Vibration Monitoring Application Solutions - ifm

3

For industrialapplications

Vibration MonitoringApplication Solutions

Systems for condition monitoring of machines

www.ifm.com/uk/octavis

22

Multicode reader

Vibration monitoring

・ Type of machine・ Criticality of machine・ Accessibility of machine・ Level of data that can be understood by

employees・ Automation / Control / IT systems and

infrastructure already on site

Vibration monitoring sensors and systems are used forcondition-based maintenance of machines and installations. They help to detect machine damage in good time and prevent costly consequential damage. Vibration monitoring is the most commonly applied condition monitoring technique as it will detect defectsbefore most other techniques.

All machines are subject to vibrations. A rise in vibrationlevels can be detrimental to machine health and can resultin the following:

・ Unexpected machine failure・ Unplanned production downtime・ Expensive repair costs・ Secondary damage to machinery・ Safety issues

A wide range of vibration monitoring options can be applied to inform the user about a change in the condition of the machine. The type of vibration monitoring solution used can depend on various factorssuch as:

Introduction

Vibrations(Vibrationanalysis)

Conditionstarts tochange

Noise(Audible)

Smoke

Breakdown

Prevention time

Co

mp

on

ent

con

dit

ion

Months Weeks Days Minutes

Heat(Touch or

heat sensors)

Excessivefrictions

(Oil particleanalysis)

33

Learn more at www.ifm.com/uk/octavis

Common vibration problems

An unbalanced machine contains a ‘heavy spot’ whichwhen rotated, exerts a force.This is one of the most common causes of vibrationproblems. On a fan, unbalancecould be caused by a build upof dirt on the blades or a damaged blade. Activity is detected at 1X the rotationalspeed of the machine. Unbalance can lead to manyother vibration defects due toexcess force being put oncomponents such as bearings.

Unbalance

Misaligned machines create abend between two shafts dueto them not being aligned correctly. When the shafts rotate this exerts a repeatingforce on the machine. It isoften caused by inaccurate assembly, uneven floors, thermal expansion, incorrecttorque of fasteners and couplings not installed correctly. Activity is normallydetected at 1X, 2X & 3X rotational speed of machine.

Mis-alignment

This is often due to excessivebearing clearances, loosemounting bolts, mismatchedparts, corrosion and cracks inthe structure. Depending onthe type of looseness, activitycan be detected at harmonicsof up to 10X the rotationalspeed of the machine. Looseness can cause vibrationsin both rotating and non-rotating machinery.

Looseness

Common issues with drivebelts are: misaligned sheaves,belt resonance and worn belts.Misaligned pulleys and belt resonance defects cause activity at 1X the rotationalspeed of either the primary orsecondary drive shaft. A wornor loose belt will show a peakat the belt rate, and its harmonics. The predominantfrequency is known as the"belt rate“. This is the rate atwhich a point on the belt passes a fixed reference point.

Belt drives

As a bearing defect develops,activity will become apparent inthe high frequency range up to 10kHz. This is usually mo-nitored with a special echnique called Enveloping orDemodulation to monitor theinner-race, outer-race and rolling element fault frequen-cies of the bearing. As the faultcontinues to worsen, activity will start to occur atlower frequencies which can bedetected by monitoring the rotational speed of the machinex the fault frequency for eachof the bearing components.

Bearing defects

A number of problems canoccur on a gearbox, such as:gear meshing, tooth wear, eccentric gears, broken teeth,misaligned gears. Most ofthese are detected by monitoring the rotationalspeed x the number of gearteeth frequency. For a numberof these gear defects there willbe sidebands around the maingear fault frequency that arevisible in the frequency spectrum.

Gears

Cavitation occurs when thereis lower pressure on thesuction side of the pump. Theliquid tends to vapourise whencoming off the impeller creating vacuum bubbles thatimplode. Cavitation normallycreates random higher frequency vibrations, or‘noise’. It is often observed as a low amplitude wideband‘hump’ in the vibration spectrum. The highest peak in the spectrum can be at thevane pass frequency – numberof vanes x rotational speed.

