From Sensor to System: How to Get Vibration Data Where You Need It

A Step-by-Step Guide to Collecting, Transmitting, and Utilizing Vibration Data for Optimal Equipment Performance

In today's fast-paced industrial environment, unplanned downtime and equipment failures can lead to significant losses in productivity and revenue. Predictive maintenance has become a crucial strategy for industries looking to stay ahead of equipment issues. Central to this approach is the ability to monitor vibration data effectively. But how do you get this vital data from the sensors on your equipment to the people who need it most?

In this guide, we'll take you through each step of the process when using GraceSense Machine Health Monitoring Solutions. We'll show you how vibration data is collected, transmitted, analyzed, and delivered to your maintenance team, empowering them to make informed, proactive decisions.

Step 1: Collecting Data at the Sensor

The journey begins with the sensors attached to your equipment. GraceSense™ VBTx Vibration & Temperature Sensors are designed to detect early signs of equipment issues through continuous monitoring of vibration and temperature data.

Key Features of VBTx Sensors:

• Best-in-Class Data Acquisition: These sensors provide precise, high-quality data essential for accurate equipment monitoring.
• Wireless Connectivity: Eliminates the need for complex wiring, making installation quick and hassle-free.
• Designed for Harsh Environments: With an IP69K rating, VBTx sensors are built to withstand extreme conditions, including high-pressure, high-temperature washdowns.
• Extended Battery Life: Up to 8-10 years of battery life at sampling rates once per minute ensures long-term reliability.
• Flexible Mounting Options: Allows for deployment across a variety of equipment types and hard-to-reach locations.

Installing VBTx sensors on critical machinery such as motors, pumps, and conveyors allows you to capture real-time vibration and temperature data essential for predictive maintenance.

Step 2: Data Transmission to the Gateway

Once the sensors collect the data, it needs to be transmitted to a central point for processing. This is where our gateway options come into play. The gateways act as communication hubs, gathering data from multiple sensors and preparing it for the next stage.

Gateway Options:

• CloudGate™: Ideal for operations requiring extensive data analysis in the cloud. It transmits data via Wi-Fi or LTE connections to the cloud-based Maintenance Hub.
• ControlGate™: Designed for direct integration with on-site control systems like PLCs and SCADA, using EtherNet/IP™ and Modbus TCP/IP protocols.
• ComboGate™: Combines the functionalities of both CloudGate™ and ControlGate™, allowing for flexible data handling both remotely and on-site.

How It Works:

• Wireless Communication: The sensors communicate wirelessly with the gateway, eliminating the need for extensive cabling.
• Data Aggregation: The gateway collects data from all connected sensors, ensuring a centralized stream of information.
• Secure Transmission: Data is securely transmitted to either the cloud, the local control system, or both, depending on your setup.

Step 3: Data to the Cloud or PLC/SCADA Systems

With the data aggregated at the gateway, the next step is to route it to where it can be analyzed and acted upon.

Cloud Integration:

• Maintenance Hub: Data sent to the cloud is accessed through the GraceSense™ Maintenance Hub, a web-based interface that processes and visualizes real-time data.
• Advanced Analytics: The cloud platform allows for sophisticated data analysis, including defect classification and trend monitoring.
• Remote Access: Maintenance teams can access the data from anywhere, facilitating quick decision-making.

PLC/SCADA Integration:

• Direct Data Transmission: For facilities that prefer on-site data handling, the gateway can transmit data directly to existing PLCs and SCADA systems.
• Standard Protocols: Supports EtherNet/IP™ and Modbus TCP/IP protocols for seamless integration.
• Real-Time Control: Allows operators to respond immediately to equipment issues through familiar control systems.

Flexible Integration:

• Third-Party Compatibility: With a public API and support for platforms like Rockwell Automation's Studio 5000 and Fiix CMMS, data can be integrated into a variety of systems.
• Custom Solutions: GraceSense™ offers the flexibility to develop custom integrations tailored to specific operational needs.

Step 4: Maintenance Hub and Data Analysis

The Maintenance Hub serves as the command center for your machine health data. Once the data reaches the cloud, it's processed and presented in an actionable format.

Key Features:

• Real-Time Monitoring: Provides up-to-the-minute data on equipment health.
• Defect Classification: Advanced algorithms identify and diagnose mechanical issues such as misalignments and bearing wear.
• User-Friendly Interface: Data is presented in formats familiar to vibration analysts, making it easy to interpret without extensive training.
• Customizable Alerts: Set thresholds and receive notifications when parameters exceed normal ranges.
• Data Visualization: Graphs, charts, and dashboards help visualize trends and patterns over time.

Benefits:

• Proactive Maintenance: Early detection of potential issues allows maintenance teams to address problems before they lead to failures.
• Data-Driven Decisions: Access to detailed analytics enables informed decision-making and efficient resource allocation.
• Enhanced Collaboration: Cloud-based access allows multiple team members to view and act on data simultaneously.

Step 5: Getting Data into the Hands of Personnel

The final step is ensuring that the right people receive the right information at the right time. GraceSense facilitates this through multiple channels.

Alert Mechanisms:

• Human-Machine Interface (HMI): Operators can view real-time data and alerts directly on their existing HMI screens.
• SMS and Email Notifications: Immediate alerts sent to mobile devices and email ensure that maintenance personnel are informed promptly.
• CMMS Integration: Automatic creation of work orders in systems like Fiix CMMS streamlines the maintenance workflow.
• Customized Reporting: Generate reports tailored to specific needs, aiding in compliance and performance tracking.

Advantages:

• Rapid Response: Quickly disseminating critical information reduces the time between issue detection and resolution.
• Improved Safety: By enabling scheduled, controlled maintenance operations, the system helps reduce the risk of accidents associated with reactive maintenance.
• Operational Efficiency: Streamlined communication ensures everyone is on the same page, reducing downtime and improving productivity.

From the initial data collection at the sensor to delivering actionable insights to your maintenance team, the GraceSense Machine Health Monitoring Solution provides a comprehensive, end-to-end system for managing equipment health.

Key Takeaways:

• Seamless Data Flow: Wireless sensors and gateways ensure data moves efficiently from equipment to analysis platforms.
• Advanced Analytics: The Maintenance Hub's powerful tools turn raw data into meaningful insights.
• Flexible Integration: Whether you prefer cloud-based analysis or direct integration with existing control systems, GraceSense adapts to your needs.
• Actionable Information: Alerts and notifications ensure the right people are informed promptly, enabling proactive maintenance.

By implementing a system like GraceSense, you can significantly reduce unplanned downtime, extend the lifespan of your equipment, and optimize your maintenance operations.

Ready to transform your maintenance strategy? Experience the benefits firsthand with our Starter Kit, which includes:

• 4 VBTx Wireless Sensors
• 1 Gateway
• Maintenance Hub Access with Defect Classification
• White-Glove Delivery

And with our Grace Guarantee, your investment is risk-free: Love it or return it! If you're not satisfied within 90 days, we'll provide a full hardware refund.

👉 Book a demo with our experts today!

Don't miss our upcoming webinar to discover how GraceSense™ Machine Health Monitoring Solutions can revolutionize your predictive maintenance strategies—and much more! Register now to explore GraceSense™ and other innovative solutions that will elevate your operations in 2025.