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Predictive Maintenance Vibration Monitors

As time progresses, the industry is facing increasing pressures to perform with less and still earn a reasonable profit. Running costs are increasing. Down time for repairs is cutting into profit margins. Engineers and operators have been looking for ways to make repairs more efficiently so they can streamline their operations and maximize their personnel and equipment.

One of the items that can be costly both in preventive maintenance & unexpected failure which can result in unscheduled repairs and even bigger costs, is the roller bearing as used in various critical applications.

Most companies either replace the bearings at pre-determined time periods or use engineers (their own or outsiders) for periodic inspection and analysis of critical points.

What we offer instead is the latest in technology, not dependent on expert reports, and more economical in usage all the way. The first sensor with integrated bearing diagnosis based on frequency analysis. A permanent vibrations monitor on each of these critical applications that will continuously monitor the condition of the bearing or shaft will give a pre-alarm warning when conditions have changed, so that maintenance can be properly scheduled in the following 3-4 weeks and an alarm, if the unit monitored has reached a dangerous condition. These units have an integrated accelerometers, signal processor & diagnostic electronics, and can function independently, or as part of a central system, or even on-line. They are easy to install and can start to monitor your selected critical points almost immediately.

  • Reduce unnecessary routine maintenance
  • Monitor component condition and plan downtime
  • Reduce unforeseen breakdowns
  • Deploy personnel more effectively
  • Reduce parts and spares stock

The intelligent rolling element bearing monitor

A compact unit that continuously Monitors Machine's Operating Condition

EPSON DSC picture

The new vibration monitoring unit, detects rolling element bearing failures and shaft unbalance conditions on critical plant equipment such as pumps, motors, compressors, fans and spindles. The monitor is permanently mounted on plant equipment to continuously monitor a machine’s operating condition through vibration analysis. The monitor has the processing capability to analyze a vibration signature and to predict failures in advance by sending an alarm output signal to a PLC or relay.

The monitor can gather, process and interpret vibration data
The monitor incorporates a MEMS accelerometer, analog-to-digital (A/D) converter, digital signal processor (DSP) and diagnostic electronics in a compact 40x40 mm package.

These electronic components enable the monitor to gather, process and interpret vibration data. The accelerometer monitors the acceleration value via a change in capacitance signal. The A/D converter transforms the analog signal from the MEMS sensor to a digital signal. An integrated DSP performs mathematical calculations to convert the time domain vibration signal into a frequency domain signal known as Fast Fourier Transformation (FFT). The integrated DSP can process up to 32,000 calculations per second.
Software used to input application parameters.

Configuration software is used to input application parameters such as bearing dimensions and shaft speed. These inputs allow the unit to monitor only critical frequencies in the vibration spectrum and ignore all external noise. One monitor can detect up to five different rolling elements on a machine.

Alarm display provides early warning and critical alarms. Pushbutton programming includes a teach button with an integrated alarm display. The monitor generates a switching alarm when there is a large increase in amplitude for a critical frequency. The alarm display provides two switching outputs that indicate an early warning alarm and a critical alarm.

The monitor has two connectors for power and software connection. A standard Micro DC connector is used to connect the monitor to a power source or output device. A PC or laptop is connected to the monitor via its RS232 connector and setup cable.

Common Technical characteristics

Measuring range[g]: ± 25
Operating voltage[V]: 10...32 DC
Current consumption[mA]: 100
Output: 2x DC PNP

Technical Specifications

Frequency range[Hz]
Spectral resolution[Hz]
Speed range[U/min]
Minimum measuring time[s]
interface Order no.
0,125...500 0,125 12...1500 8 RS-232 E1002
3...6000 1,25 120...12000 0,8 RS-232 E1001
24...12500 15,625 1.500...96.000 0,064 RS-232 E1103
3...6000 1,25 500...6000 0,8 RS-232 B1001
0,125...500 0,125 12...1500 8 RS-485 E1102
0,125...500 0,125 12...1500 RS-485 E1102ATEX
3...6000 1,25 120...12000 0,8 RS-485 E1101
3...6000 1,25 120...12000 0,8 RS-485 E1101ATEX

ACCESSORIES

Parameter setting software

Diagnostic Electronics for multiple sensors

  • Frequency-selective machine monitoring of up to 4 measuring points.
  • Ethernet interface for integration into operational data logging systems.
  • 2 analogue inputs for DC signals
  • Only 1 analogue and 1 switching output for collective alarm
  • 8 configurable I/Os: for alarm outputs or inputs of switching signals

SE 100 diagnostic electronics can be used for continuous and simultaneous analysis and evaluation of the measured signals of up to 4 vibration sensors of
this technology. In addition to standard alarm and analogue outputs SE100 can signal the state of objects being diagnosed, using up to 8 further, freely configurable I/Os.

Also,

the I/Os can be used as inputs, electronically trigger diagnosis (e.g. in a reference run of a machine tool spindle) collect switchning states of other sensors and transmit them to operational datalogging via the OPC standard.
The integrated FIFO history memory can store 33,000 values with time stamp.

SA002 vibration sensor

  • flat design, entirely flush installation
  • Measuring range [g] 25
  • Frequency range [Hz] 0...10000
  • high-grade housing material (316S12)
  • device connection: 60cm PUR cable with M12 cable plug
  • Temperature range [°C] -30...125
  • Protection IP 67

The SA002 vibration sensor is used to detect measurement values for the SE diagnostic electronics.
The special mechanical design as well as the integrated pigtail enable an almost flush integration in the machine surface. The vibration sensor SA002 permits vibration monitoring where the installation of a sensor has not been previously possible due to lack of space.

Αvailable connection (M12) sockets with PUR cables: 2m/5m/10m

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