Inspired Engineering Solutions

KDP SENSORS

Explore our range of high-performance vibration sensors, accelerometers, and industrial sensors designed for precision condition monitoring, structural testing, and predictive maintenance applications. Our sensors deliver reliable, high-fidelity data for rotating machinery, vehicles, structures, and critical industrial systems.

Available in IEPE accelerometers, Charge-output (PE) sensors, and 4–20 mA vibration sensors, each device is optimised for specific applications — from long cable runs and high-temperature environments to integration with PLCs, DAQ systems, and industrial control networks. Correct sensor selection, mounting, and signal conditioning ensures accurate, repeatable measurements for every engineering challenge.

Whether you are monitoring industrial equipment, testing structures, or conducting dynamic performance analysis, our sensor solutions provide the data needed to make informed decisions, prevent downtime, and improve system performance.

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Find clear answers to the most common questions about vibration monitoring technology and related solutions.

What is the difference between IEPE and charge-output (PE) accelerometers?

IEPE accelerometers include built-in electronics that convert the sensor’s high-impedance charge signal into a low-impedance voltage output, making them easy to use with standard signal conditioners and long cable runs.
Charge-output (PE) accelerometers produce a raw charge signal and require an external charge amplifier, but they are often preferred for very high temperatures, radiation environments, or where maximum measurement accuracy is required.

When should a 4–20 mA vibration sensor be used instead of an accelerometer?

4–20 mA vibration sensors are designed for continuous machine monitoring rather than detailed vibration analysis.

They output a standard industrial current loop signal that connects directly to PLCs, SCADA systems, and condition monitoring hardware.
They are typically used for pump, motor, and fan protection where simple trending and alarm thresholds are required.

How is an IEPE accelerometer powered?

IEPE accelerometers are powered through the same two wires that carry the output signal.
A constant current source (typically 2–20 mA at around 18–28 V) is supplied by a signal conditioner or data acquisition system.This simplifies wiring and allows the sensor to be used with standard coaxial or twisted-pair cables.

How do mounting methods affect vibration measurements?

The way a sensor is mounted has a significant impact on accuracy and frequency response.

Stud mounting provides the best high-frequency performance and repeatability, while adhesive and magnetic mounts are more convenient but reduce usable bandwidth.

Correct mounting ensures that the sensor accurately follows the motion of the structure being measured.

How do sensor mass loading and cable capacitance affect the resonant frequency and dynamic response of accelerometers?

Every accelerometer has a mechanical resonance determined by its internal seismic mass and suspension system. When the sensor is mounted to a structure or connected to long cables, the effective system dynamics can shift, altering the frequency response.

1. Mass Loading:

Mounting a sensor on a lightweight or thin structure adds the sensor’s mass (ms) to the system, lowering the natural frequency of the measured structure. The combined resonant frequency can be approximated by:

fn = (1 / 2π) × √(k / (m + ms))

where:

  • fn = resonant frequency of the combined system
  • k = stiffness of the mounting point
  • m = mass of the host structure
  • ms = mass of the sensor

Even small sensors can significantly affect lightweight or precision structures, introducing measurement errors at high frequencies.

2. Cable Capacitance (for charge-mode accelerometers):

Charge-output sensors are sensitive to cable capacitance (Cc), which effectively forms a high-pass filter with the amplifier input. The cutoff frequency is approximately:

fc = 1 / (2π ⋅ Rin ⋅ (Cs + Cc))

where:

  • Rin = input impedance of the charge amplifier
  • Cs = intrinsic sensor capacitance
  • Cc = cable capacitance

Long cables increase Cc, lowering fc, reducing sensitivity to low-frequency vibrations, and potentially introducing phase lag in dynamic measurements.


Implication:

For high-fidelity measurements, especially in modal analysis, low-frequency monitoring, or broadband high-g applications, engineers must consider both mass loading and cable effects. Ignoring these factors can lead to amplitude attenuation, frequency shifts, and distorted vibration spectra.

Accelerometer selection: Important factors

Accelerometer selection: Important factors

With the variety of vibration sensors available, choosing the right one for your application can be difficult.

December 13, 2022

Proven IEPE Performance for Your Digital Vibration Monitoring Platform

Proven IEPE Performance for Your Digital Vibration Monitoring Platform

Wilcoxon’s digital adapters and embedded sensing elements let you broaden the reach of your vibration monitoring platform beyond traditional digital sensors.

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Sensor Selection Guide

Sensor Selection Guide

This technical note will cover the important factors to consider when choosing a vibration sensor.

December 14, 2022

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