Condition Monitoring for Predictive and Preventive Maintenance

Machine Vibration Monitoring  Image

Application: Monitor machine vibration to identify potential issues and prevent failures 

Challenges: Detecting slight changes in performance from multiple machines with rotating motion. 

Accessing information in real-time from machines in remote and hard-to-access locations.

Solution: QM42VT1 Vibration and Temperature Sensors, Q45VT Wireless Sensor Nodes, and a DXM100 Wireless Controller

Customer Benefits

Reduced Maintenance Cost: Early identification of potential problems allows companies to schedule full spectrum vibration analysis and other service before equipment fails or is seriously damaged.

Increased Uptime: Collected data can be used to create more reliable service schedules and reduce unplanned shut-downs caused by machine failures.

Ease of Use: Wireless system enables communication with remote and hard-to-access equipment without the hassle or expense of running wire to each device. A machine learning algorithm makes it easy to establish baseline values and set control limits for alerts.

Machine Vibration: An Early Indicator of Potential Problems

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 too severe and cause additional damage or result in unplanned downtime.

Monitoring Assets and Accessing Data

A QM42VT1 Vibration and Temperature sensor paired with a Q45VT Wireless Sensor Node enables remote monitoring of machine health for rotating assets, such as motors, pumps, compressors, fans, blowers, and gearboxes.

The sensor installs easily onto a machine using standard or magnetic brackets or two-sided thermal transfer mounting tape. Using the default setting, the QM42VT1 will measure the temperature and RMS velocity of the machine. This information is sent by the Q45VT Wireless Sensor Node to a DXM100 Wireless Controller.

Establishing a Baseline of Performance

Each motor has its own vibration characteristics and requires a unique baseline measurement. The DXM100 Wireless Controller uses a machine learning algorithm provided by Banner Engineering to establish a baseline of performance unique to each machine and to set control limits for alerts. If limits are exceeded, the DXM100 will alert staff via email or text. Additionally, the Q45VT Node has an onboard LED light which can provide local indication of an alert. A signal can also be sent to a wireless TL70 tower light which will provide high-visibility indication of the change in status.

Extending Equipment Life

This solution acts as a Check Engine Light for rotating equipment. Potential problems are identified early on, before serious damage can occur. The data collected allows companies to better plan service and maintenance and extend the life of their equipment.

Continuous Vibration Monitoring Monitor vibration data on multiple motors sensing X and Z axis RMS Velocity and high frequency RMS Acceleration. RMS Velocity is indicative of general rotating machine health (unbalance, misalignment, looseness) and high frequency RMS Acceleration is indicative of early bearing wear.
Self-Learning Baseline and Thresholds Prevent users from having to generate baselines or alarms by using machine learning algorithms to create an initial baseline reading and warning/alarm thresholds for each motor.
Acute and Chronic Alarms Check Engine Light alarms and warnings are generated for both acute and chronic conditions for each motor. Acute thresholds indicate a short-term condition such as a motor jam or stall rapidly crossing the threshold. Chronic thresholds use a multi-hour moving average of the vibration signals to indicate a long-term condition such as a wearing/failing bearing or motor.
Motor Run-Time Recognize and differentiate running vs OFF state to track cumulative run-time for each motor. 
Temperature Alarms Each vibration sensor will also monitor temperature and send an alarm when a threshold has been exceeded.
Remote Master Light A master tower light can indicate the ord status of all vibration warnings and alarms.
SMS Text / Email Alerts Generate SMS text and/or email alerts based on individual warnings and/or alarms.
Cloud Monitoring Push data to Cloud Webserver or PLC (via LAN or Cellular connection) for remote viewing, alerting, and logging.


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