Fromvibration monitoringto Industry 4.0

Systems for condition monitoring of machines

www.ifm.com/gb/octavis

Conditionmonitoring

Vibrationmonitoring

Machine protectionProcess monitoring

System set-upProduct overview

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Systemsfor vibration monitoring –the optimum solutionfor every requirement

Early detection of potential faults andtheir causes on the basis of individualvibration characteristics and otherinfluencing factors.

Monitoring of overall vibration accordingto ISO 10816.Detect resulting damage at an earlystage, avoiding consequential damageand increasing life spans.

Avoid damage to machine components,tools or workpieces via permanent moni-toring and very short response times.The integration into the PLC makes itpossible to adjust the vibration monitoringto the process of the machine or theplant.

The ifm group of companies:our own development and productionwith high quality standard.The detection and integrated evaluationof vibration signals serves as a basis forthe seamless integration of onlinecondition monitoring into manufacturer-independent automation and controlsystems.

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4 - 5

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10 - 12

For industrialapplications

Vibration monitoring –detect damageat an early stage and avoidconsequential costs

Simple:Monitoring of the overall statusof the machine.

Standardised:Compliant to ISO 10816.

Reliable:

Protection against machinedamage.

Flexible:Easy integration in the application.

Reliable:Increase of uptime.

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Looseness, unbalance

Misalignment

Monitor vibration velocity

The vibration sensor VK monitorsonline the overall vibration conditionof machines and plants according toISO 10816. The sensor measures the rmsvibration velocity on a non-rotatingcomponent surface and triggers analarm if the machine vibrations are toostrong.

Detect unbalance and shocks in time.

Machine vibrations can quickly exceeda permissible level due to unbalance,misalignment or bearing damage. Theresult: unexpected failures and shorterlifetime. With the VN sensor vibrationsand shocks are continuously detected,indicated and documented.

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Monitor up to 4 measurement points.

With the sensor type VSA / VSP machinevibrations can also be measured atinaccessible places. Up to 4 measuringpoints can be monitored and docu-mented with the diagnostic electronicstype VSE. The Ethernet and fieldbusinterfaces simplify networking andremote diagnostics.

Why vibration monitoring?

Every machine generates vibrations during

operation. These vibrations can quickly

exceed a permissible level due to e.g.

unbalance, misalignment or resonances.

An increase in the oscillation amplitude

has a negative effect on the machine

condition. The result: unexpected failures

and shorter lifetime.

Solution with efector octavis:

The overall vibration velocity is used in

industry standards to evaluate the status

of the complete machine. ISO 10816 cate-

gorises machines and recommends limit

values for the strain caused by vibrations.

efector octavis monitors if the permissible

degree of machine vibrations is exceeded.

If damage is detected at an early stage,

the affected components can be replaced

and consequential damage can be avoided.

Simple sensor setting:www.ifm.com/gb/setting-guide

Trending of the machine vibrationsto ISO 10816

Time

Vib

rati

on

vel

oci

ty

Alarm

Warning

Acceleration sensors type VSA / VSP

Robust accelera-tion sensors typeVSA or VSP (or intrinsically safeVSP0xA) for con-nection to the VSE diagnosticelectronics.

Intelligentvibration sensorstype VN

4-digit alphanu-meric display withcolour change,integrated historymemory withreal-time clock,analogue andswitching outputor 2 switchingoutputs.

Basic vibrationsensor type VK

Switching outputand transmitterfunction.Response delay toavoid triggering atstartup.

Basic vibrationtransmitter type VT

Simple transmitterfunction, 4...20 mA.

Diagnosticelectronicstype VSE

4-channel diagnos -tic module withadditional processvalue inputs,integrated historymemory, net-working possible.

Condition monitoring –increase availability,reduce maintenance costs,quality assurance

Reliable:Permanent condition monitoringof critical machines.

Anticipate:Machine diagnosis for earlydamage detection and avoidanceof serious consequential damage.

Optimise:Maintenance actions can beplanned.

Long life:Make optimum use of the residuallife of components.

Economical:Make production processestransparent – meet TCO (totalcost of ownership) concepts.

Counter:Counter function for measure-ment of times of exposure andfor production based on key indi-cators.

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Gearbox Meshing,

tooth fault

Pump Eccentricity,

cavitation

Rolling elementbearing

Misalignment

Looseness, unbalance

Machine protection and remotemaintenance.

The monitoring of wind power gearboxes or pumps in the water supplyconcerning wear and stress makes itpossible for the operator to organiseefficient maintenance. Alarm outputsserve to protect the system, to triggerremote maintenance and to facilitatetargeted anlysis.

Vibration diagnosis on a mixing tool.

Unplanned standstills of criticalmachines cause huge cost. Permanentcondition monitoring of the wholeplant makes it possible to act withforesight and to optimise the process.

Intrinsically safeacceleration sensortype VSP0xA

For the measure-ment of vibrationin hazardousareas.Connection tothe VSE diagnosticelectronics installedoutside the ATEXzone via a barrier.

Accelerationsensors typeVSA / VSP

Different types,also for mountingin difficult to accessareas. Variousmeasuring rangeswith voltageoutput (100 mV/g)or current loop(0...10 mA).Connection tothe VSE diagnosticelectronics.

Intelligentvibration sensorstype VN

On board display,history storage fordocumentation, forrotating machines> 120 rpm.

