Vibration Condition Monitoring: a key technology for industrial equipment health management

April 01,2025

What is Vibration Condition Monitoring?
Vibration monitoring is a technique that uses velocity sensors to measure and analyze vibration levels to identify equipment defects by detecting changes in amplitude, intensity and frequency. These sensors analyze the data generated by sensing changes in a machine's rotation and magnetic field to detect unusual vibration patterns or frequencies that may indicate potential problems. By continuously monitoring the vibration status of machines, companies are able to optimize equipment performance and extend its useful life.
Simply put, a vibration condition monitoring system is a tool that monitors the health of rotating machinery (e.g., engines, drive shafts, etc.) by measuring its vibration patterns. When the system detects a change in vibration characteristics, it can provide an early warning to operators or maintenance teams, nipping potential failures in the bud.

Importance of vibration monitoring
Identifying problems through vibration data analysis: Analyzing vibration monitoring data can identify specific patterns that may signal equipment problems, helping to provide early intervention before problems worsen and lead to equipment failure.
Detecting specific mechanical defects: This technique is particularly suitable for detecting typical mechanical faults such as poor machine alignment, friction anomalies and bearing wear.
Critical tool for rotating machinery monitoring: In industries that rely on rotating machinery such as engines, gearboxes, motors, bearings and drive shafts, such as marine and oil and gas, vibration monitoring is essential to ensure that equipment operates properly.
At the heart of a predictive maintenance strategy: As a key tool for predictive maintenance, vibration analysis results directly determine maintenance schedules. This proactive maintenance strategy reduces maintenance costs and extends equipment life.

Standard Processes for Industrial Vibration Monitoring
Determine Expected Vibration Characteristics: Establish a vibration characterization model based on equipment design and specifications to provide a baseline for distinguishing between normal and abnormal vibration.
Establish baseline values: Setting a baseline vibration signature is critical to monitoring changes in equipment behavior, helping to identify problems before they lead to equipment failure.
Digitize analog signals: Converting analog vibration signals to a digital format ensures accurate data processing and analysis.
Time-to-frequency analysis: Fast Fourier Transform (FFT) algorithms are applied to convert time-domain signals into frequency-domain signals, identifying characteristic frequencies that correspond to the physical characteristics of the equipment.
Harmonic Frequency Analysis: Analyze the harmonic frequency of integer multiples of the fundamental frequency to obtain the key information about the operation status of the rotating parts of the equipment.
Time-domain waveform analysis: Especially suitable for low-speed application scenarios, providing time-domain characteristics of equipment vibration patterns.
Phase analysis: Determine the position of the vibration source relative to the equipment component, usually used in conjunction with frequency and time domain analysis.
Separation of steady state and transient signals: Distinguishing between the two types of signals helps to identify characteristic patterns in vibration data that reflect potential problems.
Synchronous/asynchronous/sub-synchronous frequency analysis: Accurately locate the root cause of equipment problems by classifying frequency characteristics.
Equipment condition and performance assessment: Prevent equipment failures by quantitatively analyzing and detecting problems such as worn bearings, poor alignment or dynamic unbalance.

Mainstream Vibration Analysis Methods
The most commonly used vibration analysis methods employ a variety of specialized equipment such as data loggers, oscilloscopes and accelerometers. These tools, usually operated by specialized technicians, are used to measure and analyze vibration data from mechanical systems. The information collected is displayed on the specialized equipment and requires professional interpretation by the technician.
Manual monitoring methods have obvious limitations: on the one hand, they require continuous professional attention for data collection and interpretation, which is time-consuming and laborious; on the other hand, they are difficult to provide real-time analysis of vibration data, and the best time to intervene before the problem worsens may be missed.

Conclusion

Vibration condition monitoring, as the core technology of modern industrial equipment health management, not only realizes early failure warning, but also is an important foundation for enterprises to implement predictive maintenance strategies. With the development of the Internet of Things and artificial intelligence technology, vibration

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