Advanced Vibration Analysis in Smart Factories
Authors
Susmita Mistri
International Ph.D. Program in Photonics, Institute of Electro-Optical Engineering, College of Electrical and Computer Engineering, National Yang - Ming Chiao Tung University, Hsinchu, 30010 Taiwan, Republic of China. (IN)
Souradip Roy
General interface Solution (GIS), Foxconn, No.2, Houke S. Road, Houli District, Taichung City – 42152, Taiwan, Republic of China. (IN)
Hao-Chung Kuo
Semiconductor Research Center, Hon Hai Research Institute, Taipei, 11492 Taiwan, Department of Photonics, Institute of Electro-Optical Engineering, National Yang - Ming Chiao Tung University, Hsinchu, 30010 Taiwan, Republic of China. (IN)
Article Information
DOI: 10.51583/IJLTEMAS.2025.140400053
Subject Category: Mechanical Engineering
Volume/Issue: 14/4 | Page No: 507-518
Publication Timeline
Submitted: 2025-05-11
Published: 2025-05-15
Abstract
Abstract: In the development of smart factories, advanced vibration analysis is essential since it allows for real-time machinery and equipment monitoring and diagnostics. Smart sensor integration signifies continuous collection, processing, and analysis of vibration data to identify early indications of mechanical failures and maintain maximum performance in intricate industrial systems. With a focus on how artificial intelligence (AI) is revolutionizing conventional diagnostic approaches, this chapter examines the most recent developments in vibration analysis techniques. Machine learning and deep learning algorithms are used in AI-driven vibration diagnostics to identify complex defect patterns that traditional techniques could overlook. On top of that, that combine vibration data from several sources improves diagnostic precision and resilience, making it possible to identify problems in big, networked systems. By integrating sensor data with advanced signal processing techniques like wavelet transformation and Fast Fourier Transform (FFT), a complete image of system health is produced, allowing for predictive maintenance and minimizing downtime. This chapter shows how as we go toward Industry 5.0, AI, sensor technology, and vibration data fusion work together to improve smart factory operations, increase overall system reliability, and facilitate the long-term growth of manufacturing sectors.
Keywords
Advanced Vibration Analysis, Industrial Internet of Things (IIOT), Industry 5.0 & 4.0, Artificial Intelligence, Predictive maintenance (PDM), Smart Manufacturing, Monitoring system, Signal Processing, Smart Sensor, Digital Twin Technology
Downloads
References
1. Cheng FT, Tieng H, Yang HC, et al (2016) Industry 4.1 for Wheel Machining Automation. IEEE Robot Autom Lett 1:332–339. https://doi.org/10.1109/LRA.2016.2517208 [Google Scholar] [Crossref]
2. Mohd Ghazali MH, Rahiman W (2021) Vibration Analysis for Machine Monitoring and Diagnosis: A Systematic Review. Shock and Vibration 2021 [Google Scholar] [Crossref]
3. Zhang J, Zhang Y, Song B, et al (2023) Vibration Detection Based on Multi-Sensor Information Fusion for Industrial Internet of Things. In: IEEE Vehicular Technology Conference. Institute of Electrical and Electronics Engineers Inc. [Google Scholar] [Crossref]
4. Pech M, Vrchota J, Bednář J (2021) Predictive maintenance and intelligent sensors in smart factory: Review. Sensors 21:1–39 [Google Scholar] [Crossref]
5. Hector I, Panjanathan R (2024) Predictive maintenance in Industry 4.0: a survey of planning models and machine learning techniques. PeerJ Comput Sci 10:1–50. https://doi.org/10.7717/peerj-cs.2016 [Google Scholar] [Crossref]
6. Singh A, Nawayseh N, Dhabi YK, et al (2024) Transforming farming with intelligence: Smart vibration monitoring and alert system. Journal of Engineering Research (Kuwait) 12:190–199. https://doi.org/10.1016/j.jer.2023.08.025 [Google Scholar] [Crossref]
7. Kumar P, Raouf I, Kim HS (2023) Review on prognostics and health management in smart factory: From conventional to deep learning perspectives. Eng Appl Artif Intell 126 [Google Scholar] [Crossref]
8. Wang X, Wang Y, Yang J, et al (2024) The survey on multi-source data fusion in cyber-physical-social systems: Foundational infrastructure for industrial metaverses and industries 5.0. Information Fusion 107 [Google Scholar] [Crossref]
9. Soori M, Arezoo B, Dastres R (2023) Internet of things for smart factories in industry 4.0, a review. Internet of Things and Cyber-Physical Systems 3:192–204 [Google Scholar] [Crossref]
10. Williams J (2024) Smart sensor technologies for real-time monitoring in machining: A review and prospects. ~ 22 ~ International Journal of Machine Tools and Maintenance Engineering 5: [Google Scholar] [Crossref]
