Vibration sensors Manufacturers online

Vibration sensors are devices that detect mechanical oscillations, vibrations or movements of objects and convert them into an evaluable electrical signal.

Such sensors are used in industry, mechanical engineering, automotive engineering and even in medical technology to monitor machine conditions, detect faults at an early stage or precisely measure movements.

Below you will find the functionality and types of vibration sensors, their use and areas of application as well as their advantages:

How vibration sensors work:

The mode of operation depends on the sensor type, but basically it follows this principle:

Mechanical oscillations or vibrations cause a measuring body within the sensor (e.g. a mass, a piezo element or a MEMS crystal) to move.
This movement is converted into an electrical signal that is proportional to the amplitude, frequency or acceleration of the vibration.

Typical physical effects that are used are:

1. Piezoelectric effect:
   A mechanical deformation of a crystal generates an electrical voltage.
2. Capacitive effect:
   Changing the distance between capacitor plates by oscillation changes the capacitance.
3. Inductive effect:
   A coil or magnetic field is influenced by movement, which changes the inductance or voltage.
4. Hall effect or MEMS technology:
   Microstructured sensors measure acceleration or vibration through tiny moving structures.

Some sensors measure acceleration (accelerometers), others velocity (velocity sensors) or position changes, depending on the application.

Types of vibration sensors:

1. Piezoelectric sensors:
   Utilize crystals such as quartz or ceramic.
   Generate an electrical voltage directly in response to pressure or bending.
   Very sensitive, ideal for high-frequency vibrations.
   Often used in industrial systems, motor monitoring or test benches.
2. MEMS acceleration sensors:
   Very small, manufactured on a silicon basis.
   Measure linear or rotational accelerations.
   Widely used in smartphones, vehicles (airbag systems), drones and robotics.
3. Inductive and eddy current sensors:
   Measure vibrations by changing a magnetic field.
   Well suited for non-contact measurements on metal parts.
   High accuracy at medium frequencies.
4. Optical vibration sensors:
   Detect vibrations via laser or light reflection.
   Contactless, extremely sensitive, ideal for micro-vibrations.
   Used in material testing or nanotechnology.
5. Capacitive sensors:
   Utilize changes in distance between electrodes.
   Precise for small movements, e.g. in microelectronics or precision machines.
6. Resonance-based sensors:
   Measure the change in resonant frequency caused by external vibrations.
   High sensitivity and accuracy.
   Used in quality assurance and in safety-critical systems.

Use of vibration sensors:

Vibration sensors are used in many areas:

1. Machine monitoring:
Early detection of imbalances, bearing defects, gearbox damage or cracks.

2. Vehicle technology:
Stability control, engine and chassis diagnostics, airbag sensors.

3. Industry 4.0:
Condition-based maintenance, predictive maintenance, prevention of failures.

4. Construction industry:
monitoring bridges, buildings or machine foundations for resonance vibrations.

5. Medicine:
Measurement of heartbeats or respiratory movements.

6. Electronic devices:
Smartphones and tablets use MEMS sensors for orientation, motion detection or gaming.

Advantages of vibration sensors:

• Early detection of problems: Vibration patterns reveal wear and tear or malfunctions before total failure occurs.
• Non-contact measurement possible: Many sensors work without direct contact, which minimizes wear and tear.
• High sensitivity: Many sensors detect very small movements, even in the micrometer or nanometer range.
• Versatility: Different technologies adapt to a wide range of environments and frequencies.
• Can be automated: Ideal for Industry 4.0, robotics or vehicle control.
• Compact and energy-saving: MEMS and piezoelectric sensors in particular are small and require little energy.

Vibration sensors are essential for measuring movements, vibrations or mechanical oscillations and obtaining information about the status, stability or performance of a system. Various technologies - from piezoelectric to capacitive, inductive and MEMS - offer different advantages depending on the frequency range, accuracy, size and application. They are indispensable in industry, automotive engineering, medical technology, construction and electronics and make a decisive contribution to the safety, efficiency and service life of machines and devices.

