ICP DAS’s equipment vibration monitoring and predictive maintenance solution utilizes the AR series accelerometer data logger to record and calculate machine vibration values and set vibration threshold levels. The VPD series HMI retrieves the data via the Modbus TCP communication protocol for real-time display. The data is then transmitted through the ET-7000 series I/O module via Modbus TCP and subsequently forwarded to the existing PLC. If the VPD series HMI detects abnormal vibrations, it triggers the ALM series sound alert module via the ET-7000 series I/O module. This enables early diagnostics and preventive maintenance, effectively reducing the likelihood of unexpected equipment failures.
Introduction:
The customer is a steel plant with a large array of complex equipment used in raw material transportation, steelmaking, and hot and cold rolling processes. During production, if any motor experiences a failure or breakdown, it will halt the entire production line, and the unfinished products must be discarded. This results in reduced overall productivity, increased costs, and potential workplace hazards. To mitigate these risks, the customer aims to proactively monitor bearing vibrations and perform early maintenance on the equipment to minimize losses and ensure the safety of the production line. The following explains how the client uses ICP DAS’s equipment vibration monitoring and predictive maintenance solution to achieve real-time monitoring of process equipment vibrations.
ICP DAS’s Equipment Vibration Monitoring and Predictive Maintenance Solution
Smart Upgrade for Traditional PLCs: Monitoring Equipment Vibration through Current Readings
To identify potential issues early and plan for equipment maintenance or replacement, the customer employs ICP DAS’s iSN-701-F15-L030 IEPE accelerometer and AR-400 accelerometer data logger to measure and store vibration data, calculate vibration features, and set vibration thresholds. The VPD-133-H2 HMI retrieves this data via the Modbus TCP protocol over an Ethernet interface and displays it in real-time. The VPD-133-H2 HMI then transmits the data via Modbus TCP to the ET-7224 Ethernet I/O module. The ET-7224’s digital output (DO) channel triggers the ALM-04-MRTU MP3 alert module, which emits audible alarms during emergencies to notify personnel. Additionally, the analog output (AO) channel of the ET-7224 sends signals to the on-site PLC, enabling real-time monitoring of machine vibration status. The system architecture diagram is shown below:
The iSN-701-F15-L030 IEPE accelerometer is designed for vibration measurement, with a range of ±80g and a frequency response from 0.5Hz to 15kHz.
In this case, the customer installed an iSN-701-F15-L030 IEPE accelerometer at each end of the motor bearing. The collected vibration data is transmitted to the AR-400 accelerometer data logger, where internal calculations are performed to determine whether the motor exhibits any abnormalities.
The AR-400 accelerometer data logger features 1 digital input channel and 4 analog input channels, capable of simultaneously collecting data from up to 4 IEPE accelerometers. Each analog input channel supports a maximum sampling rate of 125 kHz. All captured signals are stored on a 4~32GB Micro SD card for offline vibration analysis. Using the utility software provided by ICP DAS, users can configure various data collection triggers, including push-button, scheduled, threshold-based, digital input, and remote triggers. Additionally, the software allows customization of sampling rates and durations to suit specific needs.
In this case, the AR-400 accelerometer data logger calculates vibration features, such as peak-to-peak acceleration and RMS velocity, and sets vibration thresholds based on the signals collected by the iSN-701-F15-L030 IEPE accelerometer. The VPD-133-H2 HMI then reads the data via the Modbus TCP protocol.
The VPD series Touch HMI Device features a high-resolution color touch screen available in 3.5, 4.3, or 7 inches. It comes with built-in communication interfaces, including RS-232/RS-485 and Ethernet (PoE), and supports standard Modbus TCP/RTU protocols. This allows for seamless integration with various devices.
In this case, the VPD-133-H2 HMI is installed outside the control panel to display the real-time vibration data, including peak-to-peak acceleration and RMS velocity. The VPD-133-H2 HMI uses the threshold values to determine if an alarm should be triggered. If an alarm is needed, the VPD-133-H2 sends a signal to the ET-7224 Ethernet I/O module via the Modbus TCP protocol. The DO channel of the ET-7224 then activates the ALM-04-MRTU MP3 alert module. Additionally, the VPD-133-H2 uses the ET-7224 Ethernet I/O module to output the current values (4~20mA) to the PLC, allowing the PLC to monitor the machine’s vibration status in real-time.
