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Vibration Sensor Module
Overview
Provides 3-axis vibration analysis with FFT processing and RMS metrics for rotating equipment health monitoring and predictive maintenance. The module captures high-resolution acceleration data across three orthogonal axes, enabling detection of faults such as imbalance, misalignment, looseness, and bearing wear. On-board digital signal processing reduces data bandwidth while preserving the diagnostic information needed for condition-based maintenance strategies.
Features
- High-precision 3-axis accelerometer -- Industrial-grade MEMS sensor with low noise density for accurate vibration capture across a wide frequency range.
- FFT spectra, RMS, crest factor, kurtosis -- Multiple statistical and spectral metrics computed on-device, providing a comprehensive vibration signature for fault classification.
- 1-3 kHz ODR windows for diagnostics -- Selectable output data rate windows allow targeted analysis of specific frequency bands relevant to bearings, gears, or structural resonances.
- On-device DSP to reduce bandwidth -- Local processing extracts key features before transmission, minimizing RS-485 bus traffic and Edge CPU load.
Key Specifications
| Parameter | Value |
|---|---|
| Axes | 3 (X, Y, Z) |
| Measurement range | +/-16 g (selectable) |
| Frequency range | 1 Hz - 3 kHz |
| FFT resolution | Up to 2048 bins |
| Noise density | < 80 ug/sqrt(Hz) |
| Output data rate | 1 kHz / 3 kHz selectable |
| Interface | RS-485 (Modbus RTU) |
| Supply voltage | 5 V (from Edge backplane) |
Applications
- Motor bearing monitoring -- Detect early-stage bearing defects such as inner race, outer race, and rolling element faults through envelope analysis and characteristic frequency tracking.
- Gear mesh and imbalance detection -- Identify gear tooth wear, misalignment, and rotor imbalance by monitoring gear mesh frequencies and 1x/2x running speed harmonics.
- Pump cavitation and structural resonance -- Recognize cavitation signatures in pumps and detect structural resonance conditions that may lead to fatigue failures.
Edge Integration
Streams processed metrics and raw spectra to the Edge over RS-485 using Modbus RTU. Sampling windows, FFT resolution, and alarm thresholds are fully configurable through the Edge web UI. The module supports auto-discovery on the sensor bus, enabling plug-and-play deployment without manual address configuration.