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Analog Devices have a wide range of solutions for Condition monitoring, also known as condition-based monitoring (CbM), this is a predictive maintenance strategy that monitors the condition of assets using different types of sensors. Using the data extracted from these sensors, assets can be monitored in real time to establish trends, predict failure, and even calculate the lifetime of an asset. Vibration monitoring is a crucial form of CbM where vibrations from assets are analysed to determine the presence of any abnormal vibrational patterns, which are an indicator of advanced wear, malfunctioning parts, and loose mounting, amongst other issues. CbM is an important element in the drive to Industry 4.0 to achieve increased production efficiencies and reduced downtime.

To assist customers with CbM applications, Analog Devices have developed the Voyager 3 system evaluation solution which provides wireless MEMS accelerometer-based vibration monitoring. The system solution combines mechanical attach features, hardware, firmware, and PC software to enable rapid deployment and evaluation of a 3-axis vibration monitoring solution. The module can be directly attached to a motor or fixture. Furthermore, it can also be combined with other modules on the same wireless mesh network to provide a broader picture with multiple sensor nodes as part of a condition-based monitoring system.

The Voyager 3 system incorporates a signal chain consisting of a tri-axis ADXL356 accelerometer mounted to the base of the module. The output of the ADXL356 is read into a AD7685 ADC, and then processed by a ADuCM4050 low power microcontroller. Here it is buffered, transformed to the frequency domain and streamed to the SmartMesh IP mote. From the SmartMesh chip it is wirelessly streamed to the SmartMesh IP Manager. The manager connects to a PC and visualization and saving of the data can take place.

High Level Signal Chain Overview of Voyager 3 Mote

The Voyager 3 kit supports ADI SmartMesh® mote hopping. This is where a mote, which is out of range of the network manager, can hop through an in-range mote. The multiple hops network ensures that out-of-range motes can stream data to the network manager, which extends the reach and the scale of the solution deployment.

Mote Hopping

The Voyager 3 system evaluation solution utilises the versatile ADXL356 MEMS three-axis accelerometer which provides low noise performance over high frequencies and delivers high resolution vibration measurements that enable the early detection of machine failure in condition monitoring applications. This performance comes with very low power consumption, making the ADXL356 ideal for wireless sensor networks. The ADXL356 MEMS accelerometers are also designed to provide accurate and reliable tilt measurements for environments high in shock and vibration without saturating the sensor, an important requirement for tilt measurement applications on heavy equipment or airborne platforms such as unmanned aerial vehicles (UAVs).

The ADXL356 three-axis accelerometers feature an analog output and provide selectable measurement ranges of ±10 g, ±20 g and ±40 g for greater flexibility. The accelerometer offers industry leading noise density of 80 µg/root Hz, with guaranteed maximum 0 g offset drift over temperature of 0.75 mg/C, enabling precision applications with minimal calibration. In addition, the hermetic package helps ensure that the end product conforms to its repeatability and stability specifications long after it leaves the factory.

Design support

The ADXL356 MEMS sensor is supported by the EVAL-ADXL35x evaluation boards which allow quick evaluation of the performance of Analog Devices series of low power, low noise, low drift 3-axis, MEMS accelerometers. The evaluation boards are ideal for evaluation of the ADXL35x accelerometer series within an existing system because the stiffness and the small size of the evaluation board minimize the effect of the board on both the system and acceleration measurements.