Fluid noise

Impacts can be caused by anumber of issues and can ge-nerate vastly different levels offorce depending on the appli-cation. Small impacts or ‘ti-cking’ on a rotating shaft cansignify damage to either theshaft or a component. On ap-plications such as spindles, it iscrucial to detect ‘machinecrash’ should the cutting toolcome into unexpected contactwith an object. On mobile ap-plications, monitoring for un-expected impacts can signify apoor operator. Impact de-tection can also be used tomonitor a manufacturing pro-cess by confirming that an ac-ceptable level of ‘shock’ hastaken place when it should.Monitoring the peak accelera-tion levels is usually required todetect impacts.

Impact detection

This can be caused by a num-ber of issues. Worn compo-nents exert a repeating forceon the machine because of therubbing of uneven worn surfa-ces. Wear in bearings, gearsand belts is often due to im-proper mounting, manufactu-ring defects, overloading andpoor lubrication. High vibra-tion levels can usually be de-tected in the frequency rangeof 2kHz to 5kHz and are nor-mally viewed as a high ampli-tude wideband ‘hump’ in thefrequency spectrum.

Rubbing

44

Vibration Monitoring

With acceleration we are able to monitor much higher frequen-cies. We use acceleration measurements to detect faults thatexert a force, such as small shocks and impacts that occur at thestart of bearing damage, gearbox faults, pump cavitation etc.

The diagram below shows roughly which frequency rangesmany common vibration defects would normally be observed inand which measurement parameter is best suited to detectthem.

Velocity and acceleration are the two most common parameters that are monitored with vibration sensors to detect problems on rotating machinery. Velocity is the speedmeasured in a single direction. It is measured in ‘mm/sec’. Acceleration is the rate of change of velocity. It is measured in‘g’ or ‘mg’. A mg is 1/1000th of gravitational force.

The main difference between monitoring in velocity or acceleration is the frequency range that is monitored.

With velocity it is usually no more than around 3000Hz that ismonitored. We use velocity measurements to detect faultswhich exert an energy, such as unbalance, misalignment, looseness etc.

Types of vibration measurement

Most suitable measurement parameter for detecting faults

Frequency range

Suit

abili

ty t

o d

etec

t fa

ult

s

0 2kHz 10kHz

Velocity Acceleration

(not to scale)

55

Different levels of monitoring available

Faultanalysis

Intelligent vibration sensor

Machineryprotection sensors

Simple machinery protection sensors offer monitoring of the overall vibration levels,measured in velocity (mm/sec). These are commonly applied to the ISO 10816 stan-dard. This level of monitoring will not diagnose a specific machine fault, but will detect a change in the overall vibration level caused by faults such as:

Faultanalysis



Intelligent vibration sensors facilitate monitoring of both the velocity levels (mm/sec)and acceleration levels (g). This level of monitoring will not normally diagnose a specific machine fault. However, by monitoring both velocity and acceleration it ispossible to detect vibration increases caused by a wider range of issues, such as:

Faultanalysis



Fault analysis systems can be programmed to detect specific machinery problems bymonitoring the individual fault frequencies that relate to these various vibration issues. Once detected, the user can then be notified which fault is starting to developon the machine. This level of detailed analysis allows for more efficient maintenanceprocedures to take place. These systems can be programmed to diagnose specific machine faults such as:

Unbalance Mis-alignment

Looseness Belt drives


Looseness Belt drives Bearing defects

Rubbing

Gears Fluid noise Impact detection


Looseness Belt drives Bearing defects

Rubbing

Gears Fluid noise Impact detection

66

Systems forvibration monitoring –suitable productsfor all applications

Vibration sensors and transmitters forpermanent monitoring of the overallvibration level of machinery to ISO 10816.The sensors measure the rms vibrationvelocity on a non-rotating componentsurface.

Machinery protection sensors

Compact vibration sensor monitors boththe RMS velocity levels and the acceleration levels of machinery. This facilitates detection of vibration increases caused by more defects than asimple machinery protection sensor.It is characterised by easy parameter setting and a local display.

