A study using a training solution simulator to detect the presence of known faults using various Erbessd Instruments® data collection technologies.
Key Context Elements
- Machine Type: EI-TSIM4 Training Solution Simulator PRO
- Known Issues: Various known faults were introduced including defective bearings, gears and setup configurations.
- Partners Involved: Erbessd Instruments Technical Support Staff
- Exercise Dates: 04 August – 05 September 2025
- Project Participants: Chris Keniston, CMRP–VP of Technical Services, Greg Grummett–Technical Services Application Engineer, Parag Nikam–IIoT Application Engineer
- Objective: Determine the ability of various Erbessd Instruments data collection instruments to accurately and reliably capture machine faults in their data.
Technology Used
Methodology
Research team introduced components with known or suspected defects included with the EI-TSIM4 Training Solution Simulaor PRO. Machine databases and portable data collection routes were created using DigivibeMX® software and the EI-Analytic™ cloud-hosted database service.
Route files were loaded and collected using DigivibeMX® software. Duplicate route files were also synchronized to and collected with the WiSER Vibe® mobile app. Over 100 individual points of data were collected using EPH-V10E PHANTOM® vibration sensors, WiSER3X portable data collectors and GX400 USB-connected interfaces with an AC500-2P 100 mV/g single-axis accelerometer.
Comparative analysis was performed between DigivibeMX® software, EI-Analytic™ cloud-hosted database service and WiSER Vibe mobile app for the appearance, frequency accuracy and amplitude accuracy of known or suspected defect frequencies in the data.
The purpose of this exercise was to validate the following criteria:
- EI-TSIM4 Training Solution Simulator PRO reliably produces identifiable defect frequency data for training and demonstration purposes.
- EPH-V10E PHANTOM® vibration sensors, EI-WiSER3X and the GX400 interface equipped with a wired AC500-2P 100 mV/g single axis accelerometer provide comparable data, when collected at the same pointes on the same machine.
- Data appearance and analytical tools in DigivibeMX® software, EI-Analytic™ cloud-hosted database service and WiSER Vibe® mobile app are accurate, reliable, comparable and consistent.
Vibration Spectral Data Examples
Rolling element defect frequency (BSF) – SKF 6202
Inner race defect frequency (BPFI) – SKF 6202
Outer race defect frequency (BPFO) – SKF 6202
Gear Frequencies – Broken Teeth (80/40 Multiplier)
Findings
In our opinion, this exercise validated our experimental criteria:
- EI-TSIM4 Training Solution Simulator PRO reliably produces expected, identifiable defect frequency data for training and demonstration purposes.
- EPH-V10E PHANTOM® vibration sensors, EI-WiSER3X and GX400 interface equipped with a wired AC500-2P 100 mV/g single axis accelerometer provide comparable data–with expected variance due to differences in natural resonant frequencies and sensor mounting methods – when collected at the same points, in the same directions on the same machine.
- Data appearance and analytical tools in DigivibeMX®software, EI-Analytic™ cloud-hosted database service and WiSER Vibe® mobile app are accurate, reliable, comparable and consistent.
Chris Keniston, VP of Technical Services at ERBESSD INSTRUMENTS®, spent nearly 14 years in a “zero-failure” maintenance, reliability, and safety envionment with the U.S. Air Force, where he gained training in industrial EHS, maintenance reliability, and production management. He applied strategies for critical success in world-class operations while earning a Bachelor of Science in Aeronautics and two AAS degrees.
After leaving the Air Force in 2009, he focused on improving American manufacturing through reliability-centered maintenance and continuous improvement. For almost a decade, he managed maintenance and safety functions at leading companies. Since December 2017, he has helped establish ERBESSD INSTRUMENTS® as a dynamic predictive technology manufacturer in the IIoT space.
ERBESSD INSTRUMENTS® is a leading manufacturer of Vibration Analysis Equipment, Dynamic Balancing Machines, and Condition Monitoring with facilities in Mexico, the USA, England, India, and Colombia.