The core sensing workhorse for rotating machinery: capturing bearing race spalling, gear mesh harmonics, and mechanical unbalance up to 12 kHz.
Intercepts microscopic subsurface spalling in roller element bearings and early gear tooth pitting. While overall RMS velocity appears normal to standard inspections, high-frequency acceleration peak-to-peak and H-envelope peaks reveal defect impacts weeks before audible noise or thermal elevation.
Utilizes a seismic mass resting on a precision quartz or PZT ceramic crystal arranged in shear mode. When subjected to vibration, the mass exerts a dynamic inertial force on the piezoelectric crystal, producing an electrical charge proportional to instantaneous acceleration. An internal miniature FET amplifier converts the high-impedance charge into a low-impedance voltage output over a 2-wire constant-current loop.
Piezoelectric Shear Crystal → Internal Charge-to-Voltage FET → 2-wire 4 mA Constant Current Supply → Anti-Aliasing Low-Pass Butterworth Filter (48 dB/octave) → 24-bit Delta-Sigma ADC at 51.2 kS/s → Optruss FPGA Envelope Processing Pipeline.
Machined flat spot on bearing load zone perpendicular to shaft centerline
Application of thin layer of synthetic silicone grease to eliminate microscopic air gaps
Calibrated torque wrench tightening to precisely 3.5 – 4.5 Nm
Flexible stainless steel conduit protection against mechanical damage and solvent spray
Connect Pin A (Signal/Power) and Pin B (Common/Return) using MIL-C-5015 2-pin connector and Belden 8761 shielded twisted-pair cable. The outer foil shield must be grounded at the Optruss Edge Hub chassis ground ONLY to prevent ground loops. Spot-face bearing housing to Ra 0.8 µm surface finish and torque stud to 4.0 Nm with high-vacuum silicone couplant.
Envelope demodulation with bandpass filter 2 kHz - 10 kHz
Sharp nonsynchronous impact spikes at BPFO frequency with 1X shaft speed sidebands
H-Envelope spectrum peak detection
BPFI harmonic series flanked by prominent 1X shaft rotational modulation sidebands
Circular time-synchronous averaging (TSA)
High gear mesh frequency (GMF) peak with sidebands spaced at the defective gear rotational speed
Broadband high-frequency energy monitoring (1 kHz - 10 kHz)
Elevated white noise floor pedestal across the high-frequency spectrum resembling random impacts
Optruss Edge Hub samples the sensor continuously at 51.2 kS/s. The onboard real-time FPGA computes instantaneous Peak, RMS, Crest Factor, Kurtosis, and full 6,400-line FFT spectra every 60 seconds. When Kurtosis exceeds 3.8 or high-frequency envelope energy spikes above baseline, AssetCore automatically triggers an ISO 14224 Stage 2 failure event and schedules an ultrasound lubrication check.
Rapid zero-cabling deployment for Balance of Plant assets: monitoring radial, axial, and tangential vibration with 5-year battery life and long-range LoRaWAN telemetry.
The gold standard for fluid-film hydrodynamic bearings: measuring absolute shaft dynamic displacement, radial vibration, axial thrust position, and phase reference up to 10 kHz.
The earliest warning system on the P-F curve: detecting sub-micron lubrication film degradation, microscopic metal-to-metal contact, and pressurized gas leaks at 38 kHz.
Zero-downtime non-intrusive electrical monitoring from the MCC: diagnosing motor broken rotor bars, stator turn faults, and mechanical eccentricity via high-resolution current demodulation.
Continuous non-contact optical temperature telemetry: monitoring bearing housing caps, rotating kiln shells, electrical busbars, and furnace refractories up to 600°C.
Deterministic high-speed acquisition and local AI inference: running air-gapped on DIN rails with FPGA DSP, dual isolated Ethernet, and sovereign Merkle audit ledger.
Benefit from sub-millisecond edge FFT processing, early P-F curve anomaly detection, and automated CMMS work order generation.
