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　　Effects of Motor and Asset Failures on Manufacturing

　　When a critical motor unexpectedly breaks down in a factory, production stops. If a specific part or even the entire motor needs to be replaced, there is a risk that long lead times may be incurred. Unplanned downtime costs 10 times more than planned downtime.1 Annually, the average factory downtime is around 800 hours.1 The net result of this information is that CbM is growing rapidly at a time when wireless technology coupled with recent advancements in MEMS sensor technology are allowing factory and maintenance managers to rapidly deploy highly effective wireless CbM systems to stem losses due to unplanned downtime. While triaxial MEMS sensors are likely to be at the heart of this wireless revolution, there is still some confusion as to what exactly these vibration sensors are capable of.

　　Where Do Triaxial MEMS Accelerometers Fit on the Vibration Sensor Spectrum?

　　To minimize production downtime, it is imperative to know about the potential failures within the motor to be ready to deal with them. While single-axis analog output MEMS sensors, designed specifically to rival piezo vibration sensors, have recently achieved similar levels of performance to low-level/mid-level piezo sensors in terms of being able to diagnose faults, this article is more focused on narrow bandwidth monitoring (0 Hz to 1 kHz) more commonly seen in triaxial MEMS accelerometers. Not every CbM deployment is focused on diagnosing or even predicting asset faults. In some assets, it may be acceptable to detect faults at a later stage, and therefore, the sensor performance and cost can be a little lower. This is where triaxial MEMS accelerometers can offer a high performance (low noise down to 25 μg√Hz) and low cost alternative as shown in Figure 1. Comparing the ADXL356 and piezo sensor PZT 8, there is a 20× cost increase with very few high performance, low cost MEMS alternatives in between. Significant growth in this area is expected over the coming years.