Vibration Sensors for Industrial Automation

Vibration sensors are designed to attach to industrial assets, particularly machinery with high-speed rotating components, to monitor the amount and characteristics of their vibration. Specifically, vibration monitoring continuously measures a rotating asset’s root mean square (RMS) velocity, which provides a uniform measure of vibration over a wide range of machine frequencies, RMS high-frequency acceleration, and peak velocity. Sensor data showing these characteristics at optimal levels is indicative of good overall machine health. If a machine is vibrating abnormally compared to baseline conditions, that could indicate an imbalanced, misaligned, loose, or worn part—for example, a belt, fan blade, or bearing requiring service or nearing the end of its useful lifecycle. Increasing vibration can be a sign of increasing potential damage to the machine.

A vibration sensor allows you to observe how a machine vibrates under normal conditions, set that behavior as a baseline, and arrange to receive real-time alerts when the amount or intensity of vibration changes. This notification is a bit like a “check engine” light but sent directly to you as an immediate text or email. Responding to early warning signs from networked devices to make informed decisions and conduct proactive maintenance is a prime application of the Industrial Internet of Things (IIoT).

If a motor, pump, compressor, fan, blower, gearbox, or other crucial piece of equipment breaks down during production, the result is unplanned downtime, which can be catastrophically expensive. By monitoring equipment for changes in vibration, potential problems can be detected and resolved before they become severe. This proactive approach is known as predictive maintenance, and it is by far the most effective way to maintain the long-term health of your machines and thereby maximize production efficiency.

Banner provides condition monitoring technology that provides powerful, real-time insight into machine health, including vibration. Consider Banner Monitoring Solutions, end-to-end IIoT networking systems that can be installed in your facility easily and deployed in minutes—without any necessary coding or programming. Start by selecting one of two available Asset Monitoring Gateways, and then choose sensors to monitor the health of your machines.

The QM30VT is a sensor that can be connected to measure both vibration and temperature of monitored assets. It outputs actionable data such as RMS velocity, RMS high frequency acceleration, and peak velocity, which are pre-processed from the vibration waveforms in the sensor. Its compact housing fits in tight locations, increases surface contact with machines, and reduces vibration resonance. This sensor is ideal for use with the wired Asset Monitoring Gateway with SNAP ID.

The Q45VAC  all-in-one vibration and temperature sensor collects the same data points as the QM30VT, but it is designed exclusively for wireless use. Part of the Q45 Series of wireless sensor nodes, it is fully compatible with the Asset Monitoring Gateway with CLOUD ID. Q45 sensor nodes are ideal for deployment on machines in remote or hard-to-access locations, and they can each run for more than two years on a C-cell lithium battery.  Upon activation, Asset Monitoring Gateways identify connected sensors and immediately begin collecting actionable data.

In addition, you can select sensors to monitor many other asset performance variables, including differential pressure, humidity, tank level, and more. You can access metrics from all your facility assets simultaneously for a holistic view of machine health.

To create your own custom monitoring solution, Banner offers a handy Bundle Builder tool. This website feature gives you a straightforward, guided process to (1) select the appropriate gateway; (2) decide which specific sensors would be best to use for your individual machine assets; and (3) add related connectivity, if applicable (such as cabling for SNAP ID networking).