How to Save Money When Buying Balluff Pressure Sensor

In previous blogs, we discussed the different types of machine failures and their implications for different maintenance approaches, the cost-benefit tradeoffs of these maintenance approaches, and the progression of machine failures and indicators that emerge at various failure phases. We now will connect the different failure indicators to the sensors which can detect them.

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The Potential – Functional Failure (P-F) curve gives a rough picture of when various indicators may emerge during the progression of a failure:

Each indicator can be detected by one or more types of sensors. Selection of the “best” sensor will depend on the machine/asset being monitored, other attributes being sensed, budget/cost-benefit tradeoff, and the maintenance approach. In some cases, a single-purpose, dedicated condition-monitoring sensor may be the right choice. In other cases, a multi-function sensor (“Smart Automation and Monitoring System sensor”) which can handle both condition monitoring and standard sensing tasks may be an elegant and cost-effective solution.

The table below gives some guidance to possible single- and multi-function sensors which can address the various indicators:

Indicator/What is measured

Typical machine/asset to be monitored

Sensor type

Ultrasonic spike

Bearing, spindle, compressor, motor, pump, valve, gearbox

Ultrasonic sensors

Vibrations, oscillations, accelerations

Motor, bearing, conveyor, pump, fan, spindle, compressor, gearbox, robot, machine tool, press

Condition monitoring sensors*

Smart Automation and Monitoring System sensors#

Oil/Fluid analysis

Lubrication, cutting fluid, hydraulic fluid system

Fluid contamination sensor

Fluid property/Condition sensor

Temperature

Motor, bearing, conveyor, pump, fan, spindle, compressor, gearbox, machine tool, electronics cabinet, oven, furnace

Temperature sensors

Condition monitoring sensors*

Smart Automation and Monitoring System sensors#

Pressure

Lubricant, coolant or hydraulic fluid reservoir or line, pump, valve

Pressure sensors

Condition monitoring sensors*

Smart Automation and Monitoring System sensors#

Flow rate

Coolant, lubricant, hydraulic fluid or pneumatic line, pump, valve

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Flow sensors

Humidity

Electronics cabinet, packaging machine, dryer

Condition monitoring sensors*

Smart Automation and Monitoring System sensors#

Voltage & current

Motor, drive, pump, fan, compressor

Voltage, current, power meters/sensors

Smart Automation and Monitoring System sensors#

Speed

Motor, conveyor, pump, fan, spindle

Encoders

Inductive sensors

Level

Lubricant, coolant or hydraulic fluid reservoir; leak detection, pump, valve

Capacitive sensors

Ultrasonic sensors

Magnetostrictive sensors

Displacement & distance

Machine tool, press, robot, conveyor

Inductive sensors

Ultrasonic sensors

Magnetostrictive sensors

Inclination

Conveyor, press, machine tool

Inclination sensors

Smart Automation and Monitoring System sensors#

* Condition monitoring sensors are specialized sensors that can often detect multiple indicators including vibration, temperature, humidity, and ambient pressure.

# Smart Automation and Monitoring System sensors add condition monitoring sensing, such as vibration and temperature, to their standard sensing functions, such as photoelectric, inductive, or capacitive sensing.

There is a wide range of sensors that can provide the information needed for condition monitoring indication. The table above can provide some guidance, selecting the best fit requires an evaluation of the application, the costs/benefits, and fit with the maintenance strategy.

For more information, please visit Balluff Pressure Sensor.