines are only estimates of when the machine will require service, and the actual use of the machine can greatly affect the reliability of these estimates.

For example, if bearings wear prematurely or a motor overheats, a machine may require service sooner than anticipated. Furthermore, if a problem goes undetected for too long, the issue could escalate to further damage the machine and lead to costly unplanned downtime.  Predictive maintenance helps avoid these problems, saving time and costs. 


Key Elements of a Predictive Maintenance Solution

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Condition Monitoring

Vibration & Temperature Indicate Machine Health

Condition monitoring plays a key role in predictive maintenance by allowing users to identify critical changes in machine performance. One important condition to monitor is vibration. Machine vibration is often caused by imbalanced, misaligned, loose, or worn parts.

As vibration increases, so can damage to the machine. By monitoring motors, pumps, compressors, fans, blowers, and gearboxes for increases in vibration, problems can be detected before they become severe and result in unplanned downtime.

Vibration sensors typically measure RMS velocity, which provides the most uniform measurement of vibration over a wide range of machine frequencies and is indicative of overall machine health.  Another key data point is temperature change (i.e. overheating). 

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Machine Learning

Automatically Set Baseline & Alert Thresholds

Machine learning takes condition monitoring data and automatically defines a machine's baseline conditions and sets thresholds for acute and chronic conditions so that you know in advance--and with confidence--when your machine will require maintenance. 

After mounting the vibration sensor onto your machine, most sensors require you to collect enough data to establish a baseline for the machine. Machine learning removes the chances of human error by automating the data analysis.

A condition monitoring solution with machine learning will recognize the machine’s unique baseline of vibration and temperature levels and automatically set warning and alert thresholds at the appropriate points. This makes the condition monitoring system more reliable and less dependent on error-prone manual calculations. 

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Indication and Data Logging

Real Time Alerts, Long Term Optimization

When a vibration or temperature threhold has been exceeded, a smart condition monitoring system provides both local indication, such as sending a signal to a tower light in a central location, and remote alerts like emails or text messages.  This ensures that warnings are addressed quickly. 

In addition, a condition monitoring solution that allows you to log the collected data over time enables even more optimization.  With a wireless system, vibration and temperature data can be sent to a wireless controller or programmable logic controller (PLC) for in-depth, long-term analysis. 


Featured Products

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QM42VT Series

Vibration and Temperature Sensor

The QM42VT Vibration and Temperature Sensor makes it easy to monitor a machine's health. It measures RMS velocity and temperature so that problems can be detected before they become too severe and cause additional damage or result in unplanned downtime. Paired with a Banner wireless Node, it can provide local indication, wirelessly send the signal to a central location, and send the vibration and temperature data to the Gateway for collection and trending.

  • Easily monitor machine health by sending info wirelessly to wherever you need it
  • Avoid machine failures and delays by detecting problems early
  • Reduce downtime and plan maintenance more efficiently
  • Monitor a variety of machines to suit your needs: motors, pumps, compressors, fans, blowers, gear boxes
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Wireless Solutions Kit

For Vibration Monitoring

The Wireless Solutions Kit for vibration monitoring is a fully integrated and easy-to-use solution for monitoring assets for predictive maintenance. 

  • No programming required. Plug in the box, bind the nodes through the HMI screen, install vibration sensors and nodes on the equipment, and start collecting data
  • Includes pre-programmed DXM100 wireless controller, pre-programmed 10.1 inch touchscreen HMI, 5-port industrial Ethernet switch
  • Automatically generates performance baselines and thresholds
  • HMI displays alarms and graphs of raw vibration data along with baseline, warning, and alarm values
  • Identify machine performance issues caused by misalignment, unbalance, bearing failures, pump cavitation, blade damage, etc.
  • Monitor and collect data from up to 16 assets
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DXM Series

Wireless Controller for IIoT Applications

DXM Series industrial wireless controllers are designed to facilitate Ethernet connectivity and Industrial Internet of Things (IIoT) applications. 

  • ISM radios available in 900 MHz and 2.4 GHz for local wireless network
  • Converts Modbus RTU to Modbus TCP/IP or Ethernet I/P
  • Logic controller can be programmed using action rules and text language methods
  • Micro SD card for data logging
  • Email and text alerts
  • Cell modem for cellular connectivity

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