Motor and Pump Predictive Maintenance

The problem on site

A plant runs tens to hundreds of motors, pumps and fans, traditionally checked on rounds with handheld vibration meters. The data is intermittent and hard to keep on record, and bearing, alignment or looseness problems often grow between two rounds.

Architecture: sensors matched to how critical the machine is

• Critical machines: HY-VT3K / HY-VT5K compute the FFT spectrum, velocity and displacement in the sensor, output ISO 10816-3 A/B/C/D zones and limit flags directly, and report when the mounting has worked loose.
• General machines: HY-VT2000, in a 60 × 25 × 7 mm IP68 all-316 stainless housing, outputs triaxial overall vibration and two temperature channels for trend monitoring at many points (no spectrum or ISO zone rating).

All three connect over RS-485 Modbus RTU to the same ETH-VHS-A2N vibration monitoring gateway, which computes zones and a health score (0–100) using the HOYAN-CBM criteria so every machine in the plant can be ranked. The built-in four-language web interface needs no installation or licence; an existing SCADA reads the results over Modbus TCP or MQTT.

What changes

• From rounds to continuous monitoring: every machine has a trend record.
• Which machine first: health scores make machines of different sizes directly comparable.
• Cost matched to need: spectra on critical machines, trends on the rest.