Vibration monitoring is indispensable in many industrial sectors, especially when it comes to rotating machines and systems. Excessive vibrations will sooner or later cause machine problems and have a significant and unplanned impact on production processes. Vibration monitoring makes it possible to track vibrations in real time and thus avoid potential dangers such as bearing damage or imbalances on the impeller, for example.
With the right sensors and monitoring systems, it is possible to detect machine vibrations in good time and prevent unplanned production downtimes.
Vibration monitoring Definition
Vibration monitoring, also known as vibration diagnostics or condition monitoring, refers to vibration analysis procedures and methods in mechanical drive technology. These methods are designed to determine the condition of system components such as roller bearings and plain bearings in machines. Basically, vibration monitoring is a type of condition monitoring to detect excessive vibrations and oscillations in rotating machines at an early stage. With the help of sensors and monitoring systems, vibrations can be identified before they can cause damage.
What is the difference between vibration monitoring and vibration analysis?
Vibration monitoring refers to the continuous or periodic process of monitoring vibration data in real time. Its main objective is to detect unusual or abnormal vibration patterns and trigger alarms as soon as these patterns indicate potential problems. Vibration analysis, on the other hand, aims to obtain information about the characteristics of the vibrations in order to diagnose problems and identify their causes. Vibration analysis is often used in maintenance to assess the condition of machinery and predict maintenance needs.
What are the causes of vibration?
Known causes of vibration include imbalance, misalignment, gearing errors, bearing damage and electrical or magnetic interference. An imbalance occurs when the mass of a rotating part is not evenly distributed, resulting in vibrations. Alignment errors, on the other hand, occur when individual system components are not correctly aligned with each other and therefore generate unwanted vibrations.
However, loose parts that knock against each other due to vibrations, wear on bearings or circumferential toothing damage on gears can also be causes of vibration. In order to prevent costly breakdowns and ensure operation, the causes should be identified and rectified in good time.
What are vibrations in systems?
Vibrations can be described as periodic or recurring movements of an object or system. Vibrations in systems or system components are mechanical vibrations. The properties of vibrations can be explained using various parameters; the most important parameters are amplitude, frequency and phase.
Amplitude measures the strength of the vibration and is usually expressed in units such as displacement (micrometers), velocity (inches per second or millimeters per second) or acceleration (measured in g). Frequency indicates the number of vibrations per unit of time and is usually expressed in Hertz (Hz). Phase, on the other hand, describes the relative timing of the vibration mode and is usually measured in degrees. A comprehensive understanding of these parameters is a prerequisite for efficient analysis and control of vibrations in machines and systems.
The characteristic values at a glance:
- Amplitude, strength of the oscillations
- Frequency, number of vibrations per time unit
- Phase, relative timing of the oscillation form
How can vibrations be measured?
Sensors, also known as vibration switches, are generally used to measure vibrations and are attached to components of the machine to be monitored. They provide important information about vibration excitations emanating from the machine rotor, the bearings or the drive machine by detecting the vibrations and converting them into electrical signals that can be analyzed. In the event of strong vibrations, they sound an alarm or stop the machine.
Methods for analyzing the vibration of drives and other components include frequency domain analysis, time wave analysis or Fast Fourier Transformation (FFT). Vibration measurement is carried out in horizontal, vertical and axial directions. In order to better locate the spatial position and alignment of vibrating components, industrial sensors are often used in combination with 3D cameras where possible. These are used to visualize problem zones.
Monitoring vibrations with sensors
Machine monitoring ensures trouble-free operation and a high level of safety. Vibration sensors, including inductive sensors, magnetic sensors, ultrasonic sensors and flow sensors, are used to detect and monitor vibrations.
Vibrations occur during the commissioning and operation of machines and systems and can indicate problems, especially if they are caused by imbalances or misalignments. Vibration sensors are specialized in precisely detecting these vibrations in order to identify potential problems at an early stage. This is particularly important because vibrations often indicate irregularities or malfunctions that can affect the condition of machines and systems and lead to unplanned downtime. In principle, vibration sensors in conjunction with speed sensors make a significant contribution to monitoring and maintaining the reliable operation of machines and systems and help to monitor the condition of machines in accordance with DIN and ISO 10816 standards in Germany and to measure vibrations.
Advantages of condition monitoring with sensors
- Early detection of damage: The system detects damage before it leads to costly breakdowns.
- Data-based decisions: It enables informed decisions about whether a machine should continue to run or be shut down immediately.
- Minimization of unplanned downtimes: Unplanned downtimes occur less frequently, which maintains system productivity.
- Efficient and predictable maintenance: Monitoring systems prevent the unnecessary replacement of components and ensure that no components in need of maintenance are overlooked.
- Optimization potential: Data analysis can provide information about potential improvements and the development and condition of the system, and maintenance cycles can be agreed more precisely.
Web-based vibration monitoring
Nowadays, vibration monitoring can be web-based or even remote. The sensors attached to the machine or system transmit the data to IIoT devices (Industrial Internet of Things devices) that are integrated directly into the cloud. Users can monitor and analyze vibrations and performance parameters using simple web browsers or apps. Wireless, web-based monitoring systems can be particularly useful in potentially explosive environments or for decentralized machines.
Vibration analysis Motor current analysis
Motor current analysis is a method for diagnosing mechanical defects in electrically powered machines. Problems such as bearing damage, imbalances and cavitation can be detected through precise current and voltage measurements in the motors. This method is suitable for a wide range of electric motor-driven devices and generators, including pumps and turbines. The data obtained provides information about possible faults and allows a well-founded assessment of the condition of the machine. Motor current analyses are used in both stationary and mobile applications and offer effective solutions for condition monitoring.
Serafima: Your expert for vibrations in fans and compressors
Our expertise at Serafima extends across all industries to reliable solutions for the maintenance of your fluid power and process engineering systems. Not only do we offer vibration analyses and technical advice, but with our unique RaaS (Reliability as a Service) system, we also offer customized remote solutions for predictive maintenance that are tailored to your requirements and integrate seamlessly into your individual requirements and products. We focus entirely on your wishes. As a former subsidiary of FIMA Maschinenbau GmbH and with over twenty years of experience as a manufacturer-independent solution provider for systems and machines in various industries, we are your trusted partner for comprehensive system protection and sustainable success.
Our experts are always customer-oriented, professional and highly flexible. Does your company need support with the maintenance of your systems? Then don’t hesitate to contact us today. We offer you a tailor-made solution and first-class advice and are your reliable partner for your success in the industry. Please feel free to contact us.