Why Vibration Monitoring is Foundational to Smart Maintenance?

In the era of Industry 4.0, every asset becomes a source of diagnostic data. Vibration signals, emitted by rotating equipment like motors, fans, turbines, and compressors, are among the most reliable indicators of mechanical health. These signals reveal developing issues such as:

• Bearing wear
• Shaft misalignment
• Rotor imbalance
• Gear tooth damage

To make sense of this data, industries deploy vibration sensors - devices that transform mechanical motion into measurable electrical signals. With AI-driven analytics, real-time condition monitoring, and IoT-based predictive maintenance gaining momentum, choosing the right type of vibration sensor is critical.

To make an informed selection, it is first important to understand the core vibration parameters that any reliable system must be capable of capturing.

Why The Diagnostic Core - What Every Vibration Sensor Must Capture

An effective condition monitoring system must track three essential parameters:

Amplitude: Magnitude of the vibration - reflects fault severity.

Frequency: Helps classify faults - imbalance (1× RPM), bearing issues (BPFO/BPFI), misalignment, etc.

Phase: Pinpoints the fault's location - especially vital for balancing or aligning multi-bearing systems.

These parameters, when accurately measured, form the diagnostic foundation of any condition monitoring framework.

With these measurement objectives in mind, the next step is to examine the major types of vibration sensors available and their respective capabilities.

Four Types of Vibration Sensors - A Technical Comparison

Various sensor technologies are available, each with its own advantages, limitations, and suitability for specific applications. A comparative understanding of these options is essential for aligning sensor selection with asset criticality, machine design, and deployment strategy.

MEMS Triaxial Accelerometers

• Detect acceleration using capacitive MEMS structures.
• Available in triaxial configurations for full 3D motion detection.
• Direct digital output - ideal for edge computing and wireless transmission.
• Highly scalable, compact, and low-power.

Piezoelectric Triaxial Accelerometers

• Convert mechanical stress into electrical charge via piezoceramic elements.
• Offer high bandwidth and extremely low noise.
• Typically uniaxial with analog output, requiring IEPE or charge amplifiers.
• Rugged and reliable under high temperatures and forces.

Velocity Sensors

• Measure velocity directly - important for ISO 10816/ISO 20816 compliance.
• Simple architecture (magnet + coil).
• Analog signal; moderate integration effort.
• Limited to lower frequencies (~2 Hz to 1–2 kHz).

Displacement Velocity Sensors (Proximity Probes / Eddy Current)

• Measure shaft-to-casing displacement, especially for journal bearings.
• Used in critical assets like turbines, compressors, and high-speed spindles.
• Excellent for direct shaft motion measurement.
• Analog signal: high cost and complex installation.

Comparative Matrix - Sensor Performance Across Key Parameters

To facilitate direct comparison, the following matrix summarises the relative performance of each sensor type across key operational dimensions.

This comparison provides a concise overview of where each sensor type excels, helping guide selection based on your technical and operational priorities.

However, sensor performance is also influenced by how and where it is deployed. The following section outlines the typical deployment models and how each sensor aligns with them.

Deployment Models - What Each Sensor Type Supports

The practical utility of a sensor often depends on the context in which it is applied - whether in route-based programs, permanent online monitoring, or wireless IIoT networks.

This classification underscores the importance of selecting a sensor that not only meets technical requirements but also fits within the broader maintenance and data infrastructure.

Considering these factors, one sensor type emerges as particularly well-suited for modern predictive maintenance strategies.

Why MEMS Triaxial Accelerometers Lead the Future of Predictive Maintenance

When evaluating the four primary types of vibration sensors—MEMS, Piezoelectric, Velocity, and Displacement—MEMS triaxial accelerometers emerge as the most adaptable and forward-looking solution for today’s industrial reliability needs.

Digital Architecture and Integration Capabilities

MEMS sensors offer a compact design, low power consumption, and built-in digital output. Their compatibility with modern communication protocols makes them well-suited for integration into both wired and wireless systems, supporting scalable solutions like ARGUS.

Wider Application Across Industrial Equipment

Unlike piezoelectric, velocity, or displacement sensors—which are often limited to specific machines or fault types—MEMS sensors are effective across a broad range of rotating equipment, including motors, pumps, and gearboxes. They provide essential vibration data such as amplitude, frequency, and phase.

Support for Both Portable and Fixed Installations

MEMS sensors are equally effective in handheld diagnostic tools and permanently installed systems. Their triaxial measurement capability enhances fault detection accuracy, enabling early-stage issue identification when combined with AI analytics.

Compatibility with Advanced Monitoring Technologies

Designed for modern industrial environments, MEMS accelerometers support:

• Edge analytics and local processing
• Wireless data transmission
• Cloud-based dashboards
• IoT gateway integration

These features enable real-time decision-making at the machine level while allowing centralised visualisation and analysis.

Strategic Alignment with Digital Maintenance Goals

MEMS triaxial accelerometers are more than a practical solution—they represent a strategic foundation for digital reliability programs. They enable faster diagnostics, broader equipment coverage, and seamless integration with AI and IoT platforms, making predictive maintenance more scalable, insightful, and cost-efficient.

ARGUS - Smart Vibration Monitoring

In the age of connected industries, ARGUS stands as a unified vibration monitoring platform built to harness the full potential of MEMS triaxial accelerometers, edge intelligence, and IoT-ready architecture. Whether you’re performing routine condition checks or deploying plant-wide predictive analytics, ARGUS adapts to your operational goals.

By standardizing on MEMS sensing, ARGUS delivers scalable performance across rotating assets-capturing multi-axis vibration signatures with high fidelity. Combined with built-in edge processing and diagnostic algorithms, it transforms raw vibration data into early fault insights—without waiting for cloud processing. 

What sets ARGUS apart:

• Supports both portable and permanently installed sensor models
• Seamlessly integrates with existing IT/OT infrastructure
• Supports MQTT, Modbus TCP (Wi-Fi/Ethernet), and Modbus RS-485, making ARGUS the only platform in its class to offer native integration with cloud analytics, SCADA, and IIoT ecosystems
• Offers real-time alerts, FFT diagnostics, and central dashboards
• Optimised for motor-driven assets, gearboxes, and critical rotating equipment
• Flexible deployment options

ARGUS simplifies the complexity of predictive maintenance-allowing reliability teams to focus on decisions, not data acquisition.

Ready to Modernise Your Maintenance Strategy?

Whether you're piloting a few pumps or rolling out across multiple facilities, ARGUS offers the flexibility, intelligence, and integration your maintenance program needs - powered by MEMS-based sensing, edge analytics, and scalable IoT architecture.

Talk to SANDS today to see how the ARGUS vibration analyzer can help unify your vibration monitoring efforts with the latest in AI and IIoT technologies.