Industrial

Condition-Based Monitoring

Machine health solutions for improving uptime and accelerating the path to Industry 4.0


Condition-based monitoring enables early detection and diagnosis of machine and system abnormalities in real time. Identifying and isolating these issues creates opportunities for optimizing replacement part inventories, scheduling down-times for planned maintenance, and making run-time process adjustments that can extend the useful life of the equipment.
  
Vibration, current, and temperature all provide key insights into the health of equipment ranging from motors and pumps to bearings and encoders. Vibration measurements are also a source of additional data by further isolating mechanical noise from electrical noise, improving machine diagnostics.

These machine health insights result in increased productivity, improved efficiency, and maximized uptime, accelerating the path to Industry 4.0.
  

Enable Real-Time Monitoring of Industrial Assets

Bearings

Initial signs of wear typically create high frequency noise that can only be detected with wide bandwidth, low noise vibration sensors or accelerometers. Wide bandwidths allow earlier detection of initial bearing wear caused by impacts from small fragments of metal.

Misalignments and Imbalances

Small changes in shaft alignment or motor frame imbalances require low noise, stable accelerometers that detect subtle mechanical shifts that can impact motor performance.

Machine Tools

Increased vibration levels during high speed activities such as production milling or cutting can damage critical materials and reduce precision. Wide bandwidth, low noise sensors that sense irregularities can provide real-time data for feedback and machine control.

Enable Systems that Deliver Deeper Insights

With our deep domain expertise and system-level approach, we’ll work with you to understand and solve machine health challenges at the domain, system, and embedded levels. Our comprehensive portfolio of technologies and complete solutions includes:
  
    

Sensor & Signal Chain Design

Because insights and analytics are only as useful as the quality of your data, ADI’s high performance precision sensing solutions (including MEMS inertial, temperature, and magnetic field) along with supporting signal chains provide accurate and reliable data.  

Embedded Software Design

Embedded systems require careful consideration of the sampling and signal processing requirements to ensure sensor data is optimized for critical decision making. Integrated modules leverage optimized signal processing techniques to maintain sensor data fidelity, alerting you to potentially problematic machine and system signatures while minimizing false alarms.
  

Algorithms and Insights

High-quality, reliable data pave the way for algorithms to deliver machine insights capable of diagnosing and predicting machine health. Real-time anomaly and event detection enhance condition-based monitoring solutions and provide a deeper understanding of overall machine health, helping you make actionable insights.
  

Mechanical System Design

Optimized condition monitoring solutions must account for mechanical mounting considerations and sensor attachment locations to ensure that early defect signatures can be extracted from the sensor solution.
  

Condition-based Monitoring (CbM) Development Platforms

Developing accurate, reliable condition monitoring solutions for industrial assets requires a combination of technologies and design considerations to capture and convert critical signals into actionable insights, enabling diagnostic and predictive maintenance solutions.

Analog Devices' condition-based monitoring platforms combine sensor and signal chain technologies with the embedded software required to integrate these technologies and accelerate sensor data collection. 

These platforms deliver high quality, reliable data for asset evaluation and diagnostic solution development. Access to the critical design files accelerate time to market by solving the sensor, signal chain, and communication challenges required to monitor your critical assets. 
    

Choosing the Best Solution:

  • Integrated Vibration Sensor
  • Vibration Sensor Reference Designs
  • Vibration Sensor Data Acquisition Reference Designs
  • Wireless Condition Monitoring Platform
  • Wired Vibration Monitoring Platform
  • Condition-based Monitoring (CbM) Development Platform

Condition-based Monitoring (CbM) Development Platforms Ecosystem

Condition-based monitoring reference designs and development platforms combine the necessary technologies with the tools and software required to quickly collect data, perform analysis, and customize solution designs for specific applications.  

Evaluation 
Our platforms combine signal chain hardware and development software that enable the evaluation of condition monitoring solutions in industrial environments.

Development
Hardware design files and firmware/software source code is made available, enabling customized development based on the underlying evaluation system.

Support
Support is available through the Analog Devices wiki, where all supporting documentation such as hardware and software files, application code, and setup guides. Additional support and questions can be asked through EngineerZone®, which is supported by Analog Devices engineers.  