The ET-7224 Ethernet I/O module features 4 analog output channels, 5 digital input/output channels, and 2 Ethernet switch ports, enabling daisy-chain topology configurations. It provides programmable analog output options (+/-5 V, +/-10 V, 0-20 mA, and 4-20 mA), which can be set via jumper settings.
In this case, the ET-7224 Ethernet I/O module receives commands from the VPD-133-H2 HMI via the Modbus TCP protocol and outputs the current values corresponding to vibration values to the PLC through the AO channel. This setup allows the existing PLC program to remain unchanged. Additionally, when vibration values exceed the threshold, the ET-7224 module receives commands from the VPD-133-H2 HMI and triggers the ALM-04-MRTU MP3 alert module through the DO signals.
The ALM-04-MRTU MP3 alert module features 4 isolated digital input channels, 1 relay output channel, 1 MP3 audio line output, and 8 alarm modes. Also, it includes a built-in microSD card for storing pre-recorded audio files.
In this case, the ALM-04-MRTU MP3 alert module receives digital signals from the ET-7224 Ethernet I/O module and emits audible alarms when vibration values are abnormal, alerting management personnel to take action.
Benefits:
The AR-400 accelerometer data logger reads raw vibration signals, calculates vibration features and Fast Fourier Transform (FFT) spectrum values, and then provides this data via the Modbus TCP protocol to controllers and HMIs for integration, alleviating the heavy computational load on these devices.
The VPD series touch HMI device allows for remote monitoring of connected I/O modules and visually displays data on its touchscreen. This feature provides clear, immediate insights into on-site conditions for relevant personnel.
The VPD series touch HMI device features a rubber keypad that allows operators to use it while wearing gloves. Its IP65-rated enclosure ensures stable and reliable operation in harsh environments, such as steel plants.
ICP DAS’s Cloud Data Visualization Solution
In this case, the ICP DAS’s WISE-2241M intelligent IIoT edge controller can be added to perform edge computing, alleviating the workload on the central control system. When used in conjunction with the IoTstar IIoT cloud management software, the WISE-2241M sends data to a database, which is then visualized on a dashboard, achieving effective data visualization.
The WISE series intelligent IIoT edge controllers are extensively used for edge logic control and monitoring across various industrial applications. These controllers offer capabilities such as mathematical computations, scheduling, and sending alert messages via email and platforms like Line/WeChat/SMS. Their built-in IF-THEN-ELSE statement ensures stable and efficient execution of automated tasks.
In this case, the WISE-2241M controller utilizes the IF-THEN-ELSE mechanism for real-time equipment control. When an abnormal vibration value is detected, the controller can immediately activate or deactivate relevant equipment, even if it is not connected to the background monitoring software. It will also send out alarm notifications and transmit on-site data back to the control center via Modbus TCP for centralized management.
The IoTstar is an IIoT cloud management software developed by ICP DAS. It enables remote monitoring and management of ICP DAS’s WISE/PMC/PMD series IoT controllers, along with I/O modules, devices, and equipment connected to these controllers. IoTstar can be installed on private cloud platforms running on the Windows OS, as well as on public cloud platforms such as Microsoft Azure, IBM Bluemix, Google Cloud, or Amazon Web Services. Additionally, IoTstar offers reporting and query services for the values of I/O module channels (or power meters) connected to the WISE/PMC/PMD series controllers. These reports can be exported in PDF or Excel file formats. For more information, please follow the link below:
https://www.icpdas.com/en/product/guide+IIoT+Software+IoTstar__Report__Service
Conclusion:
To detect machine anomalies early and reduce potential high costs, predictive diagnostic technology has gained widespread attention in recent years. Most equipment generates vibrations during operation, making vibration signals a key indicator for predictive diagnostics. By proactively analyzing machine vibration data, early management and maintenance can be carried out, extending the equipment’s lifespan and preventing unexpected shutdowns and damage. ICP DAS offers a vibration monitoring system that allows customers to continuously monitor vibration conditions while retaining their existing equipment structure. This enables on-site personnel to preemptively arrange for material preparation, maintenance, and parts replacement before issues escalate, ensuring production stability and continuity.
ICP DAS is dedicated to providing customers with products that best meet their needs, along with the most professional services. We will continue to develop diverse solutions to address a wide range of requirements in the future.
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