Vibration Signature Analyzer ( VSA)


MachineSense Vibration Signature Analyzer (VSA) is edge enabled multi-purpose Vibration analyzer that works for rotating machines, non-rotating machines as well as vibration monitoring of Steel & Concrete Structures. The sensor has three major usages – monitoring impact vibration on structures such as Bridges and Tunnels, predictive maintenance of rotating and non-rotating machines (which will require specialized analytics) and quality control of the products that get affected by interfering vibration.

It monitors vibration data in both time and Frequency domain. Machinesense’s proprietary analytics algorithm tracks and compares the collected data against a baseline and determines overall machine health. The status of bearings, rotors, gears, valves, and oil are constantly monitored. In addition to the visualization of valuable operating metrics, MachineSense will accurately predict and alarm of pending machine and component failures, thus significantly reducing unscheduled equipment downtime.

For Bridge and Structural monitoring, the Sensor can be enabled in event trigger mode. Which means whenever a vehicle is impacting momentary vibration, the system will pick up vibration only on impact moments and will analyze those relevant data only.

The sensor easily attaches to the machine housing with a magnet and constantly measures vibration, temperature, humidity and magnetic field. The sensor is powered by a 24VDC/110-260VAC power supply. Sensor data is transmitted via Bluetooth and(or) SPI to a data hub and through a router to Machinesense’s cloud or local servers. Datahub can be communicated to server via Wifi or LAN and in case of unavailability of the formers optional feature of GSM/CDMA module can be used. To minimize cloud and network consumption raw data can be stored in SSD, which can be accessed with smartphone app for visualization and download.

The MachineSense monitoring solution includes Machinesense’s extensive Crystalball™ software, which enables the user to set up alarms and alarm recipients and provides complete historic data with trend lines about equipment performance. At-a-glance dashboards show the current status of monitored assets by department or plant. Actionable maintenance advice is sent via text or email to alert users when a machine needs their attention.

Versions:

Sensors: Basic &(or) Advanced

Data acquisition system: Datahub

Optional Features: SSD, GSM/CDMA, Premise expert system (Local Server)

Basic: It is an aggregate of sensors (accelerometer, gyroscope, magnetometer, temperature and humidity) up to 250 samples/sec. It is connected to datahub via Wireless (Bluetooth) communication.

Advanced: It is a mems-based accelerometer capable of data sending up to 2KHz over wired connection. It also comes with advanced analytic features comprising more than 100 parameters to monitor along with insights to raw data and spectrum analysis.

Datahub: It is a single board computer capable of data acquisition and processing in real time.

SSD: Stores raw and processed data to save cloud and data cost. It also comes with smartphone app to synchronize data with cloud, download raw data and visualize machine parameters.

GSM/CDMA Module: Substitute for LAN/WiFi in areas without them which require data to be sent to cloud in real time or regular interval.

ON-Premise cloud: It will provide the services of a cloud-based server by running an application which is on the same machine as the user application. It is basically a local server with huge computation and storage capabilities. It allows a user to get all the benefits of cloud without letting the data to go out of the factory premise ensuring 100% security of it.

  1. Basic Sensor
  2. Advanced Sensor
  3. SSD
  4. MachineSense Data Hub
  5. Router/4G Dongle
  6. Cloud-Based/Local Servers
  7. MachineSense CrystalBallTM Predictive Software
  8. Actionable Maintenance Advice

SENSOR FEATURES/SPECS:

