How can acoustic monitoring be integrated into existing engine test benches?

A retrofit solution requires flexible connectivity to existing automation and bus systems. With ibaPDA, both control data and high-frequency sensor signals can be integrated via modules such as ibaPADU-S and ibaBM-CAN. Bidirectional communication via fiber optics and Ethernet ensures seamless integration into existing test bench systems. This creates a continuous data foundation without interfering with the existing architecture.

How can acoustic and vibration signals be used for condition monitoring?

Acoustic emissions and vibrations provide complementary information about machine condition. With ibaInSpectra, these signals can be analyzed across defined frequency ranges to identify characteristic patterns. The combination enables a differentiated assessment of mechanical anomalies. This allows early detection of complex fault conditions.

How can long-term tests be operated safely without manual supervision?

Continuous monitoring of defined thresholds enables autonomous test bench operation. With ibaPDA and ibaInSpectra, relevant indicators are calculated and monitored in real time. If limits are exceeded, automatic shutdown can be triggered via digital outputs. This ensures safe and uninterrupted operation over extended test durations.

What are the data acquisition requirements for acoustic analysis in test benches?

Acoustic analysis requires high sampling rates and precise signal processing. With ibaPADU-S, IEPE sensors such as microphones and accelerometers can be captured at high frequency. Synchronization with process data in ibaPDA enables context-based evaluation. This allows reliable analysis of fast and complex signal patterns.

How can test bench data be efficiently analyzed and processed?

Efficient analysis requires direct access to raw and process data along with flexible evaluation tools. With ibaAnalyzer, recorded data can be visualized and analyzed in detail immediately. Combined with continuous data storage, this enables long-term comparisons and trend analysis. This creates a scalable foundation for further optimization and quality assurance.

Acoustics Testing With ibaInSpectra

Acoustical Monitoring in the Engine Testing Technology

Test benches at an automobile engine plant had to be retrofitted by the test bench manufacturer to include acoustics analysis. Before including an iba system, long-term tests (> 300 h.) had to be interrupted at night, as employees only work for two shifts.

Business Benefits The Technology Used Functions More Success Stories

To optimize testing efficiency, the test bench manufacturer decided to implement a reliable monitoring system that automatically shuts down the test bench when vibration and noise level exceed pre-defined thresholds. In the end, the manufacturer decided on the iba system because it can be configured easily and flexibly.

Uninterruptible

long-term tests

Easy integration

into existing test bench automation

Convenient solution

for acquiring, displaying, and analyzing time and frequency domain data

The Technology

Our ibaPDA (Process Data Acquisition) system can communicate with almost all automation platforms for data collection. At the same time, ibaPADU (Parallel AnalogDigital Unit) can be used to acquire fast analog and digital signals via high-quality analog-digital converters. Due to our broad connectivity and with an acquisition rate of up to 100 kHz, ibaPDA can acquire and hence optimize the behavior of complex and fast processes. With the ibaInSpectra software add-on, iba offers a convenient solution for real-time analysis and visualization of spectral components in machines.

Data recorded on the test bench are made available to experts for time domain and frequency domain analysis using ibaAnalyzer.

The iba system allows for a defined and reproducible measurement procedure that is nevertheless individually adapted to different circumstances and can be extended for further demands.

The ibaInSpectra Condition-Monitoring software is used for frequency analysis. The sensor technology (IEPE acceleration sensors and IEPE microphones) is interfaced by means of an 8-channel IEPE module on the modular ibaPADU-S I/O system at a sampling rate of 40 kHz. The test bench can be switched off using a digital output module on the ibaPADU-S. The system is connected to ibaPDA using duplex FO (fiber optic) cable. Control signals are transmitted from the test bench control system to the measurement system via CAN bus. The external ibaBM-CAN module receives data from the CAN bus and transfers them over FO to ibaPDA.

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Used Functions

The following functions of the iba system are used in this success story.

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Frequently Asked Questions (FAQ)

How can acoustic monitoring be integrated into existing engine test benches?: A retrofit solution requires flexible connectivity to existing automation and bus systems. With ibaPDA, both control data and high-frequency sensor signals can be integrated via modules such as ibaPADU-S and ibaBM-CAN. Bidirectional communication via fiber optics and Ethernet ensures seamless integration into existing test bench systems. This creates a continuous data foundation without interfering with the existing architecture.
How can acoustic and vibration signals be used for condition monitoring?: Acoustic emissions and vibrations provide complementary information about machine condition. With ibaInSpectra, these signals can be analyzed across defined frequency ranges to identify characteristic patterns. The combination enables a differentiated assessment of mechanical anomalies. This allows early detection of complex fault conditions.
How can long-term tests be operated safely without manual supervision?: Continuous monitoring of defined thresholds enables autonomous test bench operation. With ibaPDA and ibaInSpectra, relevant indicators are calculated and monitored in real time. If limits are exceeded, automatic shutdown can be triggered via digital outputs. This ensures safe and uninterrupted operation over extended test durations.
What are the data acquisition requirements for acoustic analysis in test benches?: Acoustic analysis requires high sampling rates and precise signal processing. With ibaPADU-S, IEPE sensors such as microphones and accelerometers can be captured at high frequency. Synchronization with process data in ibaPDA enables context-based evaluation. This allows reliable analysis of fast and complex signal patterns.
How can test bench data be efficiently analyzed and processed?: Efficient analysis requires direct access to raw and process data along with flexible evaluation tools. With ibaAnalyzer, recorded data can be visualized and analyzed in detail immediately. Combined with continuous data storage, this enables long-term comparisons and trend analysis. This creates a scalable foundation for further optimization and quality assurance.