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Vibration monitoring with IO-Link

  • Simple installation
  • No control cabinets or extensive wiring required
  • Accurate equipment condition assessment
  • Automated alerts
  • Root cause analysis tools without the complexity and high price
  • Leverage your existing control network for process and Real-time Maintenance

Industrial-grade machine protection integrates directly into your existing control platform. Machine condition is continually monitored for common fault conditions of impacts, component fatique, and friction. This allows timely and predictable scheduling of maintenance before major damage or failure and production downtime. Machines are continuously and permanently protected, unlike when using intermittent single measurement monitoring systems.

Measurements

The VV design aims to simplify the primary categories of machine failure. Unlike typical single measurement systems, the VV simultaneously monitors equipment for the five categories of machine problems: impact, fatigue, friction, severity, and temperature. The embedded IO-Link technology provides this data in real time, giving the VV sensor the capability to predict pending failures and mitigate catastrophic damage.

Monitoring methods
Example fault
conditions
Blades hitting
Ingested object
Struck by moving object
Improper sequence timeing
Misalignment
Unbalance
Belt issues
Loose footing
Structural issues
Failing bearing
Rubbing impeller
Dragging blade
Cavitation
Damaging condition
Instability
Loss of lubrication
Loss of coolant flow
Electrical issues
Excessive load
Fault category Impact
Crashes
Striking
Fatigue
Mechanical issues
Assembly issues
Friction
Rubbing
Grinding
Severity
Uncontrolled forces
Impulses
Temperature
Over heating
Sensor measurement Acceleration peak
(a-Peak)
Average velocity
(v-RMS)
Average acceleration
(a-RMS)
Crest factor
(a-Peak / a-RMS)
Degrees Celsius
(C)

The crest factor is a leading indicator of damaging fault conditions. It measures the severity of impacts relative to the normal operating state of the machine. It filters out the influence of rotational speed to simplify setting alarm limits.  Crest factor values in the 4...8 range indicate potential machine problems.

Each VV sensor comes with factory-set alert outputs optimized for out-of-the-box performance based upon machine size and speed. Alarming thresholds adhere to recognized standards (ISO 10816) and ifm’s years of machine monitoring experience.

Part No. Machine optimization

VVB010

Fast ( > 600 rpm) and large ( > 400 hp)

VVB011

Slow (120…600  rpm) and large ( > 400 hp)

VVB020

Fast ( > 600 rpm) and small ( < 400 hp)

VVB021

Slow (120…600  rpm ) and small ( < 400 hp)

VVB001

Industrial machines

Location of sensors and monitoring methods

Typically, we recommend mounting sensors radially to shaft rotation to detect the greatest level of movement and located mechanically as close to the target as possible. The orange dots in the images indicate approximate sensor location for smaller machines. If the mounting location is greater than 80 cm (30+ inches) apart, we recommend adding additional sensors as shown by the grey dots in the images.

Note: All sensors are capable of measuring all alarm conditions and identifying root causes. 

Axial fan

Machine No. of sensors Sensor location   Alarms Root issue

Axial fan

Primary: 1

Optional: 1

Radial H-DE motor

Radial V-NDE motor

 

a-Peak

v-RMS

a-RMS

Temp

Impact

Looseness

Friction (bearing)

Overheating

Legend:  a = acceleration, v = velocity, H = horizontal, DE = driven end  

It is suggested that mounting locations greater than 80cm apart also use the optional location.

 

Radial direct drive fan

Machine No. of sensors Sensor location   Alarms Root issue

Radial direct drive fan

Primary: 1

Optional: 1

Radial H-DE motor

Radial V-NDE motor

 

a-Peak

v-RMS

a-RMS

Temp

Impact

Looseness

Friction (bearing)

Overheating

Legend:  a = acceleration, v = velocity, H = horizontal, V = vertical, DE = driven end, NDE = non-driven end 

It is suggested that mounting locations greater than 80cm apart also use the optional location.