Here you will find an overview of the most important points to consider when purchasing vibration sensors:

Vibration sensors are central components in condition monitoring, predictive maintenance and quality control. They provide valuable information about machine condition, vibrations or movement. The purchase of such sensors therefore requires careful planning, as wrong decisions can lead to inaccurate measurements, failures or increased costs. Professional purchasers must consider technical, economic and organizational aspects in equal measure.

• The first step is to define which measured variable is required: Acceleration, speed, position or frequency spectrum.
• Piezoelectric sensors are suitable for high-frequency vibrations.
• MEMS sensors are ideal for smaller, portable applications or digital integration.
• Optical sensors deliver the highest precision for micro-vibrations.
• The sensitivity of the sensor determines how small vibrations can be detected.
• A sensor for industrial machine bearings requires a different sensitivity than a MEMS sensor for a smartphone.
• Each application has a specific frequency range that the sensor must reliably cover.
• Machine monitoring often requires 10 Hz to several kHz.
• High-precision measurements can require several 10 kHz.
• The dynamics are also crucial: the sensor must be able to detect small vibrations as well as measure large deflections without saturation.
• The measurement accuracy determines the reliability of the data.
• Professional applications often require high linearity over the entire frequency and measuring range.
• Sensors with poor linearity can cause incorrect maintenance recommendations or misdiagnosis.
• Vibration sensors are used in different environments. Important factors are:
• Temperature range: sensors must work reliably at extreme temperatures.
• Moisture, dust or oil: Protection classes such as IP67 or IP68 are often necessary.
• EMC susceptibility: In industrial environments, electromagnetic interference (EMI) can distort measurements.
• Mechanical loads: Shocks, impacts or vibrations outside the measuring range must not damage the sensor.
• Professional systems require the sensor to be compatible with existing hardware or control systems.
• Analog sensors, e.g. 4-20 mA, 0-10 V, or digital sensors, I²C, SPI, CAN, Modbus, must be compatible with the system.
• Some sensors require an external supply voltage, others work independently, e.g. piezoelectrically without an external voltage.
• Regular calibration is necessary for precise measurements. Professional purchasers should check:
• Is the sensor supplied calibrated?
• How long does the calibration remain stable?
• Is recalibration possible?
• In addition, the longevity of the sensors should meet the requirements of the application, especially in industry with continuous operation.
• The price is only part of the decision. A cheap sensor with a poor service life or insufficient accuracy can result in higher follow-up costs.
• More expensive sensors often offer higher precision, better environmental resistance and less maintenance.
• Total cost of ownership takes into account acquisition, maintenance, calibration and failure risks.
• For professional use, reliability is crucial:
• Manufacturers with experience and certifications such as ISO, CE, RoHS, deliver more reliable products.
• Technical support, spare parts supply and documentation facilitate operation and integration.
• Many applications require the sensor to be integrated into a condition monitoring or predictive maintenance system. Important points:
• Compatibility with software platforms.
• Real-time data transmission.
• Possibility of remote monitoring and alarming.
• Depending on the industry, sensors must be certified:
• ATEX or IECEx for potentially explosive environments.
• Medical standards for near-patient applications.
• EMC and CE conformity for industrial and commercial products.

The professional purchase of vibration sensors requires a holistic approach: technical parameters, environmental conditions, interfaces, service life, calibration, costs and manufacturer quality must be carefully weighed up. A successfully selected sensor provides precise, reliable and long-term stable data, minimizes downtimes, reduces maintenance costs and makes a decisive contribution to the efficiency and safety of machines and systems. The key is to clearly define the application requirements and systematically evaluate the sensors according to accuracy, frequency range, environmental resistance and integration capability, rather than just looking at price or manufacturer.

Vibration sensors can be purchased from various suppliers. Comprehensive information about manufacturers and suppliers of Vibration sensors from all over the world can be found on Exportpages.