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IoT Vibration Monitoring for Prototype Testing

With the IoT functionality of the PCH Cloud solution, you can set up your prototype or null series machinery at any test site and monitor its vibrations remotely.

This allows you to adjust alarm levels, configure appropriate shut down triggers, and obtain a deeper understanding of how your machine responds to actual use before you bring it to market.
 

A Condition Monitoring Solution that Grows with Your Need

The PCH Cloud solution is a modular, real-time vibration monitoring system consisting of vibration sensors, configurable vibration monitors, an EtherBridge module providing cloud access and a cloud-based data viewing platform, PCH Dataviewer.
 

 
As the system is modular, it is easy to add sensors and monitors as the need for additional measuring points arises.
 

Real-Time Data, SIL Safety and Remote Access in One

With the PCH Cloud solution you get local, SIL 2 machine safety as the monitor’s relay and alarm functions alert the operator of any abnormal vibrations and, if so configured, they can trigger a shut-down mechanism on the machine. 

At the same time, you get remote access to the vibration data in real time. You can access the PCH Cloud database from any browser on any device: PC, tablet or smart phone, as required.

You can either view the data on the PCH Dataviewer platform or transfer the data to a cloud storage of your choice for further analysis.
 
For more information on the PCH Cloud solution, visit iot.pch-engineering.dk or contact our experienced advisors for a discussion of your condition monitoring requirements.
 

Case Study: IoT Monitoring Solution for Danish Start-Up

IoT solutions are not just for large manufacturers or machine owners with comprehensive condition monitoring strategies for multiple factories.

Smaller businesses can also benefit from remote access to data, as evidenced by this case about the Danish engineering start-up Universal Bar Feeder.
 

Project

The Universal Bar Feeder “feeds” metal bars to industrial CNC lathe machines at very high rotation speed.

During the prototype testing, ​Anders Lykkegaard, Sc. ME, R&D, Development Engineer of Universal Bar Feeder ApS, noted that the feeder vibrated violently if a bent metal bar was fed to the machine. He realised that it was necessary to monitor the highly automated bar feeder, not just during testing, but also when used by Universal Bar Feeder's customers.

Universal Bar Feeder went looking for a solution that would alert on-site personnel to the situation before it became dangerous and contacted PCH Engineering for a vibration monitoring solution.

Solution: Vibration consulting, prototype testing and cloud setup

First, we had to determine the root cause of the problem. We rigged up a prototype with test equipment connected to our online PCH Cloud database.

By collecting and analysing the data remotely, we found that if a metal bar was not entirely straight it would cause dangerous vibrations in the bar feeder which could, ultimately, make the machine crash and cause injury to on-site personnel.

We proposed a simple, cost-effective vibration monitoring solution with a shut-down trigger and IoT functionality.
The solution consisted of:
  • 1 vibration sensor with a relay that makes the machine shut down if a certain vibration level is exceeded
  • 1 IoT EtherBridge module connected to the vibration sensor through RS485
  • An online cloud setup, PCH Cloud, allowing Universal Bar Feeder to monitor and analyse the vibration data of their prototypes and first products remotely.

Benefits

With the vibration monitoring solution from PCH Engineering, Universal Bar Feeder was able to provide greater local machine safety to their clients, as the monitoring equipment from PCH Engineering is SIL 2 rated. The monitor’s local alarms and shut-down relay protects the machine and the personnel on site from breakdowns when the machine is in operation.

The remote access to data in the PCH Cloud database has helped Universal Bar Feeder understand how their machine is being used by their first clients and to adjust the vibration alarm levels accordingly.
 

 
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