Industrial Applications for Vibration Sensors

Which industries have the most applications for vibration sensors and what are the industrial applications for vibration sensors?

Below is a list of the most common industrial sectors that use vibration sensors to monitor vibration:

1.Aerospace

2.Automotive and Transportation

3.Pulp and Paper

4.Food & Beverage

5. Oil and gas, refining, petrochemicals

6.Power Generation (Fossil Fuel, Nuclear, Hydro, Wind Turbines)

7.Machine Tools

8.Metalworking

9.Mining, Mineral Processing and Cement

Vibration Sensors: The most common industrial applications include rotating equipment such as pumps, motors, fans, compressors, gearboxes, gas turbines, bearings on conveyor systems, wind turbine gearboxes, wind turbine generators, drying sections (pulp and paper), ovens and kilns (minerals processing), and hot rolling mills (metal processing). More and more industries are beginning to realize the importance of vibration condition monitoring of their processes or production plants.

The global automotive industry has witnessed strong growth and profitability in recent years. Increased demand for automobiles has also prompted automakers to effectively monitor the health of their plant machinery to keep production lines in running condition. In addition, condition monitoring has become critical to maintaining product quality and manufacturing process stability. With the help of vibration monitoring equipment and vibration sensors, automotive plant managers can ensure the proper functioning of automated machinery, metalworking equipment and robotics to ensure the smooth flow of different production processes. The water industry now monitors its many water treatment pumps, from those located in remote pumping stations to those at large, complex water treatment and desalination sites.

Food Processing Industry: The need to monitor its many rotating mechanical parts, chips in vibrating conveyor systems, cooling fans, food pumps and mixers can cost thousands of dollars.

Building Services: is another huge area where the performance of motors, pumps and fans is critical in public buildings such as hospitals, airports, train stations, office buildings, hotels and more.

Vibration sensors play a vital role in the oil and gas industry: ensuring that production machinery is up and running and minimizing downtime, thereby reducing operating costs and increasing productivity and monetary gains. These sensors help reduce unplanned downtime and optimize machine performance. This in turn helps reduce maintenance and repair costs. Designed for monitoring applications, vibration sensors are used to monitor motors, critical pumps, fans, gearboxes and compressors in the oil and gas industry.

Chemical plants: the condition of the machines used deteriorates their performance usually related to vibration, misalignment and unbalance of moving parts; and poorly lubricated parts. Early detection of these potential problems can optimize the performance of chemical plants by correcting problems before they affect different processes. Vibration monitoring equipment and tools are used in the chemical industry to detect vibration-related problems. These tools help improve maintenance efficiency, increase profitability, provide safety warnings, and reduce chemical plant operating costs. In a typical chemical processing plant, vibration sensors with frequencies of at least 10-10,000 Hz are required to effectively monitor turbines, blades and gears.

The power industry is facing challenges due to the increasing demand for electricity and the requirement to reduce distribution losses. This has led to power generation companies to provide a continuous supply of electricity at low cost and monitor their processes for any unwanted changes. Hence, vibration sensors play a vital role in the power sector. Vibration sensors help in tracking rotor imbalance, aerodynamic asymmetry, surface roughness and overall performance, as well as performing offline and online measurements of stress and strain in the energy and power industry.

Another popular area for the use of vibration sensors is the latest construction of new wind farms, where the rotors of the blades need to be monitored for optimal and consistent performance.

In fact, wherever you see a bearing spinning, either rotationally or linearly, it could be a vibration monitoring point.

Sensor technology has been evolving rapidly. The use of advanced sensors such as wireless sensors, fiber optic sensors and microelectromechanical systems (MEMS) sensors is increasing globally. Sensors that can withstand extreme weather conditions are mainly used in monitoring applications. Many sensors are installed in wireless sensor networks to provide accurate results.

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