 

Radial indirect drive fan

Machine No. of sensors Sensor location   Alarms Root issue

Radial indirect driven fan

Primary: 1

Primary: 1

Optional: 1

Optional: 1

Radial H-DE motor

Radial V-DE fan

Radial V-NDE motor

Radial H-NDE fan

 

a-Peak

v-RMS

a-RMS

Temp

Impact

Looseness

Friction (bearing)

Overheating

Legend:  a = acceleration, v = velocity, H = horizontal, V = vertical, DE = driven end, NDE = non-driven end 

It is suggested that mounting locations greater than 80cm apart also use the optional location.

Centrifugal pump

Machine No. of sensors Sensor location   Alarms Root issue

Centrifugal pump

Primary: 1

Primary: 1

Optional: 1

Optional: 1

Radial H-DE motor

Radial H-DE pump

Radial V-NDE motor

Radial V-NDE pump

 

a-Peak

v-RMS

a-RMS

Temp

Impact

Looseness

Friction (bearing)

Overheating

Legend:  a = acceleration, v = velocity, H = horizontal, V = vertical, DE = driven end, NDE = non-driven end 

It is suggested that mounting locations greater than 80cm apart also use the optional location.

Electric motor

Machine No. of sensors Sensor location   Alarms Root issue

Electric motor

Primary: 1

Optional: 1

Radial H-DE motor

Radial V-NDE motor

 

a-Peak

v-RMS

a-RMS

Temp

Impact

Looseness

Friction (bearing)

Overheating

Legend:  a = acceleration, v = velocity, H = horizontal, V = vertical, DE = driven end, NDE = non-driven end 

It is suggested that mounting locations greater than 80cm apart also use the optional location.

Speed reducer

Machine

No of
sensors

Sensor location   Alarms Root issue

Speed reducer

Primary: 1

Optional: 1

Radial H-DE reducer

Radial V-NDE motor

 

a-Peak

v-RMS

a-RMS

Temp

Impact

Looseness

Friction (bearing)

Overheating

Legend:  a = acceleration, v = velocity, H = horizontal, V = vertical, DE = driven end, NDE = non-driven end 

It is suggested that mounting locations greater than 80cm apart also use the optional location.

When applying real-time continuous monitoring, 3-axis measurements are typically not needed. 3-axis techniques are typically used in traditional route-based analysis methods where only a snapshot of the machine health is recorded. In some cases where machine design implements axial loading, a second axial sensor may be necessary.

For a more detailed comparison of single-axis vs. multi-axis measurements, please visit our technology page.

Integration

The VV family is flexible enough to provide varying degrees of control so it can scale as your level of IIoT integration grows. From sensor to ERP.

Stand-alone switching
With a 24 VDC power supply, the VV provides simple switching outputs for machine control and / or local indication of machine status.

IO-Link system
Adding sensors to your existing IO-Link network provides a quick way to achieve Industry 4.0, IIoT and RtM.

Available cyclic data:

  • Acceleration peak (a-Peak)
  • Average velocity (v-RMS)
  • Average acceleration (a-RMS)
  • Surface temperature
  • Crest factor

Available acyclic data:

  • Peak values of all 4 vibration process values
  • Minimum and maximum temperature values
  • Hardware and parameter errors

PLC integration to higher-level systems

Collect and evaluate IO-Link measurement values in standard PLC control. Optionally, transfer data to SCADA, MES or other plant control systems.

Available cyclic data:

  • Acceleration peak (a-Peak)
  • Average velocity (v-RMS)
  • Average acceleration (a-RMS)
  • Surface temperature
  • Crest factor

Available acyclic data:

  • Peak values of all 4 vibration process values
  • Minimum and maximum temperature values
  • Hardware and parameter errors

Independent data collection system

Collect the raw vibration signal as a BLOB (Binary Large Object) data set and manipulate it as desired. Create an independent monitoring network for notification and visualization.

  • Machine trending
  • Condition change
  • Email and text alert messages
  • Analytics and data science