Radar-based Vibration Monitoring: A study defining a need for contactless vibration monitoring and the development of a radar-based sensor for industrial settings

Abstract

Undesired vibrations are a large problem within many industries as they cause damage to structures, machines, and equipment. This can lead to unplanned stops in production resulting in very costly consequences for their businesses. Emerson Automation Solutions has recently been able to modify its radar technology to monitor vibration levels contactless. With this technology, Emerson has the opportunity to be the first on the market with this technology. The aim of the project is to identify a user need and market for a contactless vibration monitoring device, as well as develop a physical concept of a radar sensor that can monitor vibrations and fulfill the needs of the users in the chosen market. To understand the needs of the users, user studies were conducted including interviews with ten companies in two rounds and four company visits. The need was then defined and used as a basis for developing the product. The results showed the users being satisfied with today’s cheap and popular accelerometer solutions used for vibration monitoring. However, a need was found for measuring vibrations where today’s solutions are not satisfactory. The market gap found was measuring vibrations on rotational equipment in inaccessible, extreme, or dangerous environments. The study visits showed a need for a flexible solution as the production sites could vary greatly between production sites. The results are compiled into a design concept of a semi-permanent radar vibration sensor. It was concluded that the flexibility the final concept offers, including the attachment solutions as well as the different versions, enables its use in many different applications.