Machine Condition Monitoring and Machine Vibration Test
NI Common Configuration Details
The links below provide a more detailed list of NI software, data acquisition, signal conditioning, instrument control, and real-time control products that you can use to build your industrial machine monitoring, test, and control system.
NI Software and PXI
- PXI -- You can automatically benefit from the low cost, ease-of-use, and flexibility of PC technology using open industry standards. PXI combines the high-speed PCI bus with integrated timing and triggering to deliver more than a 10X performance improvement over older architectures. Recommended hardware is:
- PXI-1002 -- a 4-slot chassis
- PXI-1042 - a 8-slot chassis
- PXI-8176 -- a high-speed controller that can run Windows or real-time systems
- NI Developer Suite. Professional Control Edition -- With LabVIEW, you can rapidly create automation applications using intuitive graphical development. LabVIEW integrates measurements, vision, and motion into one platform. The Professional Control Edition includes the LabVIEW Real-Time and LabVIEW Data Logging and Supervisory Control modules.
- LabVIEW Real-Time and RT Series hardware deliver deterministic, real-time control needed for machine monitoring and test systems. You can choose LabVIEW RT Series hardware targets based on PXI and FieldPoint depending on the performance and I/O requirements of your industrial machine monitoring and control system.
- LabVIEW Data Logging and Supervisory Control offers data management tools, such as easy-to-use I/O configuration for large-channel-count applications, automatic data logging, full alarm management and event logging, and real-time and historical trending. With easy networking, including a networked database for distributed logging, built-in security, and OLE for process control (OPC) connectivity, the LabVIEW Data Logging and Supervisory Control Module provides tremendous ease of use to get your high-channel-count system up and running quickly
- LabVIEW Order Analysis Toolkit helps you build custom LabVIEW-based measurement and automation applications with order analysis capabilities for order tracking, order extraction, and tachometer signal processing. The toolkit employs Gabor Order Tracking, a patent-pending algorithm based on the ideas of joint time-frequency analysis (JTFA). Order analysis is a tool for examining dynamic signals generated by mechanical systems that include rotating or reciprocating components. As with frequency-domain analysis, you can think of order analysis as a signal scalpel that can dissect sound, vibration, and other dynamic signals into components that relate to physical elements of mechanical systems. The toolkit includes ready-to-run examples including Orbit plots, Polar plots, Bode plots, waterfall plots, cascade plots, intensity plots (Campbell), order tracking with phase and magnitude, and shaft run-out compensation.
- LabVIEW Sound and Vibration Toolkit extends the Full or Pro editions of LabVIEW 6.0 (or greater) with VIs and displays for use in applications involving sound and/or vibration analysis. These tools complement the general-purpose measurement analysis of LabVIEW with analysis and visualization tools devoted to sound and vibration applications.
- DIAdem is a powerful, professional software tool used to import, analyze, present, and store your data. DIAdem is open to connect to virtually any data source or format, and it enables extraordinary visualization flexibility, design reuse, and rapid development in generating reports. The DIAdem capabilities to automate tasks and customize the user interface make it the number one choice to solve post-acquisition data processing tasks and integrate it into your technical data management framework.
Data Acquisition and Signal Conditioning
Perform your industrial machine vibration measurements faster, more flexibly, more cost-effectively, and with better systems integration using National Instruments data acquisition and signal conditioning. NI has several data acquisition and signal conditioning solutions based on high performance dynamic signal acquisition boards in PXI, NI Multifunction DAQ and SCXI, FieldPoint Distributed I/O, or PCMCIA DAQ with SCC to help solve your most demanding industrial machinery monitoring and test applications.
- Dynamic Signal Acquisition Hardware The NI 44xx Series are dynamic signal acquisition devices for making high-accuracy frequency measurements with PXI and PCI. The NI 44xx boards simultaneously digitize all input signals over the entire bandwidth. They have two analog input channels and two analog output channels. The NI 4452 and NI 4454 have four analog input channels and no analog output. The NI 4472 has eight input channels. When combined with the Sound and Vibration Toolkit, Order Analysis or other analysis tools, you can obtain a variety of accurate frequency measurements for your application.
- Multifunction DAQ delivers accurate, reliable measurements for a wide variety of desktop, portable, and networked applications. NI multifunction DAQ devices sustain analog output, digital and counter/timer I/O operations together with their analog input operations. Using custom ASIC technology and sophisticated architectures, these devices deliver reliable, high-speed measurements.