VIBRATION ANALYZER SENSOR(BASIC)
Mechanical
Weight 7.0 oz (0.2 kg)
Dimensions length x width x depth 2.6 in x 1.7 in x 1.1 in (66.7 mm x 42.7 mm x 27.6 mm)
Sensor housing material Metal plastic hybrid
Enclosure rating IP64, IP65 optional
Environmental
Operating temperature
Ambient temperature 14°F (-10°C) to 149°F (65°C)
Surface temperature up to 185°F (85° C)
Hazardous condition Class-1 Div-2
Acceleration
Range - 16g to + 16g
Resolution 2%
Accuracy 10 mg
Sampling rate (configurable)(/sec) 40/250
Power
Power supply (built in) 3.3 volt DC adapter
Bluetooth Communication
Bluetooth Low Energy (BLE)Range 15 ft
Bluetooth Low Energy (BLE)Tx power -5.8 dBm
Bluetooth Low Energy (BLE)Standard 4.1
Environmental
Operating temperature range 14°F (-10°C) to 149°F (65°C)
Power
Power in 24VDC or 110 - 270VAC
Power out 3.3 volt
Bluetooth Communication
Bluetooth Low Energy (BLE) Range 15 ft
Bluetooth Low Energy (BLE) Tx Power -7.5 dBm
Bluetooth Low Energy (BLE) Standard 4.1
VIBRATION ANALYZER SENSOR(ADVANCED)
Mechanical
Weight 2.5 oz (0.07 kg)
Dimensions length x width x depth 1.06 in x 0.98 in x 0.71 in (27.0 mm x 25.0 mm x 18.0 mm)
Sensor housing material Metal plastic hybrid
Enclosure rating IP64, IP65 optional
Environmental
Operating temperature
Ambient temperature -40°F (-40°C) to 185°F (85°C)
Surface temperature up to 185°F (85° C)
Hazardous condition Class-1 Div-2
Acceleration
Range - 16g to + 16g
Resolution 2%
Accuracy 10 mg
Sampling rate (configurable)(/sec) Upto 2000
Power
Power supply (built in) 3.3 volt from datahub
DATA HUB
Functional
Connect to sensors via Bluetooth Low Energy (BLE) and SPI
Configurable storage data for disconnected applications with optional SSD
Communication via Wifi/Lan or optional GSM/CDMA module
Smart-phone/tablet-based WiFi connect app (WiFigurator)
Local data visualisation and download app
Auto-upgrade over Internet
Mechanical
Mounting Rail/wall mount
Enclosure rating IP50
Dimensions length x width x depth 4.8 in x 3.0 in x 1.3 in (121 mm x 76 mm x 33 mm)
Weight 2.3 oz (0.06 kg)
Environmental 23°F (-5°C) to 150°F (65°C)
Power 5 volt DC adapter from 110 - 270VAC
ELECTRONICS
Processor Quad core 1.2G Hz broadcom BCM2837 64-bit CPU
Memory Micro SD card, SSD(optional)
Storage 16 GB
RAM 1 GB
I/O 40-pin extended GPIO and 4 USB Ports, full size HDMI, LAN
Radio BCM43438 WiFi and Bluetooth Low Energy (BLE) on board
OS Linux
Certification CE/IEC/FCC

Salient Features:

  1. Affordable, low investment and easy to install on existing equipment
  2. Acceleration data with high sampling rate (up to 2khz).
  3. 24*7 health and utility monitoring of a machine.
  4. Both time and frequency domain analysis.
  5. Easy-to-understand maintenance advice via text or email messages and handheld dashboard.
  6. Accurate prediction of machine and component failures, no unscheduled machine downtime.
  7. Option to store raw data locally with SSD which can be later downloaded or visualized with smartphone app.
  8. Option of GSM/CDMA module where WiFi/LAN in not available for connectivity.
  9. Event trap feature to detect abnormal event and trap the raw data for further analysis.
  10. On premise cloud to provide all the cloud features without cloud by containerizing data in local server within factory.

Basic sensor hardware design

Advanced sensor hardware design

Software and Analytic visualization:

Along with the gauges and trends the Advanced Vibration analyzer have expert visualization features for both statistical and spectrum analysis.

Gauges of a machine which shows overall condition of a machine. Comes under both basic and advanced package.

Historical trends of the above gauges. It also comes under both basic and advanced package.

In the advanced vibration analyzer, along with higher data rate comes advanced analytic features. It not only allows the user to get more information about the machine but also provide him options to monitor the raw data in time and frequency domain.

The “Variable mart” provides the visualization of more than 100 analytic parameters and their statistics for configurable time duration depending on the storage options.

“Raw data insights” provide batch wise visualization of raw data in different statistical plots.

In “Event Trap”, all abnormal events are captured under pre-decided parameter/s along with its raw data and FFT.

“FFT” provides the amplitude of vibration sorted against frequencies. Thus it shows the harmonics of the machine which is very good indicator of anomalies.

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