In industrial applications, the abnormal vibration of equipment is the main symptom of machine failures. Therefore, how to detect the abnormal vibration of the machine at the earliest possible time becomes the key to master the state of the equipment in advance and thus carry out predictive maintenance. In this paper, we will introduce how the ADcmXL3021 vibration detection system launched by ADI monitors the state of the equipment.
Condition-based monitoring reduces maintenance costs
In industrial applications, preventive or corrective maintenance has traditionally been used, which typically takes up a significant portion of production costs. Now, the use of IIoT (Industrial Internet of Things) in monitoring the health status of machines can help achieve predictive maintenance and allow industry personnel to predict failures, thus greatly saving operating costs.
Universal digitization and connectivity of industrial equipment will achieve the goal of Industry 4.0, revolutionizing production tools, increasing the flexibility of the production chain, and supporting the manufacture of customized products while maintaining profitability. Digitization and IIoT connections will also bring great benefits for maintenance.
In order to monitor the operation of the equipment, it is necessary to use sensors (especially to use accelerometers) to sense the equipment, so that the operating state of the machine can be analyzed without replacing worn parts at fixed intervals. Operator intervention is required only when certain early warning symptoms occur. This analysis of machine health status, known as condition-based monitoring (CbM), can control maintenance costs compared with the systematic maintenance relying on a usually very conservative fixed schedule. In addition to a more flexible maintenance and operation plan, it can also detect problems in the early stages, allowing operators to schedule machine downtime accordingly, which will clearly bring about more benefits than an unexpected shutdown of the production line.
To assist in the monitoring of machine condition, ADI has introduced the ADcmXL3021 to implement the triaxial measurement solution. As a complete vibration sensing system, ADcmXL3021 combines high-performance vibration sensing, the use of micro-electromechanical system (MEMS) accelerometer and various signal processing functions to simplify the development of smart sensor nodes in the condition-based monitoring (CbM) system and track vibration signals on many machine platforms.
ADcmXL3021 is a triaxial digital output MEMS vibration sensing module, with a measurement range of ±50 g and ultra-low noise density of 26 μg/√Hz (MTC mode) and wide bandwidth of DC to 10 kHz (within 3 dB flatness, RTS mode), supporting embedded fast data sampling up to 220 kSPS per axis. The module has 6 digital FIR filters and 32 taps (coefficients), and by default, it is provided with high-pass filters with cut-off frequencies of 1 kHz, 5 kHz and 10 kHz, and low-pass filters with cut-off frequencies of 1 kHz, 5 kHz and 10 kHz.Users can configure digital filter options (32 coefficients) and carry out spectral analysis through internal FFT to extend the record length to 2048 bins per axis. This module provides a user-configurable bin size from 0.42 Hz to 53.7 Hz and can be triggered manually or automatically based on a timer. Window options include rectangular, Hanning and flat top, FFT records the calculation of average values, up to 255 records can be configured, and the alarm monitoring is defined by spectral, up to 6 alarms per axis.
ADcmXL3021 is provided with time-domain capture of statistical metrics, with extended record length of 4096 samples per axis, and supports mean, standard deviation, peak, crest factor, skewness and kurtosis.Alarm monitoring can be configured, real-time data streaming can reach 220 kSPS per axis, burst mode communication can be conducted, CRC-16 error checking is supported, and 10 sets of data records can be stored for each axis. This module can realize self-test on demand, and support status flags and sleep mode, with external and timer driven wake-up function, digital temperature and power supply measurement, SPI-compatible serial interface and identification register, including factory pre-programmed serial number, device ID and user programmable ID. It is powered by a single power supply from 3.0 V to 3.6 V, its operating temperature ranges from -40℃ to +105℃ and it will automatically shutdown at 125℃ (junction temperature). It comes in 23.7 mm × 27.0 mm × 12.4 mm aluminum packaging with four mounting flanges that can be installed with standard machine screws, which can achieve consistent mechanical coupling to the core sensor over a wide frequency range.
The built-in 36 mm flexible cable with14-pin connector interface supports a variety of location and orientation options for system mating connectors, with a mass of only 13 g, rendering it possible to be used for vibration analysis, CBM system, machine health, instrumentation and diagnosis, safety shutoff sensing and other fields.
To speed up the development of customers, ADI has also introduced the evaluation kit EVAL-ADCM, a simple to use kit that can quickly evaluate the performance of triaxial digital output MEMS vibration sensing module of ADI.
The ADcmXL3021 module consists of three single axis, ultra-low noise and high bandwidth ADXL1002 accelerometers, a fully implemented signal chain and MCU with configurable digital FIR filters, spectral analysis via internal FFT, configurable alarm monitoring, and time domain capture and statistical analysis. EVAL-ADCM is ideal for evaluating the ADcmXL3021 vibration sensing module, as the kit can easily provide a full spectrum of experience with all of the features of the module. The EVAL-ADCM kit includes an ADcmXL3021 module that can be easily connected to a PC for complete features evaluation, while the evaluation software can easily configure modules, register settings, data display and data logging, and connect SPI to a USB adapter at high speed for real-time streaming (RTS) of high data rate.
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