NVH-Based Prediction System
Introduction
The NVH-Based Prediction System developed by Senseops is a cutting-edge condition monitoring solution tailored for industrial environments. Leveraging advanced MEMS-based vibration sensors and real-time data analytics, this system enables early detection of anomalies in rotating equipment, significantly reducing downtime and enhancing operational efficiency.
NVH (Noise, Vibration, Harshness) analysis provides insight into structural integrity, mechanical faults, and lifecycle performance, making it a powerful tool for predictive maintenance.
Key Features
High Sensitivity & Accuracy
Equipped with 6-axis MEMS sensors
Sensitivity: 0.488 mG
Acceleration range: ±2G to ±16G
Resolution: 16-bit
Robust Industrial Design
Rugged aluminum enclosure suitable for harsh environments
Screw mounting for stable installation
Automotive-grade connectors for durability
Smart Connectivity
Communication via BLE 5.0, Wi-Fi (2.4GHz), and RS-485 Modbus RTU
MQTT-based cloud compatibility
Real-time data streaming to local or cloud dashboards
Inbuilt Temperature Monitoring
Thermistor-based temperature sensing from -55°C to +200°C
Integrated temperature and vibration analytics
System Architecture
Sensor Node Installation
Device: Spurana NVH Sensor
Location: Mounted on blower motor output shaft
Connection: RS485 wiring to data capture system
Power Supply: 5V DC @ 500mA
Data Transmission & Processing
Real-time sensor data relayed through RS-485 to an edge gateway
Local database & ML algorithms compute condition analytics
Results visualized via ICONICS Dashboard
Dashboard Features
Status Indicator | Meaning |
|---|---|
OK | Normal operation, no fault detected |
Warning | Moderate anomaly (e.g., minor vibration drift) |
Alarm | Critical fault (e.g., high amplitude peaks >5kHz) |
Fault | Communication/sensor failure |
Maintenance Required | Sensor calibration or service due |
Calibration Due | Scheduled calibration reminder |
Emergency Messaging | Real-time alerts for critical issues |
Data Visualization
FFT & RMS graphs in real-time
Historical trend plotting (e.g., 43-minute data capture)
Interactive charts and anomaly overlays
Use Cases
Use Case | Description |
|---|---|
Predictive Maintenance | Early fault detection using vibration signatures |
Condition Monitoring | Real-time monitoring of equipment health |
Tool Breakage Detection | Alerts for mechanical failure in CNC/VMC machines |
Structure-Borne Noise Analysis | Identifies structural issues or design flaws |
Common deployments: Motors, blowers, valves, agitators, CNCs, VMCs, engines.
Pilot Test Insights
Motor tested at 20Hz and 30Hz via VFD
→ Notable frequency peak shift observed between 4kHz–5kHzManual vibration tests demonstrated accurate response
→ Clear dashboard visualization upon tap-induced vibrations
Proposed Architecture (for VFD-Integrated Deployment)
Motor → VFD → NVH Sensor (RS-485)
Edge Gateway → Local Database + ML Engine
ICONICS Dashboards → Visualization & alerts
Cloud Sync (optional) for remote monitoring
Benefits of NVH-Based Prediction System
Feature | Benefit |
|---|---|
High Resolution | Detects subtle mechanical faults |
Multi-Axis Sensing | Comprehensive vibration analysis |
Low Power & Compact | Minimal intrusion and energy consumption |
Scalable | Easily expandable to multiple equipment units |
Integrated Analytics | Enables data-driven decision making & automation |
Conclusion
Senseops' NVH-Based Prediction System brings predictive maintenance to the forefront of Industry 4.0. By combining high-fidelity sensor data, smart analytics, and intuitive dashboards, industries can prevent downtime, extend equipment life, and ensure safe operation—all in real time.
For more information or a demonstration, Contact us to schedule a live demo or site survey.