Installation Instructions for Three-Axis Vibration Sensor

Installation Instructions for Three-Axis Vibration Sensor

The installation of a three-axis piezoelectric vibration sensor is critical, as it directly affects the accuracy and reliability of measurement data. Incorrect installation can introduce errors, reduce the signal-to-noise ratio, and even damage the sensor. The following are detailed installation instructions and precautions:

1.Preparations before installation

Selecting the appropriate sensor: Based on measurement requirements, select a vibration acceleration sensor with high mechanical strength, high resonance frequency sensitivity, or high sensitivity in the low frequency range.

Inspecting the sensor: Ensure that the sensor is free of damage, that the leads and plugs are intact, and calibrate as necessary to ensure measurement accuracy.

2.Selection of installation location

Near the point of interest: Install the sensor near the area where you are most concerned about vibration conditions (such as bearing housings, gearbox casings, motor end caps, and critical structural points).

Rigid surfaces: Choose flat, sturdy, and rigid surfaces. Avoid installing on thin plates, sheet metal components, pipes, or other areas prone to local deformation or resonance. If the installation surface is uneven, apply silicone oil or lubricant to the contact surface to improve sealing.

Directional alignment: Carefully check the directional markings on the sensor (typically arrows or X/Y/Z labels); Ensure the physical orientation of the sensor strictly aligns with the desired measurement direction based on measurement requirements (e.g., Z-axis vertical upward measurement for vertical vibration, X/Y-axis measurement for radial / tangential vibration within the horizontal plane). Use a spirit level, angle ruler, or laser alignment tool to assist with positioning (especially during bolt installation).

Avoid interference: Install away from potential interference sources such as electromagnetic fields or areas with extreme temperature fluctuations.

3.Installation method

1)Bolt installation:

Use screws or other fasteners to securely attach the sensor base to the surface of the vibrating body. Pay attention to the alignment of the screw holes and the tightening force to avoid measurement errors caused by tilted bolts or screws that are too shallow. The advantage of bolt installation is its high connection strength, making it suitable for large-scale or complex vibration tests.

2)Adhesive installation:

Use a suitable adhesive (such as 502 glue, epoxy resin glue, etc.) to attach the sensor to the surface of the vibrating body. Adhesive installation is suitable for situations where drilling is not permitted, but the connection strength is relatively low, making it suitable for situations where the vibration level is not too high. When attaching the sensor, ensure that it is in close contact with the surface of the vibrating body to avoid bubbles and gaps.

3)Magnetic base installation:

Use a magnetic base to attach the sensor to the vibrating object. The advantage of magnetic base installation is that it does not damage the object being measured and is easy to move. However, it should be noted that magnetic base testing may cause a slight decrease in the frequency response of the sensor.

4.Cable connection

Disconnect power: Before connecting the sensor cable to the data logger/analyzer, ensure that the data acquisition system is powered off to avoid potential transient surges that could damage the sensor or acquisition equipment.

Secure connection: Firmly screw the cable connector into the sensor output port. Avoid partial connections.

Secure the cable: Immediately secure the cable to the structure being measured using cable ties, tape, or clamps near the sensor end. The securing points should be 10–15 cm from the sensor connector. This is critical to prevent the “chatter noise effect”! Unsecured cables can whip around like a whip, generating additional noise signals and potentially damaging the connectors.

Path Planning: When routing cables, avoid proximity to strong electromagnetic interference sources (such as motors, variable frequency drives, or high-current cables). Keep cables away from moving parts, high-temperature areas, oil contamination, and sharp edges. Use cable trays or protective conduits.

Avoid Stress: Ensure the cable bends naturally without sharp bends or tensile stress on the connector.

5.Calibration and testing

Calibrating sensors: Before formal measurement, the proportional relationship between the sensor output and the mechanical vibration it receives (i.e., sensitivity) should be determined using vibration calibration equipment. This requires calibration across different frequency and amplitude ranges to ensure the accuracy of measurement results.

Testing environment: Conduct environmental testing to determine the impact of possible environmental conditions (such as temperature, humidity, etc.) on sensor performance. This helps ensure the stability and reliability of sensors in actual applications.

6.Precautions

Avoid temperature changes: Vibration acceleration sensors may drift under high temperature conditions, so it is important to minimize the impact of temperature changes on measurements.

Prevent external impacts: During measurement, ensure that the sensor is not subjected to external impacts or vibrations, as this may damage the sensor or affect measurement accuracy.

Installation quality: The quality of sensor installation directly affects measurement results, particularly in high-frequency applications. Therefore, ensure that the sensor is securely installed with smooth contact surfaces.

In summary, the installation of a three-axis vibration sensor requires comprehensive consideration of multiple factors, including equipment type, installation location and direction, installation method, and wiring method. Correct installation methods and precautions ensure that the sensor accurately measures equipment vibration, providing reliable data support for equipment maintenance and fault diagnosis.

Xiyuan Electronic Technology Co., Ltd. is a national high-tech enterprise specializing in the design, development, production, and sale of sensors. The company has obtained ISO9001:2015 quality management system certification, and many of its products have passed explosion-proof certification. It is a sensor manufacturing enterprise with a large number of patents, strong comprehensive development capabilities, and a complete range of products. The various types of sensors produced by the company are mainly used in fields such as aerospace, energy and power, steel, civil engineering, petrochemicals, machinery manufacturing, research institutes, and universities.

Yangzhou Xiyuan Electronic Technology Co.,Ltd.

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