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MEMS sensor offers reliable system failure warning

Posted: 07 May 2008 ?? ?Print Version ?Bookmark and Share

Keywords:MEMS vibration sensor? shock sensor?


Analog Devices Inc. has introduced a high-bandwidth MEMS vibration sensor to enable better monitoring of equipment performance and reduce costly downtime due to unforeseen system failures on the factory floor. Based on ADI's iMEMS Motion Signal Processing technology, the ADXL001 industrial vibration and shock sensor for the first time allows designers of industrial process control instruments to cost-effectively incorporate high-performance, dependable high-bandwidth vibration monitoring into their applications via an easy-to-use sensor solution.

Vibration analysis is emerging as an important preventative maintenance tool in today's factory environment. For many industrial operations, however, vibration analysis remains cost-prohibitive or is conducted only periodically. Now, the ADXL001 allows vibration monitoring to be performed continuously without interrupting normal operation of the equipment. ADI's applied the same expertise it uses to address the high-reliability and harsh environmental conditions of automotive design to develop a single-chip, precision vibration sensor able to withstand the rigors of industrial applicationsat one-third the cost of competing sensors.

Many other vibration sensors operate below 5kHz of bandwidth, a frequency range that would be emitted only after extensive equipment failure. The ADXL001, however, is capable of very early detection of motor-bearing vibration and irregularities up to 22kHz, allowing system operators to identify failing equipment long before costly damage is sustained. The iMEMS vibration sensor is available in a 5mm x 5mm ceramic package that is small enough to be easily designed into the motor control circuitry or mounted on existing factory equipment at the point of measurement interest.

"A catastrophic equipment failure can cost hundreds of thousands of dollars in lost productivity and is the worst-case scenario for any manufacturing operation," said Rich Mannherz, product line director, micromachined products division of ADI. "While various vibration sensing technologies have been used for years to mitigate the risk of system failure, none have the combination of size, performance, cost and reliability to make real-time, around-the-clock equipment health monitoring broadly available in industrial applications. That's the gap we're filling with the ADXL001 product."

Industrial vibration, shock sensor
Available in three full-scale dynamic ranges of 70g, 250g and 500 g, the new vibration and shock sensors have the sensitivity to work in a wide range of applications. All three g ranges have wide bandwidth (22kHz resonant frequency) and provide frequency response down to dc. Additionally, the sensors have excellent nonlinearity of 0.2 percent of full-scale range. The ADXL001 is highly resistant to EMI and RF interference, and operates with an extended temperature range of -40C to 125C, allowing the part to be used in most hazardous industrial conditions. The ADXL001 functions on a 3.3-5V supply.

The ADXL001 requires no calibration and is ideally suited to work with ADI's precision data converters. The ADXL001 also works in conjunction with ADI's SigmaDSP processor and intuitive SigmaStudio graphical user interface to provide equipment designers with an easy-to-use programming environment. As the output of the ADXL001 passes through the SigmaDSP processor, the system designer can use the SigmaStudio software to perform various processing techniques including filtering and amplification.The ADXL001 will be available in sample quantities starting this month, with volume production scheduled for August. The ADXL001 is priced at $35 in 1,000-unit quantities and comes in an 8-pin LCC (leadless chip carrier) ceramic package.

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