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Acoustic Sensor Module
Overview
Combines audible and ultrasonic sensing for leak detection, tool wear monitoring, and quality control. The module pairs a digital MEMS microphone covering the audible range with an ultrasonic transducer for high-frequency emission detection, enabling identification of phenomena invisible to standard audio analysis. Integrated DSP performs real-time spectral analysis and pattern recognition directly on the sensor board.
Features
- Digital MEMS microphone (audible) -- Captures sound from 20 Hz to 20 kHz with a high signal-to-noise ratio, suitable for detecting mechanical noise anomalies in industrial equipment.
- Ultrasonic transducer (ultrasound) -- Extends sensing to 20-100 kHz for detecting compressed air leaks, electrical discharge, and high-frequency friction signatures.
- Real-time DSP and pattern recognition -- On-board processing computes FFT spectra, band energy levels, and learned acoustic fingerprints, reducing raw data volume before transmission.
Key Specifications
| Parameter | Value |
|---|---|
| Audible range | 20 Hz - 20 kHz |
| Ultrasonic range | 20 kHz - 100 kHz |
| MEMS SNR | > 65 dB(A) |
| ADC resolution | 24-bit |
| FFT window | Up to 1024 bins |
| Pattern memory | 8 stored fingerprints |
| Interface | RS-485 (Modbus RTU) |
| Supply voltage | 5 V (from Edge backplane) |
Applications
- Pneumatic leak detection -- Identify compressed air and gas leaks by detecting the characteristic ultrasonic emissions produced by turbulent flow through small orifices.
- Tool wear and lubrication assessment -- Monitor changes in cutting tool acoustic emissions to predict tool end-of-life and detect insufficient lubrication in machining processes.
- Gear mesh and bearing diagnostics -- Capture audible noise signatures associated with gear tooth wear, bearing defects, and mechanical looseness for early fault detection.
Edge Integration
Provides spectral data and diagnostic parameters to the Edge over RS-485 using Modbus RTU. Frequency bands, sensitivity thresholds, and pattern-matching profiles are configurable through the Edge web UI. The module is auto-discovered on the sensor bus during startup.