Intelligentvibration sensor

6-channel diagnostic system for theevaluation of dynamic signals (e.g.accelerometers) and analogue inputs.Flexible, detailed monitoring and analysis.Ethernet TCP/IP and fieldbus interface(only VSE15x) for connection to andintegration into a higher-level system /the PLC.

Online fault analysismodules

Acceleration sensors measure the dynamicforces at the machine surface and deliverthe raw signal for offline vibration analysisor connection into diagnostic modulestype VSE.

Accelerometers

The software VES004 is used for theparameter setting and the online datamonitoring of all intelligent vibrationsensors and diagnostic electronics.The ifm OPC server software can be usedfor the connection of the vibration diag -nostics to higher-level systems (SCADA,MES, ERP).

Softwareand accessories

77

OPC is a standard for manufacturer-independent communication in automationtechnology; it offers high flexibility andan easy implementation.The ifm software SMARTOBSERVER is asoftware with many functions for onlinevisualisation, storage and analysis of

measured values with the purpose ofmonitoring the condition of machines andplants.Besides mounting adapters ifm offers anextensive range of connection technology(e.g. sockets, Y cables) for differentoperating conditions as accessories.

VTV

VNB211

VSAVSP

VKV

VNB001

VSE002VSE100

VSE15x

Switc

hing o

utput

Field

bus inte

rface

Inte

grate

d disp

lay

History

functi

on

Netw

ork ca

pabilit

y TCP/

IP

Signal

inputs

e.g. t

emper

ature

Diagnosti

cs

Counter

Analogue o

utput

Type

88

Fans

Common problems

Applications

Unbalance Looseness Belt drives

Mis-alignment

Rubbing Bearing defects

Pumps

Common problems

Unbalance Looseness Cavitation

Bearing defects

Mis-alignment

Rubbing

Motors

Common problems

Bearing defects

Belt drives Rubbing

Mis-aignment

Unbalance Looseness

Faultanalysis



Faultanalysis



Faultanalysis



99

Faultanalysis



Faultanalysis



Dynamometer

Common problems

Lifts

Common problems

Gearbox

Common problems


Looseness

Gears Rubbing Bearing defects

Rubbing Impact detection

Looseness

Bearing defects

Gears Bearing defects

Rubbing


Looseness

Faultanalysis



1010

Homogeniser

Common problems

Applications

Faultanalysis



Faultanalysis



Unbalance Looseness Bearingdefects

Cavitation Gears Mis-alignment

Separator

Common problems

Unbalance Looseness Rubbing

Gears Mis-alignment

Rotary fillers

Common problems


Looseness

Gears Rubbing Bearing defects

Faultanalysis


Machineryprotection sensor

1111

Faultanalysis



Faultanalysis



Machine tools

Common problems

Robots

Common problems

Alternators

Common problems

Impactdetection

Bearingdefects

Unbalance

Rubbing Impactdetection

Bearing defects

Gears Unbalance

Mis-alignment

Looseness Rubbing

Faultanalysis



1212

Mixer

Common problems

Applications

Faultanalysis



Faultanalysis



Faultanalysis



Unbalance Looseness Gears

Bearing defects

Rubbing Mis-alignment


Bearing defects



Bearing defects


Pre-refiner

Common problems

Refiner

Common problems

1313

Conche

Common problems

Mixers

Common problems

Packaging machine

Common problems


Bearing defects

Gears Belt drives Looseness


Bearing defects



Bearing defects

Rubbing

Faultanalysis



Faultanalysis



Faultanalysis



1414

Compressor

Common problems

Applications

Faultanalysis



Mis-alignment

Bearing defects

Rubbing

Unbalance Looseness

Wind turbine

Common problems

Gears Bearing defects

Impactdetection

Unbalance Looseness

Slow rotating shafts

Common problems


Faultanalysis



Faultanalysis



1515

Mill

Common problems

Saw

Common problems

Tumbler

Common problems

Unbalance Looseness Bearing defects

Mis-alignment

Gears Rubbing

Faultanalysis




