Understanding Route-Based Data Collection

1. Definition: What is Route-Based Data Collection?

Route-Based Data Collection is the cornerstone of most predictive maintenance (PdM) and vibration monitoring programs. It is a systematic and periodic process where a technician uses a portable vibration analyzer or data collector to gather vibration data from a predefined list of machines and measurement points throughout a plant.

The “route” is a logical path that the technician follows, ensuring that all necessary data is collected consistently and efficiently at regular intervals (e.g., monthly, quarterly). This periodic data provides the basis for trending, which is essential for detecting the gradual changes in machinery health that signal developing problems.

2. The Workflow of a Route-Based Program

A mature route-based vibration program follows a continuous cycle:

1. Database Setup: A database is created in the host software on a PC. It is structured hierarchically (e.g., Plant > Area > Machine > Measurement Point). For each measurement point, specific data acquisition parameters (Fmax, resolution, averages, etc.) and alarm levels are defined.
2. Route Download: The “route” for a given day or week is downloaded from the host software to the portable data collector. The route contains the list of machines and points to be measured and all the pre-defined setup parameters.
3. Data Collection: The technician goes to the field and follows the route on the data collector. At each machine, they attach a sensor (e.g., an accelerometer with a magnet) to the specified measurement point (e.g., “Motor Outboard Bearing, Horizontal”) and acquire the data. The data collector guides the technician through the entire process.
4. Data Upload: After the route is complete, the technician connects the data collector back to the host PC and uploads the new measurements.
5. Analysis and Reporting: The software automatically flags any measurements that have exceeded their alarm thresholds. A trained vibration analyst then reviews the flagged data, analyzes the FFT spectra and time waveforms to diagnose the root cause of the problem, and generates a report with specific maintenance recommendations.

This cycle is then repeated at the next scheduled interval.

3. Advantages of a Route-Based Approach

• Cost-Effective: It allows a large number of machines (often hundreds or thousands) to be monitored with a relatively small investment in hardware and personnel compared to permanently installed online systems.
• Flexibility: The program can be easily expanded to include new machines, and the measurement parameters or intervals can be adjusted as needed.
• Consistency: By pre-defining the route and measurement settings in the software, it ensures that data is collected in a consistent manner every time, which is critical for reliable trending.
• Visual Inspection: Having a technician physically visit the machine provides an opportunity to look for other issues, such as leaks, unusual noises, or safety hazards.

4. Limitations

The main limitation of route-based collection is the interval between measurements. For highly critical machinery or machines with known rapid failure modes, a monthly or quarterly data collection interval may not be frequent enough to provide adequate warning. In these cases, a permanently installed online monitoring system is a more appropriate solution.

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