11. Rehman SU, Usman M, Toor MHY, Hussaini QA (2024) Advancing structural health monitoring: A vibration-based IoT approach for remote real-time systems. Sens Actuators A Phys 365:. https://doi.org/10.1016/j.sna.2023.114863 [Google Scholar] [Crossref]
12. Gopinath A, Teoh JW, Tagade P, et al (2023) Smart vibratory peening: An approach towards digitalisation and integration of vibratory special process into smart factories. Eng Appl Artif Intell 126:. https://doi.org/10.1016/j.engappai.2023.107118 [Google Scholar] [Crossref]
13. Asachi M, Alonso Camargo-Valero M (2023) Multi-sensors data fusion for monitoring of powdered and granule products: Current status and future perspectives. Advanced Powder Technology 34:. https://doi.org/10.1016/j.apt.2023.104055 [Google Scholar] [Crossref]
14. Elsamanty M, Ibrahim A, Saady Salman W (2023) Principal component analysis approach for detecting faults in rotary machines based on vibrational and electrical fused data. Mech Syst Signal Process 200:. https://doi.org/10.1016/j.ymssp.2023.110559 [Google Scholar] [Crossref]
15. Yan W, Wang J, Lu S, et al (2023) A Review of Real-Time Fault Diagnosis Methods for Industrial Smart Manufacturing. Processes 11 [Google Scholar] [Crossref]
16. Singh A, Nawayseh N, Samuel S, et al (2023) Real-time vibration monitoring and analysis of agricultural tractor drivers using an IoT-based system. J Field Robot 40:1723–1738. https://doi.org/10.1002/rob.22206 [Google Scholar] [Crossref]
17. Cabal-Yepez E, Garcia-Ramirez AG, Romero-Troncoso RJ, et al (2013) Reconfigurable monitoring system for time-frequency analysis on industrial equipment through STFT and DWT. In: IEEE Transactions on Industrial Informatics. pp 760–771 [Google Scholar] [Crossref]
18. Kandavalli SR, Khan AM, Iqbal A, et al (2023) Application of sophisticated sensors to advance the monitoring of machining processes: analysis and holistic review. International Journal of Advanced Manufacturing Technology 125:989–1014 [Google Scholar] [Crossref]
19. Muñiz R, Nuño F, Díaz J, et al (2023) Real-time monitoring solution with vibration analysis for industry 4.0 ventilation systems. Journal of Supercomputing 79:6203–6227. https://doi.org/10.1007/s11227-022-04897-3 [Google Scholar] [Crossref]
20. Al Mamun A, Bappy MM, Mudiyanselage AS, et al (2023) Multi-channel sensor fusion for real-time bearing fault diagnosis by frequency-domain multilinear principal component analysis. International Journal of Advanced Manufacturing Technology 124:1321–1334. https://doi.org/10.1007/s00170-022-10525-4 [Google Scholar] [Crossref]
21. Abidi MH, Mohammed MK, Alkhalefah H (2022) Predictive Maintenance Planning for Industry 4.0 Using Machine Learning for Sustainable Manufacturing. Sustainability (Switzerland) 14:. https://doi.org/10.3390/su14063387 [Google Scholar] [Crossref]
22. Liu Z, Xie K, Li L, Chen Y (2020) A paradigm of safety management in Industry 4.0. Syst Res Behav Sci 37:632–645. https://doi.org/10.1002/sres.2706 [Google Scholar] [Crossref]
23. Kumar P, Shih GL, Yao CK, et al (2023) Intelligent Vibration Monitoring System for Smart Industry Utilizing Optical Fiber Sensor Combined with Machine Learning. Electronics (Switzerland) 12:. https://doi.org/10.3390/electronics12204302 [Google Scholar] [Crossref]
24. Gao RX, Wang L, Helu M, Teti R (2020) Big data analytics for smart factories of the future. CIRP Annals 69:668–692. https://doi.org/10.1016/j.cirp.2020.05.002 [Google Scholar] [Crossref]
25. Gawde S, Patil S, Kumar S, et al (2024) An explainable predictive maintenance strategy for multi-fault diagnosis of rotating machines using multi-sensor data fusion. Decision Analytics Journal 10:. https://doi.org/10.1016/j.dajour.2024.100425 [Google Scholar] [Crossref]
26. Zhang H, Zanchetta P, Bradley KJ, Gerada C (2010) A low-intrusion load and efficiency evaluation method for in-service motors using vibration tests with an accelerometer. IEEE Trans Ind Appl 46:1341–1349. https://doi.org/10.1109/TIA.2010.2049550 [Google Scholar] [Crossref]
27. Ooi BY, Beh WL, Lee WK, Shirmohammadi S (2020) A Parameter-Free Vibration Analysis Solution for Legacy Manufacturing Machines’ Operation Tracking. IEEE Internet Things J 7:11092–11102. https://doi.org/10.1109/JIOT.2020.2994395 [Google Scholar] [Crossref]
Metrics
Views & Downloads
Similar Articles
- Exploring the Concept of Generative Artificial Intelligence: A Narrative Review
- Design, Development, and Evaluation of a Critiquing-Based Mobile-Web Employment Recommender System
- Integrating Bhagavad Gita Principles with Modern Supply Chain Management: A Framework for Ethical and Resilient Operations
- Soilless Indoor Farming: A Systematic Review of Iot-Based Monitoring Systems and Physiochemical Characterization Methods for Lactuca Sativa
- Financial Awareness: A Survey of Students in Bhopal