Monitoring & metering
NEW EDGE SENSING SOLUTION FOR INDUSTRIAL ASSET HEALTH
By Shuai Ren, software systems applications engineer, Analog Devices and Tomasz Potaczała, technical director, AMC TECH I
This article presents an in-depth exploration of a cutting-edge smart vibration sensor, emphasising its design, functionality, and applications, all rooted in microelectromechanical system (MEMS) technology. The core objective of this sensor is to provide high precision, reliability, and real-time monitoring capabilities in various industrial and research environments, showcasing the application of ADI’s different MEMS sensing technology.
n modern industrial environments, the need for precise, reliable, and real-time monitoring of machinery health is more crucial than ever. Condition-based monitoring (CbM) systems have become a cornerstone in predictive maintenance strategies, aiming to minimise downtime, enhance productivity, and reduce maintenance costs. Cutting-edge sensors utilising microelectromechanical systems (MEMS) technology, along with sophisticated diagnostic algorithms, are broadening the scope for assessing different types of machinery. MEMS accelerometer performance has recently advanced to the point where it can now compete with the piezo vibration sensor. Having key advantages such as lower power consumption, smaller size, higher levels of integration coupled with wide bandwidths, and noise levels below 100µg/√Hz means these MEMS vibration sensors have opened an entire new CbM paradigm for maintenance and facility engineers to detect, diagnose, predict, and ultimately avoid faults in their machines. Due to the ultralow power consumption of MEMS accelerometers, wired systems can now be replaced with wireless solutions, single-axis piezo sensors can be replaced with small, lightweight triaxial analogue components, and a wider range of machines can now be monitored continuously in a cost-effective way. This article discusses the latest advancements in MEMS-based vibration sensors, specifically the AVS 1001HF (high frequency) and AVS 1003LF (low frequency) accelerometers, which represent the forefront of this technology.
CONDITION-BASED MONITORING Condition-based monitoring sensors (CMS) for robotics and rotating machines such as turbines, fans, pumps, and motors record real- time data related to the health and performance of the machine. This enables targeted predictive maintenance and optimised control. Early in the machine lifecycle, targeted predictive maintenance reduces the risk of production downtime, resulting in increased reliability, significant cost savings, and enhanced productivity on the factory floor. For those companies that have experienced unplanned downtime, outages lasted an average of four hours and cost an average of $2 million, based on an average of two downtime events.
52 IMPORTANCE OF CBM
The primary function of CbM is to provide real- time data that informs the maintenance schedule of machinery. This data-driven approach allows maintenance to be performed only when necessary, preventing unexpected failures and extending the operational life of the equipment. By reducing unplanned downtimes, CbM systems help maintain continuous production flows and optimise resource allocation.
WHAT IS THIS SOLUTION? The accelerometers represent significant advancements in the field of industrial asset health monitoring. The core objective of this sensor is to provide high precision, reliability, and real-time monitoring capabilities in various industrial and research environments, showcasing the application of ADI’s different MEMS sensing technology. By integrating high frequency and low frequency vibration measurement capabilities with real-time data processing and transmission, these sensors provide a comprehensive solution for predictive maintenance. Their ease of integration, versatility, and high precision make them invaluable tools for enhancing productivity, reducing downtime, and optimising maintenance strategies in industrial environments. By redefining condition monitoring, the AVS sensor family not only improves the operational efficiency of machinery but also sets a new standard for industrial asset health management. As industries continue to adopt smart technologies, advanced sensors like the AVS series will become increasingly pivotal in driving the next generation of industrial automation and maintenance forward.
WHAT IS THE BENEFIT OF THIS SOLUTION?
A key benefit of this new AVS sensor family is the redefinition of condition monitoring. A typical CbM requires sensors, extensive cabling, and a dedicated data acquisition/processing unit. With smart AVS sensors, all these functions are now performed within the sensor itself. Analysis results can be sent directly to a programmable logic controller (PLC) or supervisory control and data acquisition (SCADA). With the use of digital RS-485 links, many sensors can be connected with a single cable.
Another important advantage is the versatility of AVS sensor applications. During normal operation,
Figure 1. The AVS 1001HF sensor
only calculated parameters can be sent. When there is a need for a more advanced analysis, a raw vibration signal can be sent and analysed.
AVS 1001HF AND AVS 1003LF SENSORS AVS 1001HF Sensor
The AVS 1001HF is a uniaxial, digital, high frequency accelerometer that, in addition to vibrations, measures temperature. It processes the vibration acceleration signal, making data available via a digital connector in the industrial standard RS-485 and the Modbus protocol. The sensor can provide two types of data: a stream of raw vibration data or determined parameters of the vibration signal (see Figure 1).
November 2025 Instrumentation Monthly
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