In practical application, a variety of measurement methods are used to monitor the condition of machines and systems. The choice of the right method depends on the specific requirements and circumstances of the respective application. Here are some examples:
Vibration Analysis / Vibration Analysis
Vibration analysis is a widely used method and enables the monitoring of mechanical vibrations that occur in rotating or oscillating machine components (e.g. machine drives). Increased vibration amplitude can indicate, for example, imbalance, misalignment, bearing damage or wear. Continuous measurement and analysis of vibration signals leads to early detection of problems. This means that these can be remedied even before machine failures occur.
Ultrasonic testing is another common method in condition monitoring, which uses sound waves with frequencies above the audible range, and as a result detects e.g. material defects, cracks or corrosion in machine components. It is particularly suitable for monitoring high-pressure vessels, pipelines and structures. As a result of the early detection of material defects, the risk of equipment failures and safety problems can be significantly reduced.
Thermography is an imaging method based on infrared radiation, which makes it possible to visualize the surface temperatures of machines and systems. This makes it possible to detect temperature anomalies, which in turn indicate excessive friction, poor heat dissipation, electrical malfunctions or other problems, for example. Thermography also allows contactless and fast monitoring of large plant areas and accordingly leads to improved efficiency and safety in companies.
Oil level monitoring
Oil level monitoring is an important method for monitoring hydraulic systems, transmissions, and engines. Continuous monitoring of the oil level and oil quality helps to detect lubricant shortages, contamination or wear particles at an early stage. Timely maintenance measures, such as oil changes or filter cleaning, prevent machine failures and also extend the service life of the system components
Acoustic Emission Testing
Acoustic emission testing is an acoustic monitoring in condition monitoring that records noise and vibrations in the audible and ultrasound-based range. As a result, the identification of anomalies in machinery and equipment is convenient. Noise emissions can be e.g. due to material defects, friction, cracks but also other mechanical problems. Based on the analysis of the sound emissions and their frequency spectra, experts can draw conclusions about the condition of the monitored machines and identify potential problems at an early stage.
In short, these measurement methods offer effective options for monitoring the condition of machines and systems. In addition, the combination of different methods provides comprehensive monitoring and thus helps to ensure the reliability, efficiency and safety of the equipment.