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
2. Hardware Products for Machine Condition Monitoring
There are two primary hardware systems from NI for machine condition monitoring: PXI and C Series.
- Use the NI CompactRIO Advisor to build your own embedded system
- Use the NI CompactDAQ Advisor to build your own portable system
- Use the PXI Advisor to build your own high-performance, high-channel-count system
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.
- PXI chassis home page
- PXI embedded controller (Windows)
- PXI embedded controller (real-time OS)
- NI PXI-4472 - dynamic signal acquisition for accelerometers, proximity probes, and tachs (8-channel module)
- NI PXIe-4497 - dynamic signal acquisition for accelerometers, proximity probes, and tachs (16-channel module)
- Other PXI modules
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)
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