Configure Your Machine Condition Monitoring System Using National Instruments Products

Publish Date: Feb 13, 2015 | 9 Ratings | 2.78 out of 5 |  PDF


Machine health and predictive maintenance is critical to every plant's reliability program. Machine manufacturers use the same data collection and analysis for factory acceptance test. Whether you are in-plant or factory test focused, the NI machine condition monitoring and machine test platform provides the test and analysis you need, including online and off-line analysis capabilities, high-speed time waveform logging, Ethernet connectivity with client/server architectures, data acquisition, data analysis, and data presentation all in one platform. And it all has the flexibility to integrate with current systems and expand with your company's needs.

Table of Contents

  1. A Typical Machine Condition Monitoring System
  2. Hardware Products for Machine Condition Monitoring
  3. Software

1. A Typical Machine Condition Monitoring System

Figure 1 shows a block diagram for a typical machine condition monitoring system. Hardware components include sensors, controllers, data acquisition I/O, and networking interfaces. Software components include analysis and control tools.

Figure 1. Block Diagram of a Typical Machine Condition Monitoring System

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2. Hardware Products for Machine Condition Monitoring

There are two primary hardware systems from NI for machine condition monitoring: PXI and C Series.

PXI C Series
  • High-performance processing
  • High-channel-count systems (500+)
  • Solid-state hard drives for rugged data storage
  • Ethernet, RS232, CAN, and many industrial comm buses available
  • Dynamic input sample rates at over 200 kS/s/ch
  • Rugged operating specs (temp and shock)
  • Portable or fixed implementation
  • USB/Ethernet/Wireless-based system with  CompactDAQ
  • Embedded processing and storage with CompactRIO and CompactDAQ controllers
  • 3- to 32-channel systems for distributed monitoring
  • Dynamic input sample rates at up to 102.4 kS/s/ch


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, offers an ideal remote monitoring and field diagnostics tool.

C Series

The C Series-based configuration provides a rugged, flexible set of hardware for creating either a portable or a permanently mounted machine condition monitoring system. With an operating temperature range up to -40 to 70 °C and a shock rating of up to 50 g, the C Series line of hardware is ideal for more rugged environments. More than 60 C Series I/O modules are available for everything from proximity probes and accelerometers to temperature and strain. You can add control by using digital I/O modules or analog output modules.

  • NI CompactDAQ chassis for up to eight modules over USB/Ethernet/wireless or with an embedded controller for onboard processing and storage.
  • NI CompactRIO featuring an onboard FPGA and embedded controller for up to eight modules with onboard processing and storage and integrated real time control applications.
  • NI 9232 - dynamic signal acquisition for industrial accelerometers, proximity probes, and tachometers (102.4 kS/s/ch, 3-channel module)
  • NI 9234 - dynamic signal acquisition for accelerometers and microphones (51.2 kS/s/ch, 4-channel module) 
  • NI 9229 - dynamic signal acquisition for ±60 V input (50 kS/s/ch, 4-channel module)
  • NI 9239 - dynamic signal acquisition for ±10 V input (50 kS/s/ch, 4-channel module)
  • NI 9237 - dynamic signal acquisition for bridge-based measurements like strain (50 kS/s/ch, 4-channel module)
  • NI 9219 - universal module for temp, voltage, current, strain with channel-to-channel isolation (100 S/s/ch, 4-channel module)
  • NI 9217 - RTD module (400 S/s, 4-channel module)
  • NI 9212 - thermocouple module (95 S/s/ch, ch-ch iso, 8 channel module)

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3. Software

As machine condition monitoring software, NI LabVIEW combines advanced analysis with a user-defined graphical user interface (GUI) or human machine interface (HMI). By implementing a software solution based on the LabVIEW programming environment, you can completely control the look and feel of your monitoring system. In addition to a custom interface, LabVIEW and the NI Sound and Vibration Measurement Suite contain hundreds of analysis functions such as fast Fourier transform (FFT), order analysis, RMS, and peak detection. Learn more about the software implementation by viewing the Using LabVIEW for Embedded Condition Monitoring and Machine Protection webcast.

The images below display the variety of some of the analysis functions that are available as well as user interface customization.

Figure 2. Orbit Plot and Analysis in LabVIEW

Figure 3. Polar Plots

Figure 4. Waterfall Plots for Run-Up Analysis

Figure 5. Custom Data Views and Charts

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