Acoustic FEATURE TRENDING for CONDITION MONITORING

Noise in an industrial facility is normal. But what happens when parts of a process begin to deteriorate? Often, the sound signature of equipment will change—gradually over time, or suddenly through acoustic events that signal faults or failures.

In industries like shipping, pulp and paper, oil and gas, and metal production, critical systems are typically equipped with a variety of sensors to measure performance and stability, also known as asset management or condition monitoring. Despite this, one of the most vital diagnostic tools remains the operator’s ear, which is trained to recognize subtle shifts in how equipment sounds. Replicating this sensory expertise digitally, especially in noisy, harsh environments, has long been a challenge.

Listening With Superhearing

Squarehead’s microphone arrays offer a breakthrough. Composed of hundreds of “ears,” the array provides advanced acoustic awareness of your monitored environment. By placing listening points at strategic locations, you can stream multiple acoustic trends simultaneously and integrate them directly with your industrial control system. This offers not just early warning of problems but greater efficiency, predictive maintenance, and reduced unplanned downtime overall.

How Acoustic Condition Monitoring Works

Our acoustic sensors act as precise instruments for capturing and analyzing sound in industrial environments. By continuously monitoring the acoustic profile of key components and processes, they can detect subtle changes—whether in trend, intensity, or frequency—that may signal early signs of wear, leakage, or failure.

Through both real-time streaming and historical analysis, deviations from normal behavior can be identified before they escalate. These insights enable proactive maintenance planning, improved resource allocation, and reduced unplanned downtime.

Each microphone array can monitor multiple machines or processes simultaneously, isolating individual audio streams and extracting features that can be linked to specific mechanical behaviors, enabling accurate trend tracking and root cause analysis.

Asset Management Across Machinery

Acoustic feature trending is applicable across a wide range of machinery. Below are key examples of components and the types of events that can be detected through sound analysis:

PUMPS

• Cavitation

• Seal leakage

• Bearing wear

GEARS

• Wear and tear

• Tooth damage

• Lack of lubrication

FANS

• Imbalance

• Damaged fan blade

• Obstruction or blocking

COMPRESSORS

• Valve failure

• Pressure exhaust issues

• Air leakage

• Pressure imbalance

BEARINGS

• General wear

• Ring or ball damage

• Lubrication failure

Acoustic feature trending transforms sound from an overlooked byproduct into a powerful data source for condition monitoring. With the ability to detect subtle changes early and from a safe distance, microphone arrays offer a safer, smarter, more proactive way to maintain equipment health across industrial operations.

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• Why use acoustic monitoring if we already have sensors on our machines?

  While traditional sensors are essential for measuring mechanical performance, the human ear has long remained a key diagnostic tool—able to detect subtle changes in how equipment sounds. Squarehead’s microphone arrays digitally replicate this auditory capability, capturing nuanced acoustic data that traditional sensors may miss, especially in noisy and complex environments.

• What can Squarehead’s microphone arrays detect in an industrial setting?

  These arrays can identify subtle or sudden changes in equipment sound signatures that may indicate wear, leakage, imbalance, or component failure. Examples include cavitation in pumps, gear tooth damage, fan obstructions, compressor valve failures, and bearing degradation. The system captures and analyzes acoustic trends to provide early warnings and enable proactive maintenance.

• How do the arrays work in real time?

  Microphone arrays are placed at strategic points to continuously monitor the acoustic environment. They stream multiple audio signals in real time, which can be integrated directly into your industrial control system. The system detects deviations in sound patterns, providing actionable insights before a fault escalates into a failure.

• Can one system monitor more than one machine or process?

  Yes. Each Squarehead microphone array can isolate and track the acoustic profiles of multiple machines or processes simultaneously. It distinguishes individual audio streams and links them to specific components, enabling trend tracking, fault detection, and root cause analysis.

• What kinds of machines or components can benefit from acoustic monitoring?

  Acoustic condition monitoring is applicable across a wide range of industrial equipment. This includes pumps (detecting cavitation, seal leaks), gears (wear, lubrication issues), fans (imbalance, damage), compressors (valve or pressure issues), and bearings (wear, lubrication failure). Essentially, any equipment that produces sound can be monitored for changes over time.