Mis-alignment

Gears Rubbing

Faultanalysis




Belt drives Gears Rubbing

Faultanalysis



1616

Mixer / grinder

Common problems

Applications

Cutter

Common problems

Screw conveyor

Common problems

Faultanalysis



Faultanalysis



Faultanalysis




Belt drives Gears Rubbing


Mis-alignment

Gears Rubbing


Impactdetection

Gears Rubbing

1717

Bucket elevator

Common problems

Chain drives

Common problems

Sleeve / Journal bearing

Common problems

Rubbing Unbalance

Faultanalysis



Faultanalysis



Faultanalysis




Impactdetection

Gears Rubbing

Mis-alignment

Looseness Bearing defects

Impactdetection

Gears Rubbing

1818

Ship to shore crane

Common problems

Applications

Rail vehicles

Common problems

Faultanalysis



Faultanalysis



Mis-alignment


Impactdetection

Gears Rubbing

Mis-alignment


Impactdetection

Gears Rubbing

Roller conveyors

Common problems

Faultanalysis




Mis-alignment

Rubbing Bearing defects

1919

Refuse truck

Common problems

Fire engine

Common problems

Cavitation Bearing defects

Rubbing

Unbalance Looseness Impactdetection


Rubbing

Unbalance Looseness

Faultanalysis



Faultanalysis



Rotary mill

Common problems

Unbalance Looseness Cavitation

Bearing defects

Mis-alignment

Faultanalysis



2020

Stone crusher

Common problems

Applications

Sweeper

Common problems

Shredder

Common problems

Faultanalysis



Faultanalysis



Faultanalysis



Mis-alignment

Looseness Unbalance

Impactdetection

Bearing defects

Rubbing


Rubbing

Unbalance Looseness Impactdetection


Rubbing

Unbalance Looseness

2121

Hydraulic power pack

Common problems

Air handling unit

Common problems

Injection moulding machine

Common problems



Bearing defects

Bearing defects

Cavitation Gears

Mis-alignment

Unbalance

Faultanalysis



Faultanalysis



Faultanalysis




Rubbing

Unbalance Looseness

2222

Systems forvibration monitoring –from sensor to ERP

Process control level MES SCADA CMMS

Network (LAN)

VibrationsensorVKxxxx

Operating andparameter setting softwareVES004

Fieldbus

DiagnosticelectronicsVSE15x

DiagnosticelectronicsVSE002 / VSE100

PLC

VibrationtransmitterVTVxxx

VibrationsensorVNBxxx

AccelerationsensorsVSAxxx / VSPxxx

ZenerBarrier

ATEXTemperaturesensorTRxxxx

Compressedair consumption meterSDxxxx

AccelerationsensorsVSAxxx / VSPxxx

ZenerBarrier

ATEXTemperaturesensorTRxxxx

Compressedair consumption meterSDxxxx

*not compatible with VSE15x

OPC server softwareVOS00x*

Operating and parameter setting softwareVES004

Analogue and switching signals

2323

Systems forvibration monitoring –the choice is yours

Machinery protection sensorsDescription Order no.

Vibration sensor to ISO 10816;RMS velocity 10…1000 Hz; analogue output 4…20 mA,switching output PNP, response delay andswitch point adjustable via setting rings,measuring ranges 0…25 / 0…50 mm/s

VNB001VKV021VKV022

Intelligent vibration sensorDescription Order no.

Vibration sensor to ISO 10816;2 switching outputs or 1 switching output and 1analogue output, history memory with real-time clock,4-digit alphanumeric display, data interface USB;2/10...1000 Hz RMS velocity;measuring range 0…25 mm/s; external input 4…20 mA /4…20 mA or VNA001 acceleration sensor

VNB001

Vibration sensor to ISO 10816;2 switching outputs or 1 switching output and 1analogue output, history memory with real-time clock,4-digit alphanumeric display, data interface USB;RMS acceleration / velocity and a-Peak 0…6000 Hz;measuring range +/- 25 g; external input 4…20 mA /4…20 mA or VNA001 acceleration sensor

VNB211

Vibration transmitter to ISO 10816,10…1000 Hz RMS velocity, analogue output 4…20 mA,measuring ranges 0…50 / 0…25 / 0…25 mm/s,use in hazardous areas (type VTV12A)

VTV121VTV122VTV12A

Online fault analysis modulesDescription Order no.

