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  1. Programmable edge controller
  2. Applications

Programmable vibration edge controllers for asset health

The following application examples highlight the use of diagnostic electronics in essential systems across industries, including machine tools, compressors, conveyors, separators, filling systems, and complex machinery. Condition monitoring is vital to ensure reliable operation and prevent costly downtime. With high-resolution vibration sensors, the vibration edge controller enables precise machine monitoring, reducing unplanned downtime and minimizing damage.

Machine tools

During the machining of metal blocks, high process forces are generated. At the same time, these machines must achieve high machining speeds while maintaining consitently high production quality. Early damage directly impacts the condition of machine components, tools, and product quality.

The VSA or VSM vibration sensors, when paired with VSE diagnostic electronics, can detect such damage early and communicate it in real time.

Dynamic monitoring of various conditions enables reliable oversight of processes and machines. Increased unbalance, tool wear, main spindle bearing issues, and sudden impacts from crashes can be precisely monitored, preventing costly secondary damage. With a fast response time of 1 ms, the VSE diagnostic electronics provide reliable protection for your machine. Flexible integration with common fieldbus interfaces ensures seamless interaction between the diagnostic electronics and the machine controller. The diagnostic electronics are designed for comprehensive condition monitoring, process monitoring, and the reliable protection of machine tools.

Decanter centrifuges

Decanter centrifuges are specially designed for the sedimentation and separation of solid particles or suspended solids from liquids. They are widely used in industries such as wastewater treatment, food and beverage, chemical and pharmaceutical manufacturing, as well as heavy industries like oil and gas, mining, and minerals.

Decanters are subject to various vibration frequencies, including unbalance, bearing frequencies, gear frequencies, liquid vibrations, process-related vibrations, and machine resonances. These vibrations are detected by vibration sensors and analyzed, separated, and dynamically monitored by the high-resolution VSE diagnostic electronics based on relevant process states.

Screw and reciprocating compressors

Screw and reciprocating compressors are mechanical devices used to compress gas or vapor based on the volumetric principle, increasing pressure. They are indispensable across many industries, used for applications such as compressed air supply, refrigerant compression, gas transport (e.g. ammonia), and many other production processes.

These compressors often operate under variable parameters (speed, flow rate, nominal pressure, intake volume, medium temperature, and output) and feature complex kinematic arrangements, including electric motors, multiple gear stages, screws/pistons, and outlet valves. These factors make reliable condition monitoring a challenge.

The VSE diagnostic electronics can dynamically monitor increased unbalance, gear tooth damage, bearing wear, or increased friction in metallic components. Thanks to the analog inputs of the VSE, existing pressure or flow signals can be utilized as auxiliary variables to enhance monitoring tasks. Using current transducers (ZJF056), motor current can be employed as a trigger for a load changes. These current transducers provide a standardized 4-20 mA output signal, which can be connected to the VSE;s analog inputs to enable load-dependent vibration monitoring. The diagnostic electronics can be used for measuring and evaluating vibrations according to DIN ISO 20816-3/-7, ISO 7919-3 and VDI standard 3836.

Gearboxes

Gearboxes are indispensable components in almost every industry, serving as integral parts of systems across countless applications. Gearboxes are mechanical or electromechanical devices that use kinematic arrangements to transfer, increase, or reduce the speed and torque of motors or drive trains.

The interaction of kinematic components, mechanical forces, various shafts, and bearing seats makes vibration analysis complex. VSE diagnostic electronics can dynamically monitor different transmission ratios. Additionally, individual components can be easily and reliably monitored using narrowband analysis methods.