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IT Vibration Sensors for Process Monitoring and Machine Protection
With vibration sensors like our BV100 from Montronix, you can detect tool breakage, collisions, and process errors immediately during operation. The sensor measures vibrations and structure-borne sound on the machine and reports critical deviations before damage or failures occur.
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What does a vibration sensor do and why do you need it?
A vibration sensor like the BV100 detects the finest mechanical vibrations and high-frequency structure-borne sound signals. These are generated by machining operations and indicate breakages, collisions, or tool failures. Unlike conventional systems, the BV100 also analyzes signals up to 400 kHz and thus detects even the smallest errors with small tools, sensitive processes, or hidden bearing damage.
Vibration Sensor BV100: Technical Data
The BV100 vibration sensor measures both mechanical vibrations and high-frequency structure-borne sound directly on the machine. It is designed for continuous use in industrial environments and withstands even extreme loads. The following technical data show why the BV100 is suitable for a wide range of machines and applications:
How the BV100 Vibration Sensor Works
The sensor detects vibrations directly on the machine structure and forwards the signal to the TSVA2-DGM amplifier. This processes it and transmits it to the SPECTRA™ unit. The amplifier housing is waterproof (IP67), and mounting is done directly in the wet area. The signal cables are available in 5, 15, or 30 meters. This allows vibration sensors to be flexibly installed even on large systems.
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- Test installation in your machine
We offer you a non-binding test installation directly on site to show how the BV100 works in your application. - Consulting and individual solution
Every machine is different. We support you in selecting, positioning, and integrating the sensor into your processes. - Compatibility with existing systems
Whether SPECTRA™, IBU Plus, or other evaluation units: our sensors can be easily connected, even in older machine parks. - Long-term support and training
We support you not only during commissioning but also during operation and training of your team.
Product Advantages of the BV100 Vibration Sensor
Broadband detection for maximum precision
The BV100 covers a frequency range from 0.1 Hz to 500 kHz, capturing both classic vibrations and high-frequency AE structure-borne sound signals. This allows it to detect not only major faults such as collisions or spindle defects, but also the smallest process deviations with micro-drills or thread cutters.
Robust design for industrial continuous use
The stainless steel housing and IP67 protection class make the sensor extremely resistant to moisture, coolants, and mechanical stress. It works reliably even under extreme temperatures and shock loads (up to 7000 g).
Easy installation and retrofit capability
Thanks to its compact design and mounting with just one M6 screw, the BV100 can be quickly and easily installed on almost any machine. The 5 m long cable with M12 screw connection ensures flexible integration even in confined spaces.
High sensitivity for the smallest signal changes
With a sensitivity of 100 mV/g and low output resistance (< 100 Ω), the sensor provides highly precise data. This signal fidelity is crucial for reliably detecting even minimal deviations in the machining process.
Perfect integration into SPECTRA™ systems
The BV100 is specially designed for use with the TSVA2-DGM amplifier and the Montronix SPECTRA™ electronic unit. System integration enables powerful and intelligent process monitoring over distances up to 30 m.
Versatile applications in machine monitoring
The sensor is suitable for detecting tool breakage, collisions, bearing damage, spindle problems, or missing tools. It offers a central solution for condition monitoring in machining centers, lathes, and special systems.
Typical Application Areas for Vibration Sensors
- Machine tools in machining
Vibration sensors monitor conditions in milling, turning, and drilling processes and detect errors directly during engagement. The BV100 reliably reports collisions, tool failure, or unstable processes during operation. - Monitoring small tools
For tool diameters under 3 mm, conventional systems often do not provide usable data. The BV100 detects high-frequency structure-borne sound signals and recognizes even minimal deviations. - Grinding machines and rotating spindles
High speeds lead to fine vibrations that can quickly escalate in the event of bearing damage or imbalance. The BV100 detects these changes at an early stage and helps prevent machine damage. - Systems with rotating components
Even outside of machining, vibration sensors detect mechanical changes in rotating parts. The BV100 is suitable for pumps, drives, and special solutions in continuous operation.
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Would you like to see how our sensor works under real conditions? Or are you planning a retrofit of your machines? With us you will find quick support with direct, personal contact.
Request a test installation nowFAQ: Frequently Asked Questions about Vibration Sensors
Is the BV100 also suitable for older machines?
Yes, the BV100 can be easily integrated into existing machines, even if they do not have modern interfaces. Retrofitting is done via analog signal paths and works independently of the machine control. This makes the sensor particularly suitable for retrofit projects or mixed machine parks. Many customers use the BV100 especially where digital monitoring was previously not possible.
What distinguishes the BV100 from an acceleration sensor?
Unlike classic acceleration sensors, the BV100 measures not only low-frequency vibrations but also high-frequency structure-borne sound signals up to 400 kHz. This allows it to detect faults that do not manifest as pure vibrations, such as crack formation or the smallest tool failures. Especially with micro tools or sensitive machining, the BV100 offers a clear advantage. It thus combines two monitoring concepts in one compact device.
Can I install the sensor myself?
Yes, installing the BV100 is straightforward and is done with a single M6 screw. The cable is pre-assembled, and connection to the amplifier is made with an M12 screw connection. Even without special training, the sensor can be installed within a few minutes. This makes the BV100 ideal for retrofits or test setups.
What additional components do I need?
To operate the BV100, you need the TSVA2-DGM signal amplifier, which processes the sensor signal. In addition, a SPECTRA™ unit is required to evaluate the data and process it further in the machine. Both components are optimally matched and can be flexibly integrated into existing systems. On request, we supply the complete unit including cables, mounting, and installation support.