- SCXI is a modular signal conditioning platform for E Series DAQ devices that delivers a wide range of analog and digital conditioning options. See the DAQ/SCXI section below for more additional information on a typical NI Data Aquisition/SCXI system configuration.
- SCC is a modular per channel signal conditioning platform designed for low-profile and portable applications.
- FieldPoint Distributed I/O provides a cost-effective, distributed I/O solution when you need to distribute your measurement and control functionality in the field and need hardware optimized for reliable, networked I/O in an industrial ruggedized package.
Instrument Control and Connectivity
National Instruments offers a wide selection of industry-standard instrument control and connectivity hardware and software tools to integrate and automate your industrial machine vibration and test measurements and reduce development time.
- GPIB provides industry-standard, high-performance GPIB instrument control for connecting to any GPIB-based device such as programmable load controllers.
- Serial Interface Boards (RS-232, RS-422, and RS-485) can communicate with devices, such as mass flow controllers, gas analyzers, and industrial devices such as PLCs, and single-loop temperature controllers. NI offers a variety of serial hardware and driver software products that are 100 percent compatible with standard PC serial ports.
- The Industrial Automation Servers CD with OPC Interface provides OPC servers to 3rd-party industrial devices such as programmable logic controls (PLCs) and industrial networks.
- National Instruments offers hardware and driver software products for communication with industrial devices using Ethernet, CAN, DeviceNet, FOUNDATION Fieldbus, and PROFIBUS.
Example System Configurations
There are four configurations available for factory test and field monitoring and diagnostics applications. Many customers may want to mix and match configurations.
Our trained technical sales staff is more than happy to assist in alternative configurations.
PXI Based Configuration
The PXI Based Configuration provides the highest dynamic range and best signal conditioning options available from National Instruments. This solution, when configured as a LabVIEW Real-Time application, provides an ideal remote monitoring and field diagnostics tool.
- NI-PXI-1002 (four slot) or NI PXI-1042 (8 slot) Chassis
- NI-PXI-4472 - Dynamic Signal Acquisition
- NI-PXI-6602 - Speed Measurements
- CA-1000 Signal Conditioning Interface with BNC Connectivity
- NI-PXI-6527 - Contact Closure
- NI-PXI-4351 - Temperature Measurements
- NI-PXI-6052E - General Purpose Analog Inputs, Outputs, and Digital I/O
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| Measurement | Channel Type | Signal Conditioning | SCXI Modules |
|---|
| Machine Vibration (Accelerometers, Proximity Probes, Velocity Probes) | Analog Input | 24 bit dynamic range, Anti-Aliasing, Accelerometer Power, Simultaneous Sampling | PXI-4472 |
| Tachometers and Encoders | Analog/Digital Input | CA-1000 based signal conditioning system | PXI-6602 counter |
| Machine Voltages and Current Signatures (Using Current and Voltage Transformers) | Analog Input | 24 bit dynamic range, Anti-Aliasing, Simultaneous Sampling | PXI-4472 |
| Current (4-20mA) Using Precision Shunt Resistors | Analog Input | 24 bit dynamic range, Anti-Aliasing, Simultaneous Sampling | PXI-4472 or PXI-6052E |
| Pressure (0-5V) | Analog Input | 24 bit dynamic range, Anti-Aliasing, Simultaneous Sampling | PXI-4472 or PXI-6052E |
| Flow Rate (pulse train) | Encoder | Scaling, Frequency to Voltage | PXI-6602 counter |
| Temperature (thermocouple) | Analog Input | Scaling, Amplification | PXI-4351 |
| Emergency Shut Off | Digital Output | Switching | PXI-6527 |
| Load | GPIB or Digital Output | | NI PXI-GPIB |
DAQ/SCXI-Based Machine Vibration Monitoring and Test Common Configuration
The DAQ/SCXI Based Configuration is recommended if you need to measure sensors or raw signals, generate voltages or currents, monitor digital lines, or route signals with switching. The DAQ/SCXI based configuration offers the widest range of signal inputs and outputs for your machine monitoring and control platform.
