- Real-time maintenance
- Vibration
- Product platforms
- IO-Link vibration monitoring
Real-time maintenance: IO-Link vibration monitoring
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 vibration meter 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.
| 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.
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. |
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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. |
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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. |
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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 |
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. |
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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