5 Critical Specifications That Determine the Success or Failure of Industrial Accelerometer Selection (With Comparison Table)

Introduction

Industrial accelerometers are vital for monitoring vibration, shock, and motion in harsh environments—from heavy machinery to aerospace systems. However, selecting the wrong sensor can lead to inaccurate data, equipment failure, or costly downtime. This blog breaks down the 5 key specifications that define accelerometer performance and provides actionable insights to guide your selection process.

 

1. Measurement Range (±g)

Why It Matters:

The measurement range defines the maximum acceleration force (in g-force) the sensor can accurately detect. Exceeding this limit causes signal clipping or sensor damage.

Key Considerations:

 

• • Low-g ranges (±2g to ±10g): Ideal for subtle vibrations (e.g., HVAC systems).

• • High-g ranges (±50g to ±500g): Suited for heavy machinery or impact testing.

• • Overload protection: Sensors with 200% overload capacity prevent damage in transient spikes.

 

2. Sensitivity (mV/g or pC/g)

Why It Matters:

Sensitivity determines how effectively the sensor converts mechanical motion into an electrical signal. Higher sensitivity suits low-frequency vibrations; lower sensitivity avoids saturation in high-g environments.

Trade-offs:

 

• • Voltage-output sensors (10–100 mV/g): Simple integration but susceptible to noise.

• • Charge-output sensors (1–10 pC/g): Better for high-temperature environments but require external amplifiers.

 

3. Frequency Response

Why It Matters:

The frequency range (Hz) a sensor can accurately measure must align with your application’s vibration characteristics.

Critical Factors:

 

• • Resonant frequency: Avoid operating near the sensor’s natural resonant frequency (typically 5–50 kHz).

• • Sampling rate: Follow the Nyquist theorem (sample at ≥2x the max target frequency).

Example: For monitoring gearbox vibrations (up to 2 kHz), choose a sensor with a 0.5–10 kHz bandwidth.

 

4. Environmental Durability

Why It Matters:

Industrial environments expose sensors to extreme temperatures, moisture, and shocks.

Key Ratings:

 

• • Operating temperature: Industrial-grade models should withstand -50°C to +300°C.

• • IP protection: IP67 (dust/water resistance) or IP68 (high-pressure cleaning).

• • Hermetic sealing: Essential for corrosive or explosive atmospheres (e.g., oil and gas).

 

5. Output Type & Signal Conditioning

Why It Matters:

The output format impacts compatibility with data acquisition systems.

Options:

 

• • Analog output (IEPE): Built-in electronics simplify integration but limit temperature ranges.

• • Digital output (CAN, SPI): Noise-resistant for long cable runs; ideal for Industry 4.0 systems.

• • Wireless: Enables remote monitoring in hard-to-reach locations.

Conclusion

Choosing the right industrial accelerometer requires balancing technical specifications with operational demands. A sensor with excessive range or sensitivity wastes budget, while an underperforming unit risks system failure. Always validate your selection with real-world testing and consult manufacturers for application-specific guidance.

Need a custom solution? Request a Free Sample of our IP68-rated accelerometers for your next project.