Thought Leadership Article

The Wearable for Machine

Health: Condition-Based
Monitoring
Stuart Servis, Senior Applications Engineer

Condition-based monitoring (CbM) is the Industry 4.0 equivalent of wearable The combined need for earlier and earlier indication of machine wear-out
fitness devices. With the explosion of connectivity comes the opportunity to and information about machine output quality drives the need for more
observe the physical world like never before and to see physical processes in sensitive and more ubiquitous sensing. Measurement types are also
action, in real time, in fine detail. In industrial systems, one of the processes broadening, with sensing modalities such as temperature and vibration
important for us to understand is the process of the aging of equipment and being supplemented with acoustic, motor current, and voltage measure-
machines. This is important in diverse markets from oil and gas, wind power ments. These measurement systems are being combined to give a more
generation, and industrial process control, where capital equipment costs are holistic view of the state of equipment. This leads to increasing numbers
high, and downtime is costly. of measurement channels per machine. The individual measurements often
need to be well synchronized to show relationships, such as between x-, y-,
Unplanned downtime can cost thousands of dollars per hour. One study and z-axis measurements of vibration. This need for synchronization further
in 2017 found that companies reported an average cost of $2 million due increases the complexity of systems.
to downtime alone, and unplanned downtime is significantly more costly
than planned maintenance because a machine must be offline while it’s The increasing spread of measurement nodes and modalities means that
diagnosed, parts are ordered, and repairs are made. manual inspection and measurement routines, based on manual resources,
are no longer able to keep up. Systems must be deployable across the
The continued operation of machines within specification, and the expected factory floor or remote site, with connectivity using existing wired infra-
remaining lifetime of machines, is impacted by variables such as the time in structure or wirelessly using robust and secure wireless systems. Bulky and
operation, varying loads and operating environments, and damaging events. expensive sensors and aggregator units must be smaller, cheaper, and more
Condition-based monitoring seeks to quantify these impacts, provide alerts power efficient to fit in these environments.
when immediate attention is required, and accurately predict when inter- There are new, precise solutions at the component and subsystem level
vention will be required. with higher levels of integration to allow system builders to make this
Every machine is different, and every machine will age in a different way, increased sensing future a reality now.
although the aging process is usually slow and imperceptible. Unless we
actively look for indications of subtle changes over time, aging may go Data Acquisition
unnoticed for some time. Then suddenly there’s a failure, possibly cata- To achieve the earliest possible indication of machine wear-out, you almost
strophic, that means that the machine is offline and in need of repair. End need to see into the future. In the realm of condition monitoring analytics,
users are demanding earlier notice of impending failure to plan for down- this is achieved by looking for the minutest changes in the system, whether
time well in advance. They are also looking for indicators of more subtle it be system temperature, vibration, or acoustic signature. To sense these
changes in the machines that may affect the quality of their end product, small changes requires sensors and data acquisition systems that can see
such as paper and sheet metal. the small changes clearly at the lowest detection levels, even amongst
high levels of vibration or temperature. This requires signal chains with
extremely high dynamic range, meaning systems with extremely low noise
performance while still being able to deal with large variations in signal
level. For example, to detect the onset of wear-out in a reciprocating pump
may require the detection of a change in less than 1/10th of a mm of the
end stroke position of the piston, where the piston is moving up to 300 mm
overall. To ensure that we can see this change, the system noise must be be-
low this by at least a factor of 10. This pushes the detection level to 1:300,000,
or 109 dB, and requires 18-bit or more accurate data acquisition systems.
Another consideration is the need to push out of the bandwidth of inter-
est. Motor axles and many gear systems have characteristic vibrations at
relatively low frequencies, with frequencies at close to the rotation speed
of the axle or low multiples of this. However, there are other components
in the systems that have higher frequency features. To detect shifts in the
wear of components that have higher frequency characteristics, such as ball
and oil bearings, the sensing must be able to achieve high resolution and
Figure 1. Manual inspection of equipment using piezo sensors and a handheld logger. high dynamic range at frequencies beyond 10 kHz and up to 80 kHz.

// // // // // Visit analog.com
 25 These μModule devices combine key components commonly used in data
acquisition signal chain designs within a compact, integrated circuit (IC)-like
Rotational/Natural form factor.
20 Frequency
1×
The μModule approach transfers the design burden of analog and mixed-
Vibration Amplitude (mg)

signal component selection, optimization, and layout from designer to

15
device, which shortens the overall design time and system troubleshooting,
2× Harmonics as well as ultimately improves time to market. Housed in tiny packages,
10 4× μModule devices are well suited to distributed low channel count, compact
CbM systems or for higher channel count rack-based systems.
3× 5×
5 Wideband
Content

0
0 1 2 3 4 5 6 7 8 9 10
Frequency (kHz)

Figure 2. Typical vibration frequency signature.

