What is online vibration monitoring?
Online vibration monitoring is a continuous process for monitoring the vibrations of machines and systems in real time. Sensors are attached to critical points on the machines to record vibrations and oscillations. This data is then transmitted to a central monitoring system, which analyzes and evaluates it.
The main objectives of online vibration monitoring are the early detection of deviations and potential problems in the machinery, extending the service life of systems, improving safety and optimizing maintenance processes. Continuous monitoring enables companies to react to deviations in good time, plan maintenance work efficiently and prevent unplanned downtime. This leads to cost savings, higher productivity and safer operating conditions.
How does it work?
Running machines generate vibrations, which contain a lot of information about the machine’s condition. Acceleration sensors are used to measure vibrations. In most cases, they are installed on rolling bearing housings. For plain bearings, eddy current or laser relative displacement sensors should be considered.
If it is necessary to measure the sound intensity and/or analyze the acoustic signal in detail, microphones can be used. The signal from the sensors is processed and pre-analyzed by the DiBox monitoring and recording unit.
What can we offer you with our systems?
Online vibration monitoring provides numerous advantages in various industrial and commercial applications. This technology enables continuous monitoring and analysis of machine vibrations to ensure smooth equipment operation and prevent potential issues. Here are some of the key benefits of online vibration monitoring:
- Early Fault Detection: Online vibration monitoring delivers real-time machine condition data, allowing early detection of potential issues like misalignment, imbalance, wear and tear, and bearing defects. Identifying problems in their early stages enables maintenance teams to address them before they lead to costly breakdowns or production interruptions.
- Enhanced Maintenance Efficiency: Predictive maintenance based on vibration data enables companies to plan maintenance tasks more efficiently. Instead of relying on fixed schedules or running machines until they fail, maintenance teams can plan and execute maintenance when it’s actually needed. This reduces both planned and unplanned downtime, resulting in cost savings and increased productivity.
- Prolonged Equipment Lifespan: By proactively addressing issues, online vibration monitoring helps extend the lifespan of critical equipment. Regular maintenance based on condition data can prevent the cumulative damage that occurs when machines are operated to failure. As a result, companies can extract more value from their equipment and delay the need for costly replacements.
- Increased Safety: Unplanned equipment failures can pose serious safety risks to personnel and the environment. Online vibration monitoring helps identify potential safety hazards by detecting equipment problems early and ensuring that maintenance is performed before issues escalate into dangerous situations.
- Cost Reduction: Online vibration monitoring can lead to significant cost savings. Predictive maintenance reduces the need for emergency repairs and minimizes the use of expensive spare parts. It also cuts down on overtime labor costs associated with unplanned failures and decreases energy consumption by maintaining machines at optimal efficiency.
- Energy Efficiency: Well-maintained equipment operates more efficiently, reducing energy consumption. Online vibration monitoring allows companies to fine-tune their machinery for optimal performance, resulting in energy savings and lower operating costs.
- Data-Driven Decision Making: The wealth of data collected through online vibration monitoring can be used for informed decision-making regarding equipment replacement, repair, and optimization. This data-driven approach leads to improved resource allocation and overall operational efficiency.
- Remote Monitoring: Online vibration monitoring systems often offer remote access to real-time data, which is particularly valuable for companies with multiple sites or locations. This capability allows experts to monitor equipment health from a centralized control center, making it easier to allocate resources and expertise where needed.
- Compliance and Reporting: In regulated industries, online vibration monitoring can help companies meet compliance requirements by maintaining detailed records of equipment condition and maintenance activities. This is crucial for demonstrating adherence to safety and environmental standards.
- Competitive Advantage: Companies that embrace online vibration monitoring gain a competitive edge by maximizing equipment uptime, reducing operational costs, and minimizing disruptions. This can lead to improved customer satisfaction and a stronger market position.
In summary, online vibration monitoring is a powerful tool for maintaining equipment reliability, reducing operational costs, and enhancing safety. It enables companies to transition from reactive maintenance to a proactive, data-driven approach, ensuring smoother operations and a stronger financial position.
DiBox – Intelligent online vibration meter
Number of channels: 4 with simultaneous sampling, full synchronization with other channels
Analog-to-digital converter type 4 measuring value converters of the type
Resolution of the analog-to-digital converter: 24 bit
Analog input type: voltage, unipolar, input impedance min. 200 kΩ; – voltage supply with connected current source for supplying CLPSTM sensors ( 4 mA, supply voltage 20 V, sensor and signal cable status check); current, unipolar, input impedance 200 Ω; active or passive; factory configuration
Configuration of the analog inputs: voltage mode or current mode
Input voltage range 0 ÷ 20 V; 0 ÷ 20 mA;
Effective signal sampling frequency (fout) maximum 65.536 kHz
Total noise level for analog inputs 15µVRMS
Built-in filter Analog third-order Butterworth low-pass filter, cut-off frequency f3dB high = 68 kHz
Digital low-pass anti-aliasing filter, linear phase, cut-off frequency automatically adjustable to f3dB high = 0.49fout (f0.005dB high = 0.39fout, f-100dB high = 0.54fout)
Gain error ±0.05 %
Total maximum measurement error ±0.1 % of the measurement range (for calibration under measurement conditions)
Calibration Factory calibration of the measuring circuits;
Power supply for CLPSTM sensors: 4 mA current source supplied with 22 V voltage;
ADDITIONAL ANALOG INPUTS (STATIC)
Number of channels: 4 with simultaneous sampling, full synchronization with other measuring channels;
Analog-to-digital converter type 4 SA-type converters
Resolution of the analog-to-digital converter 16 bit
Analog input type: input impedance min. 200 kΩ; current, unipolar, input impedance 200 Ω; active or passive; factory configuration
Configuration of the analog inputs 0 ÷ 2.5 V; 0 ÷ 20 mA;
Input voltage range 1 kHz, determination of the average value for each measurement from the main analog inputs
Effective signal sampling frequency (fout) 40µVRMS
Total noise level for analog inputs Second-order analog Butterworth low-pass filter, cut-off frequency f3dB hi gh = 100 Hz; built-in filter ±0.5%; gain error ±1%
DIGITAL INPUTS: Number of channels 4 with simultaneous sampling, full synchronization with other measurement channels
Type of digital inputs Voltage, unipolar, input impedance min. 200 kΩ;
Current, unipolar, input impedance 200 Ω; galvanic isolation, common ground
Input voltage range 0 ÷ 24 V; 0 ÷ 20 mA; Effective signal sampling frequency (fout) maximum 65.536 kHz
COMMUNICATION INTERFACES:
Digital interfaces Ethernet 10/100Base/TX; WiFi (IEEE 802.11bgn); EIA-RS485; GSM;
Communication protocols MODBUS TCP; MODBUS RTU (half duplex/full duplex); ATC MESbus;
Relay outputs Outputs with NC contacts; load capacity of DC contacts: 24V/1A, AC: 125V/0.3A;
Link with exceeding of any threshold of any analysis; response delay;
Analog outputs 4 active current outputs 4-20 mA;
galvanic isolation (common ground of the analog outputs);
Link to the result of any analysis;
Synchronization maximum error 0.1%;
Interface for complete synchronization of the sampling process between the devices
devices; real-time clock synchronization protocol;
SOFTWARE available
OPERATING CONDITIONS
Environment Temperature -5…+50°C; Humidity: 10…90% RH without condensation;
Power supply 12÷24V; 1A; screw connection;
Technical dimensions 99mm x 45.2mm x 113.6mm (HxWxD)
The available functions and configurations depend on the device version (digital designation).