Vibration monitoring in mechanical engineering, especially for fans, enables real-time tracking of vibrations for the precise identification of hazards such as bearing damage and ensures permanent monitoring. This allows changes in condition and incipient damage to be detected at an early stage. This allows you to plan maintenance and repairs economically and predictably and ensures the efficiency and operational continuity of your systems.
What is meant by vibration monitoring?
Vibration monitoring provides important information on balancing conditions and other causes of vibration and is a method for continuously monitoring the condition of vibrations in machines and systems. Vibration sensors are used to record vibrations, convert them into electrical signals and then analyze them. As a result, the machine condition is monitored precisely and continuously and preventive maintenance is possible. Various analysis methods are available for vibration monitoring.
Functionality of vibration monitoring for fans
Vibration monitoring for fans and other electrical devices (SWES: vibration monitoring for electrical devices) is based on precise measurements by vibration sensors. These sensors, also known as vibration switches, are placed at various positions on the machine to measure vibrations and convert these vibrations into electrical signals. They are primarily designed to identify vibrations from critical components such as the machine rotor or bearings.
The vibrations are analyzed using various methods such as frequency domain analysis, time wave analysis or Fast Fourier Transformation (FFT), which enable a detailed examination of the vibration characteristics in different directions, including horizontal, vertical and axial. In addition to these analysis techniques, sensors are often used together with 3D cameras. This combination facilitates the precise location of the spatial position and orientation of vibrating components, which in turn leads to an effective visualization of potential problem areas. In this way, weak points can be identified at an early stage and preventive measures can be taken.
How do vibrations occur in fans?
Vibrations in fans can be attributed to various causes, including imbalance, misalignment, gearing errors, bearing damage and electrical or magnetic interference. Imbalances occur when the mass of a rotating part is not evenly distributed, resulting in unwanted vibrations throughout the machine. Vibration monitoring in combination with operational balancing makes it possible to make specific adjustments that improve the performance of the machine and reduce imbalances. Alignment errors occur as soon as individual components are not correctly aligned with each other, which also leads to vibrations.
Vibrations can also be caused by loose parts knocking against each other due to vibrations, as well as wear on bearings or circumferential toothing damage on gear wheels. Misalignment or lubrication problems in motors are also often the cause of unwanted movements within the fan. In order to prevent costly failures and ensure smooth operation, it is crucial to identify and rectify these causes in good time by means of seamless condition monitoring.
Mechanical engineering fans: causes of vibration at a glance
- Imbalances
- Alignment error
- Toothing error
- Bearing damage
- Electrical or magnetic interference
- Loose parts
- Wear and tear on bearings
- Circumferential toothing damage on gears
- Electric motors
Detecting vibrations through vibration monitoring – important characteristic values
Vibrations in fans are periodic or recurring movements of mechanical components that are characterized by various parameters. Three important parameters in oscillation and vibration analysis are amplitude, frequency and phase. The amplitude, measured in units such as displacement, velocity or acceleration, provides information about the strength of the vibration. The frequency, expressed in Hertz, describes the number of vibrations per unit of time. An equally important parameter is the phase, which provides important information on the timing of the vibration mode.
Vibration monitoring applications in industry
In mechanical engineering, vibration monitoring is an integral part of maintenance. Measuring vibrations enables irregularities to be identified at an early stage, which in turn helps to prevent costly breakdowns. Comprehensive vibration diagnostics and portable balancing devices also have a wide range of applications in other industrial contexts; among other things, modern, decentralized KWL systems (controlled domestic ventilation) benefit from such diagnostics to ensure the safety and efficiency of fans in residential buildings.
Another important area of application is the operational balancing of rotors, gas turbines, spindles and pumps. Precise monitoring ensures that these crucial components are optimally balanced. This extends the service life of the equipment and prevents unwanted vibrations and operating noise.
Non-contact eddy current sensors and accelerometers in vibration monitoring
As highly developed sensors, non-contact eddy current transducers and acceleration/velocity transducers are essential components in the vibration monitoring of fans. Non-contact eddy current sensors detect even the finest vibrations in the fan components, while acceleration sensors precisely measure speeds and accelerations. By using these sensors, deviations in the vibration pattern can be identified at an early stage, often indicating potential problems such as imbalances or misalignment. In this way, the sensors help to increase the reliability and efficiency of fans.
Vibration analysis and 3D technologies
The integration of advanced technologies plays a central role in the vibration analysis of fans. 3D technologies are becoming increasingly important in this context. The use of 3D analysis enables extremely precise investigation of vibrations, especially in relation to grinding wheels and axial positions. With the help of 3D technologies, detailed spatial visualizations of vibration patterns can be created, leading to improved results in identifying potential problems. The combination of vibration analysis and 3D technology provides in-depth insights into the condition of the fans.
Condition monitoring is also important: this monitoring method records vibration data and other relevant parameters in real time, enabling the continuous assessment of the machine’s condition. The integration of condition monitoring into vibration analysis offers a proactive approach to maintenance, as potential problems can be identified at an early stage and appropriate measures can be taken.
Preventive vibration monitoring through condition monitoring
Preventive vibration monitoring using condition monitoring represents a proactive strategy in machine management, especially for fans in an industrial context. Condition monitoring is an advanced technology that enables the continuous recording, analysis and evaluation of vibration data in real time. This method identifies changes in the condition of the machine before serious problems or failures can occur.
The focus is on detecting irregularities in the vibration patterns that could indicate potential defects or inefficient operating conditions. Once these patterns have been identified, operators can take timely action before costly damage develops. The recorded vibration data is analyzed in real time and warnings are automatically triggered if predefined limit values are exceeded.
The advantages of this preventive strategy are manifold: it reduces the occurrence of unplanned downtime and optimizes maintenance planning. Instead of having to rely on reactive repairs, maintenance activities can be planned and carried out in advance, which increases efficiency and significantly extends the service life of the fans. This makes a significant contribution to increasing system reliability and cost efficiency.
Serafima: Reliability and efficiency in fan vibration monitoring
With its Reliability as a Service (RaaS) concept, Serafima is at the forefront when it comes to ensuring reliability and efficiency in fan vibration monitoring. Through years of experience and in-depth expertise, we offer our customers advanced vibration analysis and technical advice as well as innovative solutions in the field of fans and compressors. – Using low-code/no-code software, such as UReason’s APM Studio, Serafima successfully makes its implicit and explicit knowledge accessible to customers. By implementing Reliability as a Service (RaaS), Serafima offers customers a comprehensive service package that can be fully customized to their requirements and wishes – without restrictions in terms of manufacturers or systems. This not only includes monitoring, but also guarantees the necessary maintenance measures and has a modular structure.
Whether on-site machine diagnostics or maintenance in different areas: Our services are designed to deliver customized remote solutions for predictive maintenance that can be seamlessly integrated into individual requirements. As a trusted partner for comprehensive plant protection in various industries, we stand for customer-oriented, professional and highly flexible solutions.
If you need reliable support with the maintenance of your systems, do not hesitate to contact us. We are your reliable partner for sustainable success in the industry. Get in touch with us today – our experts are ready to discuss your individual requirements and show you a path to greater reliability and efficiency in your plant maintenance.