A key factor in any production process is reliable and efficient machinery. In order to work efficiently and effectively we need to maximise production output. However, it is often the case that equipment suffers an unexpected failure, which leads to unplanned downtime and reduces the OEE rate.

How to prevent this type of event?

Optimal operation of machines can be achieved by monitoring their condition. This is possible by monitoring the physical and environmental status of the equipment. It is important that this data can be easily accessed and monitored. For this purpose, Condition Monitoring Sensors are ideal.

One such sensor is the BCM - Balluff Condition Monitoring Sensor. It is a new multifunctional anomaly monitoring sensor. It supports the trouble-free operation of any installation. Thanks to the BCM, unplanned downtime and disruptions in the production process can be significantly reduced.

How does the BCM work?

The primary role of the BCM sensor is to continuously monitor vibration levels and indicate anomalies in the operation of drives, motors , pumps, compressors etc.

The purpose of the measurement is to detect anomalies in the operation of equipment or the deterioration of condition over time, helping the user to reduce costly maintenance to only when it is required.

The sensor measures vibration in three axes in the range of 2 to 3200 Hz. In addition, its operation involves recording various physical parameters: vibration, temperature, humidity, ambient pressure. It processes the collected data internally and then sends it to a higher-level system via IO-link.

Once installed, the sensor monitors the metrics building trend data over time which can be analysed to indicate changes in the condition of the equipment over its lifetime.

In accordance with ISO 10816-3

The BCM sensor has implemented standards for rotating machinery in accordance with ISO 10816-3. According to the standard, the sensor analyses vibration rms velocity (VRMS) in the range of 10 to 1000 Hz. The time window for vibration measurement is set at 1000 ms. Measuring the velocity within this range allows a general assessment of the current state of equipment. Damage such as imbalance, unbalance or misalignment will be noticed and signalled if the vibration level rises to warning levels.

Where can the BCM sensor be used?

Sensors from the Condition Monitoring family can be used wherever knowledge of the condition of a machine is crucial. They are useful and suitable for implementation in any industry. We present examples of applications:

Observing the trend of value changes over the long term helps manage overhauls, schedule replacements, reduce losses and optimize the production process.