- NI SCXI-1531
- NI SCXI-1125
- NI SCXI-1316
- NI SCXI-1104C
- NI SCXI-1102C
- NI SCXI-1126
- NI SCXI-1102B
- NI SCXI-1161
- NI SCXI-1124
- PXI-6052E
- NI PXI-6602
- NI PXI-GPIB
- NI PXI-1011 Combo Chassis
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| Measurement | Channel Type | Signal Conditioning | SCXI Modules |
|---|
| Machine Vibration (Dynamic Signals from Acclerometer, Velocimiter) | Analog Input +/-5V AC | Anti-Aliasing, Accelerometer, Simultaneous Sampling | SCXI-1531 |
| Machine Vibration (Proximity Probes) | Analog Input +/- 60V | Low-Pass Filter, 32 channels | SCXI-1104C |
| Machine Voltages and Current Signatures | Analog Input +/- 1000V AC RMS | Isolation, Attenuation | NI SCXI-1125 (TBX-1316) |
| Current (4-20mA) | Analog Input | Scaling, Attenuation | NI SCXI-1102C |
| Pressure (0-5V) | Analog Input | Scaling | NI SCXI-1102C |
| Flow Rate (pulse train) | Analog Input | Scaling, Frequency to Voltage | NI SCXI-1126 or PXI-6602 counter |
| Temperature (thermocouple) | Analog Input | Scaling, Amplification | NI SCXI-1102B |
| Emergency Shut Off | Digital Output | Switching | NI SCXI-1161 |
| Pressure Valves | 4-20mA Analog Output | Amplification | NI SCXI-1124 |
| Load | GPIB or Digital Output | | NI PXI-GPIB |
PCMCIA Notebook Based Vibration Monitoring Solution with SCC Signal Conditioning
The PCMCIA Notebook Based Configuration is the recommended solution where notebook portability is desired.
- DAQCard-6036E
- SC-2345 SCC Carrier
- SCC-ACC01 Accelerometer Input Module
- SCC-AI01 +/-42 Isolated Input Module
- SCC-FT01 Feed-through Counter Conditioning
- SCC-RTD01 RTD Temperature Input
- SCC-DO01 Isolated Digital Output
- SCC-CI20 0-20mA input module
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| Measurement | Channel Type | Signal Conditioning | SCC Modules |
|---|
| Vibration (Accelerometer) | Analog Input | Isolation, Low-Pass Filter, Accelerometer Power | SCC-ACC01 |
| Vibration (Proximity Probe) | Analog Input | Isolation, Low-Pass Filter, Attenuation | SCC-AI01 |
| Voltage and Current Signatures (using Voltage and Current Transformers) | Analog Input | Isolation, Low-Pass Filter, Attenuation | SCC-AI01 |
| Current (0-20mA inputs), RMS Vibration and RMS Voltage and Current Signatures | Analog Input | Current to Voltage conversion | SCC-CI20 |
| Pressure (0-20mA) | Analog Input | Scaling | SCC-CI20 |
| Speed Sensor (Pulse) | Counter Input | Pulse to TTL | SCC-FT01 |
| Temperature | Analog Input | RTD Power, Low Pass Filter, Isolation | SCC=RTD01 |
| Emergency Shut Off (Contact Closure) | Digital Output | TTL to 24V Contact Closure | SCC-DO01 |
FieldPoint Distributed I/O Based Machinery Monitoring Configuration
For a RMS vibration and electrical power measurements system, NI recommends the FieldPoint Distributed I/O Based Configuration.
- cFP-2020
- cFP-AI-111
- cFP-AI-110
- cFP-RTD-124
- cFP-DO-400
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| Measurement | Channel Type | Signal Conditioning | FieldPoint Modules |
|---|
| Voltage (RMS Vibration, Voltage, and Current) | Analog Input | Isolation, Attenuation, Scaling | NI cFP-AI-110 |
| Current (0-20mA) RMS Vibration, RMS Current and Voltage | Analog Input | Scaling, Attenuation, Isolation | NI cFP-AI-111 |
| Pressure | Analog Input | Scaling, Isolation | NI FP-AI-110 or 100 |
| Flow Rate | Analog Input | Scaling, Isolation | NI cFP-AI-111 |
| Temperature | Analog Input | Scaling, Amplification | NI cFP- RTD-124 |
| Emergency Shut Off (Contact Closure) | Digital Output | Contact Closure | NI cFP-DO-400 |
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