The sensing system specifications must include high dynamic range (DR), as
well as extremely low total harmonic distortion (THD) in order to resolve these
frequency domain features in the system vibration profile. In these systems,
the latest precision wide bandwidth sigma-delta (Σ-Δ) converters are used
to perform the analog-to-digital conversion step. There are extremely accurate
analog-to-digital converters that meet the key requirements for these
systems. Converters in this category are specified with superior dynamic Figure 3. 3D render of µModule assembly.
range and THD (typically +108 dB DR and −120 dB THD), which is achieved
across a bandwidth of dc to at least 80 kHz, combined with ease-of-use Sensors
features such as analog input precharge buffers, integrated digital filters,
Providing high dynamic range, wider bandwidths, greater power efficiency,
and cross-device synchronization for multichannel phase matching, make
and higher channel densities in the data acquisition part of the signal chain
these key components in the building of the highest performance CbM
alone only addresses part of the system design challenge for CbM systems.
data acquisition systems. Power scaling features allow the same physical
Traditional integrated electronics piezoelectric (IEPE) vibration sensors are
hardware to be tuned to meet specific power ceilings, where dynamic range
large, bulky, and expensive, and are usually run off relatively much higher
or bandwidth can be traded-off against total power. And providing accuracy
voltage rails than the data acquisition system. Common piezoelectric sen-
at dc as well as wider bandwidth allows the input channels to address the
sors use a −24 V single supply, consuming upward of 2 mA, and are housed
needs of temperature, strain, and other dc or low bandwidth sensing in the
in heavy metal cases. Because the sensor supplies are usually provided by the
same platform, which simplifies the overall condition monitoring system
data acquisition module, increasing the channel density in the box becomes
architecture and complexity—a single platform for all CbM sensor types.
a power density problem and a component density problem. Adding to this
the need for wireless battery-powered acquisition nodes, the traditional piezo
Simultaneous Sampling
vibration sensor no longer meets the demands of these signal chains.
In CbM systems, simultaneous sampling is used to ensure the phase
relationships between sets of time domain data is preserved. For example, MEMS vibration and inertial sensors are now meeting the requirements
where two orthogonally arranged vibration sensors are used, this allows the of these systems. The latest wide bandwidth MEMS devices have noise
direction and amplitude of the vibration phasors to be detected. Ideally the and bandwidth performance that is ideal for CbM applications, and they
phase delays through each sensor input path should be well matched and achieve this performance in tiny standard surface-mount packages with
track over temperature. power levels that are 20 times lower than comparable IEPE sensors. The
small size and power profile of these MEMS sensors allow very small
For CbM systems that require even more flexibility in their design for wider multiaxis, battery-powered systems to be developed for permanent and
range in their sampling rate, bandwidth, or power scaling needs, SAR ADC constant condition monitoring.
products are also appropriate. These devices also offer high dynamic range
and THD, and at throughputs up to 2 MSPS, and also incorporate ease of Power and Connectivity
use features that reduce signal chain power consumption, reduce signal
Sensing the temperature, vibration, or noise of the machine and converting
chain complexity, and enable higher channel density. Converters with higher
this to digital information is a key part of the monitoring task, but these
input impedance modes broaden the range of low power precision amplifiers
details do not provide the complete picture. To build condition monitoring
that can drive these ADCs directly, while still achieving optimum performance.
systems requires paying close attention to all of the analog, digital, and
To allow system builders to achieve the highest possible channel densities mixedsignal components in the design. To achieve low noise in the data
in more compact or distributed acquisition nodes, and to achieve faster time acquisition chain requires not only low noise sensors and analog-to-digital
to market, signal chain μModule® products with higher levels of integration conversion components, but also low noise power design. And achieving
than ever before are being developed. low power in the system also requires power components that efficiently
take power from the battery or field wiring without adding to the complexity
of the design.