Diagnostic electronics for evaluation of dynamic signals,e.g. of acceleration sensors type VSA / VSP;panel mounted; frequency-selective machine monitoringof up to 4 measuring points; TCP/IP Ethernet interface;integrated history memory with real-time clock;2 digital outputs or 1 analogue and 1 digital output;counter function; further interfaces: - / 8 digitalinputs/ouptuts / Profinet / Ethernet IP / Modbus TCP

VSE002VSE100VSE150VSE151VSE153

AccelerometersDescription Order no.

Acceleration sensor for connection todiagnostic electronics type VSE, MEMS,frequency range 0...6000 Hz,measuring ranges ± 25 g / ± 250 g

VSA001VSA201

Acceleration sensor for connection todiagnostic electronics type VSE,MEMS, frequency range 0...1000 Hz,measuring range ± 3.3 g

VSA101

Acceleration sensor for connectionto diagnostic electronics type VSE,MEMS; Frequency range 0…10,000 Hz,measuring range ± 25 g,3 m cable / 10 m cable / 0.8 m cable andM12 connector / 6 m cable

VSA004VSA005VSA002VSA006

Acceleration sensor; piezo; 100 mV/g frequency range0…10,000 Hz; measuring range ± 50 g

VSP001VSP003

Acceleration sensor for use in hazardous areas,group II category 1D/1G, connection via safety barrier,100 mV/g; frequency range 2…10,000 Hz,measuring range ± 50 g

VSP01AVSP02A

AccessoriesDescription Order no.

Conical washer, 5 pcs.,mounting accessories for acceleration sensors typeVSA001, VSA101, VSA201, VNA001

E30115

Description Order no.

Parameter setting software for diagnostic electronicstype VSE and vibration sensor type VNB VES004

OPC server software (OPC DA) for diagnostic electronicstype VSE002 and VSE100, licence depending on thenumber of connections 25 / 50 / 75 / 100 / 1000

VOS001to

VOS005

PEEK adapter, mounting accessories for electricalinsulation of the sensor, for acceleration sensorstype VSA001, VSA101, VSA201, VNA001

E30132

Safety barrier for acceleration sensorstype VSP01A, VSP02A ZB0633

Acceleration sensor for connectionto vibration sensor type VN VNA001

Y cable for vibration sensor type VN E12405

USB cable for vibration sensor type VN E30136

Protective cover for vibration sensor type VK E30094

Cross-over patch cable for diagnostic electronicstype VSE, 2 m / 5 m

EC2080E30112

Socket for acceleration sensors type VSA / VSP, M12,straight, PUR cable, shielded, 5 m / 30 m

EVC527EVC561

Socket for acceleration sensors type VSA / VSP, M12,angled, PUR cable, shielded, 20 m EVC597

Software

The compact all-rounder:Orientation-independentidentification of 1D and 2Dcodes as well as text

Multicode reader

ifm a

rtic

le n

o. 7

8002

451

· We

rese

rve

the

right

to

mak

e te

chni

cal a

ltera

tions

with

out

prio

r no

tice.

· Pr

inte

d in

Ger

man

y on

non

-chl

orin

e bl

each

ed p

aper

. 10

/17

Visit our website:www.ifm.com

Position sensors

Sensors formotion control

Industrial imaging

Safety technology

Process sensors

Systems formobile machines

Industrialcommunication

Condition monitoringsystems

Connectiontechnology

Software

Power supplies

AccessoriesIO-Link

years

W

ARRANTY

on ifm products

Identification systems

ifm electronic gmbhFriedrichstraße 145128 EssenTel. +49 / 201 / 24 22-0Fax +49 / 201 / 24 22-1200E-mail [email protected]

Vibration Monitoring Application Solutions - ifm

Documents

Transcript of Vibration Monitoring Application Solutions - ifm