Mouser - White Papers

Mouser Electronics White Paper The sensor supports a higher sample rate and extends the measurable vibration spectrum up to 5.3kHz. Its effective monitoring range is approximately 6Hz to 5.3kHz under ideal conditions, although practical performance depends on the frequency maximum (F max ) and filtering settings. This range covers the vast majority of vibration signatures encountered in industrial rotating machinery, from slow-turning gearboxes to high-speed motors. For more specialized analysis, the QM30VT3 features two key enhancements: high-frequency enveloping (HFE) and adjustable F max . HFE is a signal-processing technique used to detect repetitive impact events hidden in a machine's vibration signal. It operates by applying a bandpass filter to isolate high-frequency resonance and performs envelope detection to reveal impact patterns. This mode is useful for detecting early-stage bearing faults. For example, in slow or low- vibration machines, classical vibration metrics like overall RMS may not show a significant change until very late. Enveloping can detect the signatures of a developing fault much earlier. The adjustable F max allows the user to set the maximum frequency range (bandwidth) that the sensor will capture and analyze. A higher F max setting enables the capture of a broader range of frequencies, which is ideal for high-speed machinery with potential high- frequency fault components. A lower F max can increase the frequency resolution in a narrower band, allowing for finer detail around specific frequencies. For example, a user can choose a 1kHz F max for a slow gearbox to obtain very detailed data in a low frequency spectrum, or a 5kHz F max for a fast spindle to capture everything. The ability to adjust F max and use HFE gives maintenance engineers powerful diagnostic options for deeper investigation, without the need to swap hardware. In addition to vibration sensing, the QM30VT3 features an integrated temperature sensor with a detection range of approximately -40°C to +105°C. By capturing both temperature and vibration, the sensor provides a holistic view of asset conditions. For example, a combination of rising vibration and temperature is a strong warning sign of a developing problem. DXMR90-X1 Series Industrial Controller The Banner DXMR90-X1 industrial controller acts as a central hub for a PdM system. It has four separate input ports that operate as independent Modbus client interfaces, allowing it to collect data from multiple sensors. This flexibility addresses the need to minimize new cable runs, allowing for drop-in installation of a local hub to collect nearby sensors. A key feature of the DXMR90 is its support for multiple mainstream industrial Ethernet protocols out of the box. In a brownfield retrofit, this means the PdM system can take vibration and temperature data from the new sensors and feed it directly into the existing control and monitoring system without needing a new software platform. VIBE-IQ Vibration Analysis Software The third pillar of Banner's PdM solutions is the VIBE-IQ vibration analysis software, which is embedded into the sensors and controllers. The software serves as a library of machine learning algorithms and vibration analysis tools for condition monitoring, which transform raw machine data into actionable maintenance information. Initially, the VIBE-IQ software learns the baseline by capturing the typical vibration spectrum and levels for the specific machine under normal conditions. This is important because different machines have different normal vibration fingerprints. Once the baseline is set, the software automatically defines warning and alarm thresholds using a percentage and standard deviation above the baseline noise floor. VIBE-IQ runs continuously in firmware to monitor new machine data against those learned models. It looks for acute anomalies, such as spikes or sudden changes, and chronic trends, like the gradual drift upward of overall vibration over days and weeks. The platform automates time-consuming analysis tasks by performing complex calculations on the time waveform and frequency spectrum. Conclusion Complex and expensive solutions often hinder the adoption of PdM in legacy industrial environments. Banner Engineering's integrated PdM tools, combining QM30VT3 smart sensors, DXMR90 edge controllers, and VIBE-IQ analytics, address key challenges that have historically delayed brownfield deployments. These comprehensive PdM solutions demonstrate that even legacy systems can leverage cutting-edge Industrial IoT (IIoT) sensors and artificial intelligence (AI)-based analytics without massive investments or a complete overhaul. Banner Engineering's PdM tools enable plant managers, reliability engineers, and automation specialists to collaborate in reducing downtime and optimizing asset performance. 1 https://www.plantengineering.com/wp-content/uploads/sites/4/2022/11/Plant- Engineering-2022-Maintenance-Management-Software-Report.pdf 2 https://www.plantengineering.com/2018-maintenance-survey-playing-offense-and- defense/ 3 https://www.mckinsey.com/capabilities/operations/our-insights/digitally-enabled- reliability-beyond-predictive-maintenance#/ 4 https://www.plantengineering.com/an-evolutionary-challenge-faces-the-maintenance- function/

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