Diagnosticelectronicstype VSE

4-channel diagnos -tic module withadditional processvalue inputs,integrated historymemory, net-working possible.

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ifm systems for condition monitoringof machines:

Systems for measurement of oil qualitycomplete the solutions for onlinecondition monitoring.ifm also offers software tools forconfiguration, visualisation and datarecording.

More information about systems forcondition monitoring of machines:www.ifm.com/gb/condition-monitoring

Why condition monitoring?

Condition monitoring enables early

detection of arising machine damage.

So, maintenance can be planned and the

residual life of important components

can be used accordingly.

Vibrations that influence quality can be

detected automatically in order to avoid

reject parts.

Counters can be used to determine produc-

tion variables (operating hours, production

hours, good/bad parts, reject rate,...) and

factors influencing the components’ life-

time (shock, time of exposure to increased

amplitudes, temperature, power, rotational

speed,...).

Solution with efector octavis.

efector octavis is a vibration monitoring

solution which not only detects vibration

data, but also carries out signal analysis

and machine diagnosis directly on the

machine.

The machine condition is determined

locally and transferred to the controller /

process control level via alarms or as con-

dition values. In addition, the unit features

an onboard memory to store the trend

history of all diagnostic characteristics.

Condition monitoringTime

Pro

bab

ility

of

failu

re

Machine protection andprocess monitoring –reduce rejects andconsequential damage

Dynamic:Monitoring of dynamic forces,e.g. in milling processes.

Fast:Response times of 1 ms.

Reliable:Machine, tools and workpiecesare protected against expensiveconsequential damage.

Preventive:Early condition monitoring avoidsunplanned failures.

Integrated:Direct connection to the machinecontrol via a fieldbus interface.

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Workpiece protection

Tool protection

Protection of machine

components

Detect unusual vibrations.

The micromechanical accelerationsensor type VSA is screwed into thehousing of the spindle and detectseven the most subtle changes of thevibration behaviour. The sensor with-stands even fast movements and highforces without problems.

T3

T2

T1Photo source: DMG / MORI SEIKIwww.dmgmoriseiki.com

Diagnosticelectronicstype VSE150

Frequency-selective monito-ring, historymemory with realtime clock, counterfunction, networkcapability TCP/IP,PROFINET/IOinterface.

Diagnosticelectronics typeVSE002 / VSE100

Frequency-selective monito-ring, historymemory with real-time clock, counterfunction, networkcapability TCP/IP.

Accelerationsensors type VSA

Trouble-freeoperation in theevent of fastmovement orinfluence of highforces. Integratedself-test for per-manent safety.

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Avoid consequential damageto machine tools.

Changes in the cutting forces such ascaused by blunt drilling machines orswarf jam are detected on the basis ofthe changed vibration characteristics.Each tool can be assigned individualtolerance limits e.g. a warning andswitch-off threshold. Damage to theworkpiece is reliably prevented.

Alarm

Warning

Why machine protection and

process monitoring?

Faulty settings and process parameters or

wrong tools can lead to crash situations

between components and tool spindle, to

high strain of the spindle (increased wear)

or to bad quality. This results in high

consequential costs, a shortened lifetime

and rejects.

Solution with efector octavis:

The permanent measurement and evalua-

tion of different vibration characteristics

enables ideal monitoring and diagnostics

of the tool spindle.

Based on the dynamic increase in power,

crash situations are detected in time and

displayed. The switching output can react

to the crash within a millisecond in order

to minimise or even avoid consequential

damage.

The integration of the vibration monitoring

into the machine control via the fieldbus

interface enables an ideal adjustment of

the evaluation (adjustment of the alarm

thresholds, suppression of characteristic

values that cannot be evaluated during

processing, e.g. spindle bearing) to the

current operating status of the machine.

Machine protection:spindle collision detectable in 1 ms

Time

Dyn

amic

fo

rces

Warning

Alarm

Crash curvewithout alarm

Trending in a stamping processTime

Alarm

1 ms

Alarm

Warning

Process cycle

Adaptive limit value consideration

Vibration sensors and transmitters forpermanent monitoring of the overallvibration condition of machines and plantsto ISO 10816. The sensors measure therms vibration velocity on a non-rotatingcomponent surface.

BasicVibration sensorsand transmitters

The compact vibration sensor type VNmonitors the overall vibration conditionof machines and plants to ISO 10816.It is characterised by easy parametersetting and a local display.Configuration software is not a necessity.

Intelligentvibration sensors

6-channel diagnostic system for theevaluation of dynamic signals (e.g.acceleration) 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.

Diagnosticelectronics

Acceleration sensors measure the dynamicforces at the machine surface and deliverthe raw signal for a downstream vibrationmonitoring or vibration diagnostics e.g.in the diagnostic electronics type VSE.

Accelerationsensors

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

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Systems forvibration monitoring –suitable productsfor all applications

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.

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For industrialapplications

VT

VN

VSAVSP

VK

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

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Systems forvibration monitoring –the choice is yours

Basic vibration sensor and transmitterDescription 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

VKV021VKV022

Intelligent vibration sensorsDescription 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

Diagnostic electronicsDescription 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/outputs / PROFINET/IO interface

VSE002VSE100VSE150

Acceleration sensorsDescription 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 VSP001

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

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

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