How to Choose the Right Vibration Sensor for Your Project

When you’re working on any kind of project which requires you to record the level of vibrations, the type of vibration sensor that you choose will determine if the project will be successful or not. Accelerometers or more commonly referred to as vibration sensors are important for monitoring of machinery, identification of faults in structures as well as checking the functionality of systems. Due to the current availability of different types and specifications, one would have no easy task of making the right decision. At the end of the reading on this article, the reader will be in a better position to make the right choice when it comes to choosing a vibration sensor.

Understand the Types of Vibration Sensors

The vibration sensors are of several types and they all have different usage from the others. Some of these are the piezoelectric sensors, capacitive sensors, strain gauge sensors, magnetostrictive sensors and micro-electro-mechanical systems sensors.

Amongst these, piezoelectric sensors are extremely sensitive and can pick frequencies of vibrations and there is a great variability of such frequencies in industrial processes. Capacitive sensors provide better results for low frequency measurements, for example, in structural vibrations. Strain gauge sensors are used in precision tests such as in testing of sensitive equipment while magnetostrictive sensors are widely used in areas that experience high temperatures. MEMS sensors, on the other hand, are small and portable hence can be incorporated in consumer products and small scale applications.

To ensure one can make the right decision, it is essential to understand the various types of the vibration sensor to choose from in the project.

Determine Your Frequency Range Requirements

The frequency range of a vibration sensor is the range of vibrations that can be measured by the sensor. Vibrations detected in the analyzed environment are characterized by different frequencies and thus, different types of projects need devices with different frequency characteristics.

A low frequency is characterized by low energy or slow moving vibrations and is usually detected systems applied large structures such as buildings or bridges. Mid-frequency sensors are ideal for detecting vibrations from machines and mechanical equipment as they have a capability of detecting a greater range of frequencies in contrast to the high-frequency sensors which is mainly used in applications that require detection of high and/ or fast frequencies of vibrations.

To ensure accurate measurements, it’s essential to choose a vibration sensor with a frequency range that matches the specific requirements of your project. Selecting a sensor with an inappropriate frequency range could lead to inaccurate data and potential issues in your application.

Consider the Sensor Sensitivity

Another parameter which the selection of a vibration sensor depends on is sensitivity. This means the capability of the sensor to pick the minimal movements and translate them into electrical signals.

Such sensors are useful in measuring small or low vibrations in situations where the machinery or equipment is sensitive or in scientific applications. Medium sensitivity sensors are particularly useful where equipment needs to be monitored over other physical parameters based on its utilization in most industries. Low-sensitivity sensors are better suitable for high vibration RV environments where intense signals are present such as automotive testing and heavy machinery.

The decision of sensor sensitivity is essential in achieving the correct worth from the sensor. Choosing a wrong sensitivity of the sensor may lead to situations when essential vibrations are not detected or when excessive noise is produced which is also unbeneficial for the result of the project.

Evaluate the Environmental Conditions

Of importance to consider are the environmental conditions in which your vibration sensor will work in, to improve performances and its durability. The changes in temperature, humidity, dust and gasses are some of the main factors that may alter the performance of the sensor.

Compatibility with temperature is also important, due to poor temperatures that prevail in some projects. Some of the sensors are constructed to bear high and low temperatures and some of the sensors have restricted temperature range. Furthermore, if your sensor is going to operate in a hostile environment, be it aquatic, dusty, or chemical, then the sensor must be able to resist the said environments.

Sensors which come with high IP (Ingress Protection) are preferred for areas that have contact with water and dust. In the cases where the sensors are likely to come into contact with corrosive substances then there is need to consider using sensors made from chemically resistant materials.

By getting a vibration sensor appropriate for the environment of the project you are working on, then you are in a position to get good and accurate readings as well as the lifespan of the sensor.

Choose the Right Mounting Method

Proper positioning of the vibration sensor plays a crucial role in capturing the correct vibration values. How the sensors are mounted is a critical factor that may affect the entire performance of a given system.

Stud mounting also ensures a good and direct contact between the sensor and the measured object that is preferred for highly accurate applications. Adhesive mounting proved convenient when installing or removing the device in the short term or when stud mounting is impossible. Magnetic mounting is another one used in cases when it is required to apply vibration measurements over a short period within different environments. Other mounting methods are also possible and include probe and clip mounting and particularly for portable or hand-held sensors.

If it was noted that the choice of the sensor is very important, then the choice of the method of its mounting is no less significant. Unsatisfactory installation of the sensor results in poor readings and possible damaging of the sensor which can lead to poor results on your project.

Data output and connectivity selection

Various types of signal outputs and connection possibilities are present in the latest vibration sensors. These features enable the sensors to be easily connected to monitor systems or data analysis software improves the work of the latter.

Analog sensors are used for generating a constant stream of information that is useful for real time monitoring processes. They are typically applied in application that are likely to involve response soon such as in diagnosing machinery. Digital sensors on the other hand encodes the vibration measurements into a digital format that can quickly be analyzed by a computer or microcontroller. Due to this they are suitable for use where data is to be logged, analyzed or when a system is to be remotely monitored.

Another feature relates to wireless capability which is also important when choosing a device. Cable-less sensors include the wireless vibration sensors which are useful when monitoring some hard to reach areas or equipment that is in continuous motion. It can send the acquired data wirelessly through WI-Fi, Bluetooth or other wireless connections hence the ease of installation of the sensors. Also, smart sensors have their processors that enable data analysis on the sensor itself, which is more beneficial in applications that need the data to be analyzed immediately as in the case of predictive maintenance.

Selecting the best output of data and connectivity means that your vibration sensor provides a proper interface with other systems to fit the data analysis required in the project.

Conclusion

Choosing a basic vibration sensor for your project requires the understanding of many criteria that are available in the market such as type of sensor, frequency range, sensitivity, operating environment, methods of installation, and data output format. With these aspects in mind, you will be able to make the right decision of achieving the correct measurements and improve the chances of success of your project. With regards to machinery monitoring, equipment validation or structural vibration analysis, selection of a proper vibration sensor will determine the right information that is needed for the advancement of your projects.