Piezoelectric Acceleration Sensors: “Silent Sentinels” for Motor Bearing Health Monitoring

Piezoelectric Acceleration Sensors: “Silent Sentinels” for Motor Bearing Health Monitoring

In thermal power plants, chemical plants, iron and steel mills and other industrial scenarios, large fans are like the “lungs” of industrial production, continuously delivering power to the system. Motor bearings as the core transmission components of the fan, its micron-level vibration deviation may trigger a domino effect - light lead to a decline in energy efficiency, or cause damage to the entire machine. How to accurately capture the subtle vibration signals of bearings? Piezoelectric acceleration sensors are opening a new chapter in the Industry 4.0 era with millimeter-wave radar-like sensitivity for dynamic balance testing of bearings.

1.Precise capture of imbalance signals: the core advantage of piezoelectric technology

Piezoelectric acceleration sensor based on the piezoelectric effect, can be bearing vibration generated by the mechanical energy directly into an electrical signal, to achieve real-time monitoring of micron-level vibration magnitude, especially good at capturing the following key imbalance characteristics:

1,uneven mass distribution: centrifugal force fluctuations due to mounting deviations or bearing wear;

2,Resonance hazard: resonance frequency shift of bearings and structural components at specific rotational speeds;

3,early fatigue cracks: metal fatigue-induced micro-amplitude high-frequency vibration signals. Technical highlights: Wide frequency response (0.5Hz~15kHz): covering the full working condition monitoring from low-speed rotation to high-speed vibration of motor bearings; IP68 protection level: fearless of wind, sand, rain, salt spray and other harsh environments;

2.From monitoring to decision-making: a closed-loop solution for dynamic balance testing

1,Data collection: multi-dimensional deployment, accurate positioning

Deploying sensor networks in key locations such as the main shaft of the wind turbine and gearbox bearings can build a “three-dimensional portrait” of the running state of the bearings through the three-axis vibration data (X/Y/Z direction), and accurately identify the phase and amplitude of the imbalance.

2,Intelligent diagnosis: algorithm empowerment, risk prediction combined with AI algorithms, automatically separating environmental noise and fault signals, and generating vibration trend reports.

3.The Leap from “Reactive Repair” to “Predictive Maintenance”

A petrochemical company's oil transfer pumps frequently triggered downtime due to dynamic bearing imbalance, with annual losses exceeding 5 million RMB.

Solution: Deploy piezoelectric acceleration sensors + edge computing platform to realize real-time transmission and cloud analysis of vibration data.

Comparison of results: Fault warning accuracy increased to 95%, unplanned downtime reduced by 80%, energy consumption reduced by 10%, annual savings of more than 800,000 yuan in electricity costs;

Sensor return on investment cycle of only 4 months, was certified by the Ministry of Industry and Information Technology, “Intelligent Manufacturing Demonstration Project”.

Product Overview

A26D100 is a piezoelectric single-axis acceleration sensor, utilizing the positive piezoelectric effect of piezoelectric materials, with an internal IEPE isolated two-core low-resistance voltage output, isolated floating, industrial field monitoring, and strong anti-interference performance.

Performance Parameters

Temperature Curve

Typical Impact Curve

Activate the vitality of industrial monitoring with “intelligent” escort

Driven by the goals of Industry 4.0 and “Double Carbon”, piezoelectric acceleration sensors promote the transformation of equipment from “post-failure repair” to “predictive maintenance” with lower cost and higher reliability. The transition from “post-failure maintenance” to “predictive maintenance” is facilitated by lower cost and higher reliability, enabling every pump to operate stably under complex working conditions and injecting lasting vitality into the industrial bloodstream.

Yangzhou Xiyuan Electronic Technology Co.,Ltd.

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