2 // The Wearable for Machine Health: Condition-Based Monitoring

Connectivity needs will depend on the specific application environment. equipment can be retasked for different combinations of sensors. In smaller
Many industrial facilities already have extensive wiring in place for process equipment, the systems will need to be adaptable to different power pro-
control or existing environmental sensing, such as temperature. However, files so that the same monitoring node can be used in a washing machine or
much of this existing infrastructure may not be able to deal with the large a battery-powered tool.
amounts of raw data, or the data rates, required for extensive condition-
based monitoring. Conclusion
One approach is to enhance the capabilities of existing wiring by add- Condition-based monitoring seeks to quantify the state of health of machines
ing more data in ways that it does not affect the existing functions. For by sensing various measurable parameters within the machines. Increasing
example, HART® technology is used to add diagnostic information in digital the accuracy and sensitivity of these measurements, as well as reducing
form on top of the ubiquitous 4 mA to 20 mA analog interface. Similarly, the size, weight, and power of the monitoring equipment, allow the factory
Industrial Ethernet adds determinism and real-time control where existing manager to deploy this sensing across the factory floor.
Ethernet cabling exists, which allows for known latency in control applica- The factory now has a health monitor—a fitness tracker—that gives new
tions as well as higher bandwidth where vibration or FFT data is required, levels of insight into the factory operations. Factory managers can be advised
as well as allowing multiple nodes on each link. of minute changes in machine operation to make early and informed deci-
Another approach is to transfer the information wirelessly. In industrial sions with this information.
environments, robust and secure wireless networking is required. The Scheduling maintenance in advance, and only planning it for those machines
latest intelligent mesh radio products are wireless chips, and precertified that really need it, can significantly reduce maintenance costs. After-hours
PCB modules, which enable low power communication and >99.999% call-out and on-call technician costs can be reduced to zero.
data reliability even in harsh, dynamically changing RF environments. For
condition-based monitoring, this means that fault or transient events are Capital equipment costs can be reduced due to the more controlled nature
guaranteed to be communicated to the host and can be acted on in the of the factory. Earlier detection and replacement of worn components
shortest possible time. protects the overall health of the machines. Closer monitoring reduces the
occurrence of catastrophic failures. Equipment lifespans can be extended as
Power the machines are carefully managed to end of life.
The cost of production of the factory end product can be reduced. With
Reference
insight into machine health comes the possibility of maintaining control of
the tolerances on the machines. End product output quality is more con-
Sensor Amp ADC Processor
Communication sistent from lot to lot. The occurrence of machine out-of-bound, or sudden
Interface
LPF stoppage, is reduced. Therefore, product rework and wastage are reduced.
Figure 4. Block diagram showing sub-blocks of a typical precision data acquisition
signal chain.
How Analog Devices Helps Solve This Problem
Analog Devices, Inc. (ADI) understands the sensing and measurement needs
The Future of CbM of end customers who want to maximize the efficiency and lifetime of their
installed equipment, or who provide these measurement and analytics solu-
Condition-based monitoring is an absolute need for large capital cost
tions to their end users.
equipment such as for energy and oil and gas, where unplanned downtime
has a direct impact on production costs. It is also becoming more and more The sensing and measurement tasks required by CbM can be solved with
important on the factory floor where it can be used as both a proactive the combined technology offering available from ADI, at the component
approach to machine maintenance, but also a way to ensure machines are level, as most customers are familiar with, but also now at higher levels
producing product in a consistent way in normal operation. As the value of integration with signal chain μModule devices and power μModule
of these monitoring capabilities becomes more apparent, this technology products, which allow faster time to prototype or design a viable product for
will start to be applied across more and more of the machines that we use our customers’ products.
every day—no longer the preserve of wind turbines or paper mills, we will
see CbM in trains, planes, and automobiles, and eventually in washing ADI can provide the full signal chain, from low power MEMS sensors, high
machines and even smaller appliances. performance and power efficient data converters, to wireless connectiv-
ity and power management solutions. ADI technology continues to offer
Manufacturers of system components will integrate the sensor, or even the best performance options for central rack-based systems, as well as
the whole channel, into the component. Motors will come with vibration addressing the needs of distributed monitoring nodes. The analog world is
and current sensing included, and the same may become true for bearings where data is born, and Analog Devices has always been at the forefront
and gearboxes. There will be self-contained sensor nodes that will report of making sense of that world to convert it into real information that is
to your mobile device—deploy one on your garage door so it can warn meaningful and useful.
you before your car gets stuck inside!
For more information on condition-based monitoring solutions from
To meet the growing need for sensing in these many different scenarios, Analog Devices, please visit analog.com/cbm.
equipment makers will need to take a platform approach, where a smaller
set of platforms can serve a more varied set of needs. Measurement For more details, see the article “Choose the Right Accelerometer for
channels will need to handle different sensor types so that rack-based Predictive Maintenance.”

Visit analog.com // 3
 About the Author
Stuart Servis is a product applications engineer at Analog Devices,
where he works in the precision signal chains team, within the
Instrumentation and Precision Technology Group. His area of
expertise is precision data acquisition signal chains based on
sigma-delta and SAR ADCs. He received his B.Sc. in applied physics
and electronics from National University of Ireland, Galway. He can
be reached at [email protected].

Online Support
Community
Engage with the
Analog Devices technology experts in our online support
community. Ask your tough design questions, browse FAQs,
or join a conversation.

Visit ez.analog.com

For regional headquarters, sales, and distributors or ©2019 Analog Devices, Inc. All rights reserved. Trademarks and
to contact customer service and technical support, registered trademarks are the property of their respective owners.
visit analog.com/contact.
Ahead of What’s Possible is a trademark of Analog Devices.
Ask our ADI technology experts tough questions,
browse FAQs, or join a conversation at the
Analog Devices, Inc. EngineerZone Online Support Community.
Visit analog.com Visit ez.analog.com. TA21568-10/19