What are the best practices for using vibration analysis in equipment maintenance?

Recently we are in a trouble in our assembly area as we used sensors with less proximity area while product interactions are wide. In my POV 👀 using the right sensors and locations for vibration analysis in equipment maintenance enables early detection of issues, accurate diagnostics, predictive maintenance, improved equipment reliability, cost savings, and enhanced safety, making it a valuable tool for optimizing equipment performance and minimizing downtime.

Select appropriate vibration sensors based on the equipment type, operating conditions, and vibration frequency range of interest. Install sensors at critical locations on the equipment where vibrations are most likely to occur or where they can provide the most valuable data. Conduct a thorough assessment of equipment requirements and consult with vibration analysis experts to determine the optimal sensor types and locations.

Establish a baseline vibration profile for each piece of equipment during normal operation. Set alarm thresholds based on acceptable vibration levels to detect deviations from the baseline that may indicate potential issues or impending failures. Ensure alarms are configured to trigger timely notifications to maintenance personnel. Use historical data and trending analysis to establish baseline vibration levels and define alarm thresholds tailored to each equipment type and application.

Implement a scheduled vibration monitoring program to perform regular and consistent measurements across all monitored equipment. Establish a frequency for vibration data collection based on equipment criticality, operating conditions, and maintenance requirements. Consistent measurement intervals enable early detection of changes in vibration patterns and facilitate proactive maintenance interventions. Develop a comprehensive vibration measurement schedule and integrate it into routine maintenance activities to ensure consistency and reliability.

Utilize advanced vibration analysis tools and techniques to interpret vibration data accurately and identify underlying issues. Employ signal processing methods such as FFT (Fast Fourier Transform) analysis, time waveform analysis, and frequency spectrum analysis to extract valuable insights from vibration signals. Leverage predictive maintenance software and condition monitoring systems to streamline data analysis and visualization. Invest in training for maintenance personnel to enhance their proficiency in using vibration analysis tools and interpreting vibration data effectively.

Take prompt action based on the results of vibration analysis findings to address identified issues and prevent equipment failures. Implement appropriate corrective actions, such as equipment adjustments, repairs, or component replacements, to mitigate potential risks and restore optimal equipment performance. After implementing corrective measures, verify the effectiveness of interventions by conducting follow-up vibration measurements and trend analysis. Establish a closed-loop feedback system to track the outcomes of corrective actions and ensure continuous improvement in equipment reliability and maintenance practices.

Todos os tópicos listados são importantes, mas considero imprescindível um sistema de aquisição/analise/alerta on line. Este sistema deverá ter análise por IA de tendência e referências cruzadas com outras variáveis do equipamento monitorado (rotação,tensão,corrente,velocidade e temperaturas)