As the steel and tube industry continues to evolve, the challenges faced by mills are becoming increasingly complex. One area that has become more important is the use of predictive maintenance to improve the efficiency and reliability of production equipment. In this post, we will explore some of the key differences between battery-operated and wired vibration sensors, and how they can help steel and tube mills achieve better performance.
- One major challenge with battery-operated sensors is their limited temperature range. Batteries can quickly fail under hot and cold environments, so most battery-operated vibration sensors are limited in their temperature use specification, with a high end of around +70C and a low end of -20C.
- Another challenge is the difference in data capture between battery-operated and wired sensors. Battery-operated sensors typically capture periodic data to save on computing and battery power, whereas wired sensors provide continuous monitoring of assets and never miss any critical alarms.
- The sampling rate is also a key consideration. Battery-powered sensors typically have a higher sampling rate, but poor bin frequency resolution. In contrast, wired sensors have a lower sampling rate but provide better resolution.
- Hours of operation are another important factor to consider. Wired sensors can operate 24/7/365, while battery-operated sensors typically work less than 66 hours per year.
- Finally, battery maintenance is a critical issue to consider. After 3-5 years, battery maintenance can become difficult, and in a plant environment, you may need to replace two batteries a week. Wired sensors, on the other hand, are maintenance-free.
In conclusion, it's essential to understand the differences between battery-operated and wired vibration sensors when it comes to predictive maintenance. Both types have their unique strengths and weaknesses, and the right sensor for a particular application will depend on the specific requirements of the steel and tube mill.