Next-Generation Condition-Based Monitoring Technologies for Machine Health Monitoring

Good decisions require good information. Predicting and diagnosing a machine’s health before it becomes problematic requires insights that can only come from having accurate and reliable data. Discover how condition-based monitoring technologies can significantly improve uptime, productivity, and quality.
  
Get the Brochure
    
    

End-to-End Solutions for Condition Monitoring and Predictive Maintenance Services

Learn about Analog Devices condition monitoring solutions, from sensing to AI-enabled actionable insights. Accelerate your hardware, software and predictive maintenance service offerings with ADI’s complete system level solutions
  

Featured Products

Integrated Vibration Monitoring Modules

Integrated modules combine ADI’s high performance MEMS sensors with an optimized signal chain and embedded signal processing into a mechanically optimized package, enabling predictive maintenance solutions.

  • On-board pre-processing
  • User configurable operating modes 

Part Number Axis Range
(g)
Resonance
(kHz)
Noise
g/√Hz)
Temp Range (°C)
ADcmXL3021* 3 50 21 25 –40 to +105

* Digital Output

Sensors

High performance sensors provide precision, stability, and flexibility for a variety of applications.

  • MEMS accelerometers
  • Temperature 

Part Number Axis Range
(g)
Resonance
(kHz)
Noise
g/√Hz)
Temp Range (°C)
ADXL1001 1 100 21 30 –40 to +125
ADXL1002 1 50 21 25 –40 to +125
ADXL1003 1 200 28 45 –40 to +125
ADXL1004 1 500 45 125 –40 to +125
ADXL1005 1 100 42 75 –40 to +125
ADXL356 3 40 5.5 80 –40 to +125
ADXL357* 3 40 5.5 80 –40 to +125

* Digital Output

Amplifiers and Converters

High performance sensors demand precision measurement. ADI’s amplifiers and converters are optimized for sensor measurement.

  • High resolution
  • Low noise
  • Simultaneous sampling

Part Number Channel Bits
(g)
Sample Rate
(kHz)
Power
(mW)
Temp Range (°C)
AD4008 1 16 500 2.5 –40 to +125
LTC2344 4 16 to 18 400 81 –40 to +125
ADAQ7980 1 16 1000 21 –40 to +125
AD7768-1 1 24 204 <37 –40 to +125

Wireless Radio

Enabling wireless industrial applications requires a robust, low power wireless interface. SmartMesh® technology supports operation in harsh environments and simplifies network accessibility.

  • Proven reliability
  • Robust
  • Stable
  • Small footprints

Part Number Band
(GHz)
Upstream Data Throughput
(Max Packets/sec)
Temp Range (°C)
LTP5902 2.4 24 –40 to +125

Processors

Converting information into insights requires powerful processors that enable efficient processing at the node, reducing wireless bandwidth requirements.

  • Ultra low power
  • Flexibility

Part Number Core Max Speed
(MHz)
Flash/SRAM
(Max kB)
Hibernate Current
(nA)
Temp Range (°C)
ADuCM3027 M3 26 128/64 750 –40 to +85
ADuCM3029 M3 26 256/64 750 –40 to +85
ADuCM4050 M4F 52 512/128 680 –40 to +85

Isolated Digital Interface

Harsh industrial environments require robust, isolated signals to drive long cable lengths and minimize interference.

  • iCoupler® technology reduces board space requirements
  • Industrial operating temperature ranges
  • Support long cable lengths

Part Number Channel Data Rate
(Max Mbps)
Insulation Rating
(kV rms)
Temp Range (°C)
ADM2486 1 20 2.5 –40 to +85
ADuM4150 6 40 256/64 –40 to +125
ADN4651 2 600 512/128 –40 to +125

Power Management

Maintaining system performance is only as good as the power supplies that support the system. Power by Linear™ provides efficient and flexible solutions to support a wide breadth of applications.
 
  • Low noise
  • Stable
  • Small footprints

Part Number Type VIN Range (V) VOUT (V) Max Out Current
(mA)
Temp Range (°C)
LTC1928 Doubler 2.7 to 4.4 5 30 –40 to +85
ADP5300 Switch 2.15 to 6.5 0.8 to 5 500 –40 to +125
LTC3499 Switch 1.8 to 5.5 2 to 6 750 –40 to +85
ADP7118 LDO 2.7 to 20 1.8 to 5 200 –40 to +125

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