What is a vibration sensor?

What is a vibration sensor?

The vibration sensor is a device designed to measure the amount and frequency of vibration in a system, machine, or piece of equipment.

In order to reduce overall costs and increase the performance of machinery, vibration sensors can be used to provide insight into conditions within key assets that can lead to equipment failure, thus allowing maintenance teams to predict maintenance, and increase efficiency.

Vibration sensors today use either piezoelectric or piezoresistive technology. Usually, piezoelectric sensors are used in plant monitoring.

CONSTRUCTION OF VIBRATION SENSOR

The construction consists of a piezoelectric crystal to which is attached a seismic mass.

Whenever the crystal is stressed in tension or compression, an electrical charge is generated that is proportional to the acceleration level.

A crystal under tension or compression generates an electrical charge proportional to the acceleration it experiences.

This signal is converted internally into a voltage or current (4-20mA) output for data collectors or process control loops.

A robust device with no moving parts, this device offers long-term stability and reliability.

It has a wide frequency range and dynamic range, and signals can be integrated to have velocity and displacement values.

A piezoresistive accelerometer consists of a seismic mass attached to a cantilever beam.

When a beam is deflected by 'g' forces, this movement is converted to an electrical signal by resistance changes in a semiconductor sensing element.

Internal circuitry amplifies the signal and compensates for temperature changes.

As a result, the frequency range of this device is lower than piezoelectric versions, but it has the advantage of being able to measure static acceleration or DC acceleration.

Different vibration sensors have been developed over the last twenty five years to adjust to a wide range of environmental conditions and perform consistently in a variety of industrial applications.

These conditions have led to the development of models that have an outer stainless steel construction that is primarily robust.

The devices will operate successfully at both high and low temperatures, typically between -55 and +140 degrees Celsius.

Stainless steel housing ensures full liquid submersion in underwater applications, or IP68 protection.

In addition to radiation-resistant models, ATEX-approved intrinsically safe models are available for use in potentially explosive atmospheres.

Cable choices include stainless steel braiding, submersible, and high-temperature PTFE cables.


Mechanics are also essential for the proper fixation of the sensor to ensure proper transfer of the vibration signal, which are available in the form of threads, adaptors, quick-fit or glue mounting studs, and magnets.


There are also custom-designed versions, where a sensor is created exactly to meet the conditions it will need to operate in.

Which industries use the vibration sensor the most?

Following is a list of the most common industrial sectors where vibration sensors are used:

• Aerospace

• Automotive & Transportation

• Pulp and Paper

• Food and Beverage

• Oil and Gas, Refining, Petrochemicals

• Power Generation (fossil fuel, nuclear, hydro, wind turbines)

• Machine tools

• Metalworking

• Mining, Mineral Processing, and Cement

The most common industrial applications of vibration sensors include rotating equipment such as pumps, motors, fans, compressors, gearboxes, gas turbines, bearings on conveyor systems, wind turbine gearboxes, wind turbine generators, dryer sections (pulp & paper), ovens & kilns (mineral processing), and hot rolling mills (metalworking).

Process and production plants are becoming increasingly aware of the importance of vibration condition monitoring.

Automotive industry

• Globally, the automotive industry has experienced strong growth and profitability in recent years.

• Increasing demand for automobiles has also encouraged automobile manufacturers to monitor the health of their plant machinery effectively in order to maintain the production line.

• In addition, condition monitoring has become essential for the stability of manufacturing processes and the quality of products. Managers can ensure the proper functioning of automobile manufacturing plants by using vibration monitoring equipment and vibration sensors, automated machines, metalworking equipment, and robotics, thus ensuring the smooth flow of different production processes.

Water industry

• Today, the water industry monitors many of its water processing pumps, including those in remote pumping stations and those in large-scale, sophisticated water treatment and desalination facilities.

Food processing industry

• The food processing industry needs to monitor the many rotating machinery parts in its vibratory conveyor systems, cooling fans, food pumps and mixers, the chip, which can cause thousands of dollars in losses.

Building services

• In public buildings, like hospitals, airports, railway stations, office blocks, hotels, etc., motors, pumps, and fans also have a crucial role to play.

Oil and gas Industry

• Vibration sensors play a vital role in the oil and gas industry by ensuring that the production machinery is operational and the downtime is minimized, thereby leading to a reduction in operating costs and an increase in productivity and monetary gains.

• These sensors help reduce unplanned outages and optimize machine performance. This, in turn, helps in reducing maintenance and repair costs.

• Vibration sensors designed for monitoring applications are used to monitor motors, critical pumps, fans, gearboxes, and compressors in the oil and gas industry.

Chemical Industry

• Deterioration in the condition and performance of chemical plants' machines is commonly associated with vibration, misalignment, and imbalance in moving parts; and poorly lubricated parts.

• By detecting these underlying problems at an early stage, chemical plants can be optimized before they affect the different processes.

• In the chemicals industry, vibration monitoring equipment and tools are used to detect vibration issues.

• As a result of these tools, maintenance effectiveness is improved, profitability is increased, safety warnings are provided, and operating costs are reduced.

• Effective monitoring of turbines, blades, and gears require vibration sensors with a frequency range of 10–10,000 Hz.

Power Industry

• The power industry faces challenges due to the continually increasing demand for power and the need to reduce distribution losses. Power generation companies have responded by providing continuous power at low costs and by monitoring their processes for any unwanted changes. Vibration sensors are therefore vital in the power sector. In the energy and power industry, vibration sensors help track rotor imbalances, aerodynamic asymmetry, surface roughness, and overall performance, as well as measuring stress and strain online and offline.

• Vibration sensors are being used also as part of the construction of new wind farms, where the rotor of the blades needs to be monitored for optimum and continuous performance.

• Any bearing that rotates, whether rotary or linear, can be used as a vibration monitoring point.

• Sensor technology has advanced rapidly in recent years. The use of advanced sensors such as wireless sensors, fiber-optic sensors, and micro-electrical mechanical systems (MEMS) sensors is growing continuously around the world. Sensors that can withstand extreme climatic conditions are largely used in monitoring applications. Wireless sensor networks are equipped with a large number of sensors to offer accurate data.