Real-time maintenance
Vibration

Vibration

What if your equipment could provide alarms before it fails? The detection and integrated evaluation of vibration signals serves as the basis for the seamless integration of online condition monitoring and real-time maintenance into automation and control systems.

Eliminate unplanned downtime due to equipment failures.
Monitor key machine condition indicators to predict and plan maintenance activities.
Implement advanced real-time vibration monitoring without the complexity of traditional systems.
Integrate easily into your process systems.

Systems for vibration monitoring -- from sensor to ERP (Enterprise Resource Planning)

ifm provides a wide range of vibration solutions from simple switches to fully programmable systems aimed at improving your machine uptime and overall profitability.

Comparison of ifm vibration instruments in regards to application flexibility

Which solution below best describes your application or machine? Click on the desired platform to learn more.

		Vibration sensor platform
		Single point	Multiple points	IO-Link monitoring	Diagnostic & monitoring controller
Application	Machines	VK VT	VN	VV	VSE
Type 1 machines Basic monitoring Simple machines, single switch / analog output	Simple motors and fans	++	++	+++
Type 1 machines Multiple measurements and locations Multiple indicators for broad range of fault conditions	Indirect driven fans and pumps		++	+++	+
Type 1 / Type 2 machines Multiple measurement Ethernet system Easy to deploy, multiple points, networking capability	Blowers and simple speed reducers			++	+++
Type 3 machines Complex machine and process monitoring Machines requiring multiple points with root cause capability and process monitoring	Centrifugal compressors and machine tools			+	+++

Vibration behavior and excitation

To understand the best applicaton solution, we must differentiate the forces that cause vibration and excitation.

Construction-based excitation (C-forces) -- defined by the construction and geometry of the machine.
Process-based excitation (P-forces) -- caused by dynamic forces of the running process
Failure-based excitation (F-forces) -- occur when a machine component no longer performs its intended purpose

Construction-based forces

Predefined by the construction and geometry of the machine
External sources excite the machine's construction, amplifying the excitation frequency
C-forces are always present, but controlled in properly operating machines
Examples
- Unbalance
- Gear mesh
- Fan / pump blade pass
- Motor rotor / commutator pass

Process-based forces

Dynamic forces resulting from a process
Occur from the work the machine is performing
Vibration is only high while the work is performed
Baseline must be established while the machine is idling
Examples
- Forming
- Cutting
- Grinding
- Moving
- Separating

Fault-based forces

Occur when a machine component no longer performs its intended purpose
Usually lower in amplitude than P-forces
Caused by a fault or failure
Examples
- Misalignment
- Damaged bearing
- Looseness or excessive clearance
- Damaged belts
- Cavitation

Machine type classification

Machines are classified by the type of forces they experience

Type 1 -- simple machines, dominated by C-forces
Type 2 -- simple machines, dominated by P-forces
Type 3 -- complex machines, dominated by high C-forces and P-forces

Type 1 machines

Simple machines normally running at constant speed
C-forces occur at low levels
Fault-based changes are easily monitored during operation
P-forces are low and do not have an influence

Examples	C-forces	P-forces	F-forces
Pumps	Unbalance	Flow noise	Bearing damage, alignment, cavitation
Motors	Unbalance	Electric fields	Bearing damage, alignment, coupling
Blowers	Unbalance	Flow noise	Bearing damage, alignment, stripping, belt resonance

Type 2 machines

Simple machines with high process forces
Clear P-force dominance with a low C-forces
Fault-based vibrations are lower than process-based vibrations
P-forces depend on the type and step of the process
Machine operator can influence the process and create overloading
Operating excessive P-forces will reduce machine lifetime
Determination of F-forces is only possible in a reference run during machine idle

Examples	C-forces	P-forces	F-forces
Simple machine tool	Unbalance	Cutting forces	Bearing damage
Hammer mills	Unbalance, couplings	Striking forces	Bearing damage, alignment
Shredders	Unbalance, couplings	Cutting forces	Bearing damage, alignment

Type 3 machines

Complex machines
Continuously high C- and P-forces during machining and in idling modes
Fault-based vibrations are significantly lower than process-based vibrations
Simple strategies (e.g. reference run) do not work here
Diagnosis algoritms are required to detect F-forces
- High frequency-resolution and narrow bands
- Separation of carrier and interference frequencies by appying H-FFT filter

Examples	C-forces	P-forces	F-forces
Multi-axis machine tools	Unbalance	Cutting forces	Bearing damage, process damage
Multi-stage compressors	Unbalance, couplings	Pumping frequency	Bearing damage, alignment
Multi-stage blowers	Unbalance, couplings	Blowing frequency	Bearing damage, alignment

Integration methods

Online condition monitoring and real-time maintenance can easily be added to your existing controls and network architecture. It can be upscaled as your needs change.