In the monitoring of industrial equipment operation, the phase comparator module is one of the key components. Its core function is to capture the phase signals of rotating machinery, providing a reference for vibration analysis, speed measurement, etc. The improved 3500/25 phase comparator module launched by Bently in the United States belongs to the sensor module category and is specifically designed for frame instrument systems. By optimizing the signal processing capability, it enhances the reliability of equipment condition monitoring.
I. Technical Principle and Core Components:
The working principle of the phase keying module is based on electromagnetic induction or photoelectric encoding technology. By detecting the key grooves or marking points on the rotating shaft, it converts mechanical motion into electrical pulse signals. The 3500/25 module of Bechtel adopts a dual-channel design, supporting the simultaneous acquisition of two phase key signals. The input voltage is 24V and the current input is 12mA, ensuring stable operation under complex conditions. The main module weighs only 0.34kg, and the input/output (I/O) module weighs 0.40kg. The lightweight design facilitates integration into existing monitoring systems.
II. Functional Features and Application Scenarios:
The “frame instrument” feature of this module enables seamless integration with the Bently 3500 series monitoring system, supporting functions such as speed measurement and phase analysis. For instance, in the monitoring of steam turbines or compressors, the module can accurately capture the key phase signal of the rotor for each revolution, providing a time reference for vibration spectrum analysis, and helping engineers identify faults such as misalignment and imbalance of the shaft system. The minimum packaging volume is 1, making it suitable for upgrading a single equipment or small-scale deployment.
III. Technical Improvements and Practical Performance:
Compared to traditional phase shifters, the 3500/25 module has significantly enhanced its signal anti-interference capability and response speed. Through optimized circuit design, the module can effectively filter out electromagnetic noise in industrial environments, and the stability of the output signal has increased by more than 30%. Additionally, the module supports hot-swapping functionality, eliminating the need for equipment shutdown during maintenance and reducing downtime losses. Practical tests have shown that under a rotational speed fluctuation range of ±5%, the module can still maintain a phase measurement accuracy of ±0.1°.
IV. Usage Method and Precautions:
During installation, ensure that the sensor is aligned with the keyway of the rotating shaft, with the spacing controlled within the range of 0.5 – 2mm to achieve the best signal strength. The module supports DIN rail or panel installation and is compatible with various cabinet layouts. During daily use, regularly check the tightness of the wiring terminals to prevent poor contact due to vibration. The operating temperature range of the module is -20℃ to +60℃, making it suitable for most industrial environments.