Characterization of wireless accelerometer sensor and its industrial applications

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The basic idea of this paper is to characterize wireless MEMS capacitive accelerometer sensor based on their field of applications. The selection of accelerometers are difficult for certain applications, that demands the sensor to be mount on rotating platform, higher value of g, sensitivity, and wide bandwidth of operation. Whenever higher sensitivity is chosen, the short fall is in the range of g and the bandwidth of operation. This is a serious issue with the sensor as far as industrial applications i.e., ball mill and sag mills are concerned. There is a misconception of using higher value of g (approximately around 500 g) with lower sensitivity in ball mill that is justified in this paper. Generally, the internal frequency of vibration of the ball mill is unknown, and the vibration due to impact during grinding is also random due to non uniformity in the grinding action inside the mill. For such an application, random selection of sensors can mislead the data acquisition and interpretation process. The perplexity of the application demands the characterization of accelerometer, when they are mounted on rotating platform. In this paper the sensor is characterized in mechanical testing lab using lathe machine and later on the same sensor is subjected to measure vibration of the industrial ball mill. Further, the data is transmitted using Zigbee (IEEE 802.15.4), and the RF signal losses during rotation and transmission are also taken care to avoid the high frequency losses due to multiple reflections. Finally, the vibration signatures obtained during experimental phases are analyzed using Fast Fourier Transform (FFT) to characterize the sensor at different operating speeds of the lathe machine.