condition monitoring systems
TRANSCRIPT
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Increase System Efficiency with Condition Monitoring
Embedded Control and Monitoring Summit
National Instruments
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Impeller – Contact with casing and diffuser vanes
Bent Diffuser Vanes
Bending failure of gear teeth- seized rotor
Motivation of Condition Monitoring
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The many Sources of machinery vibration
Each has a unique signature which can be learned using a simulator.
Source: “Machinery Noise and Diagnostics by Richard H. Lyon
Sources of Mechanical Failure
Types of Machine Failures
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What is Condition Monitoring
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What is Condition Monitoring Preventative Maintenance
Predictive Maintenance
Run to-Failure
Machine Health
Time
Acceptable Operating Zone
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Machine Availability
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Why Condition Monitoring? • Increase customer confidence
• Increase production output
• Reduce scrap and raw material use
• Increase product quality
• Reduce repair time and spare parts
• Lengthen maintenance cycle
• Stop unscheduled outages
• Optimize machine performance
• Prevent catastrophic failure
• Avoid injury, environmental harm Safety
Production Assurance
Reduce Costs
Quality Control
Increase Revenue
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Time
Conditions
start to
change
Vibrations
Noise
Heat
Smoke
Emergency
stop
3 month
2 weeks 2 days
10 min
Ma
ch
ine
co
nd
itio
n
Credit F’IS
What to Monitor and Test
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What to Measure
Vibration
Strain
Electrical Power
Temperature
Location (GPS)
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Condition Monitoring Signal Sources
Vibration
Electrical Power
Strain
Temperature
Acoustic Emissions
Imbalance Vibration
Fluid Analysis
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Basic Fault Frequency Analysis
0.0
001
0.0
01
0.0
1
misalignment
unbalance
bearing frequencies
Frequency (Hz)
100 1000 10000 100000
Velo
cit
y (
ips
)
gear mesh frequencies
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1k 2k 3k 4k 5k Frequency
Order Analysis
• Resample frequency information to order information
1 2 3 4 5 Order
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Order Analysis
1x 1x
2x
1x
GM 1x 2x
3x 4x
Imbalance Misalignment
Looseness Gear Wear
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Additional Signal Processing
– Waterfall
– Colormap
– Orbit Plot
– Shaft Centerline
– Envelope Analysis
– Limit Masks
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Types of Monitoring Today
Handheld, $100
Portable, $90
Online, $260
Protection, $400
Test, $50
Market Size (In Millions $)
Source: Frost and Sullivan Market Survey
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Wireless Sensor Nodes
• Wirelessly transmit basic analytics
• Low power permanent devices
• Low channel counts
• Only works for local distributions
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Portable
• More advanced analysis
• Larger channel counts
• Usually used with a laptop
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Online
• Embedded intelligence
• Limited signal processing
• 10’s of channels
• High fidelity data
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Protection
• Triggers machine shutdown
• Safety certifications required
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Challenges in the Application Today
• Data overload
• Remote locations
• Prognostics
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TDMS File Format
Read TDMS Files in Excel, Math Packages, C, etc.
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Remote Data Collection
• Assets are geographically distant
• Analysts spend too much time collecting
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Remote Data Collection
• Data acquisition – Vibration
– Temperature
– Strain
– Voltage
– 4-20 mA
• Onboard computer – decision based data
logging
• Onboard storage
• Communication – TCP/IP
– FTP
– Modbus
• Rugged casing
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Sensors
Signal Conditioning Data Acquisition
Communication Protocols
Onboard Analysis and File Recording
Remote Storage and Analysis
User Interface and Configuration
Embedded Condition Monitoring System
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Prognostics
Confidence Value
for performance degradation assessment
(CV ~ 0-1)
Health Map for potential issues and
pattern classification
Health Radar Chart
for multiple components degradation monitoring
Risk Radar Chart
to prioritize maintenance decision
0
0.2
0.4
0.6
0.8
1
0
0.2
0.4
0.6
0.8
1
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IMS Instrumentation Approach DATA ACQUISITION / SIGNAL PROCESSING
3 4 5 6 7 8 92
3
4
5
6
7
8
9
Feature 1
Featu
re 2
Baseline
Current Data
FEATURE EXTRACTION & SELECTION
HEALTH ASSESSMENT
CRITICAL ASSET
PERFORMANCE PREDICTION HEALTH VISUALIZATION
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Signal Processing & Feature Extraction
Stationary
Non-Stationary
Signal Processing &
Feature Extraction
Time Domain Analysis
Frequency Domain Analysis
Time-Frequency Analysis
Wavelet/Wavelet Packet Analysis
Principal Component Analysis (PCA)
CWT of time synchronous signal for gearbox with broken tooth (File 105)
Time (for 1 revolution)
scale
s a
1000 2000 3000 4000 5000 6000 7000 8000 1
5
9
13
17
21
25
29
33
37
41
45
49
53
57
61
Raw Vibrations
Time-synchronous Average
FFT + Envelope
Raw Vibrations
Wavelets
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Watchdog Agent™ Prognostics Toolkit for LabVIEW
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Sound and Vibration Measurement Suite
• Vibration Measurements
• Tachometer Analysis
• Signal Processing
• Visualization
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Sound and Vibration Measurement Suite
Optimized for Embedded
• Similar functionality
• Analysis only, no GUI
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NI CompactRIO Rugged Industrial Form Factor
Mixed Measurement
Types
Module Based Solution for Custom Systems
Onboard Signal Processing
Real-Time Computer and
Storage Open Communication Standards
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Measurement Modules
Thermocouples 4 to 20mA Time (GPS) RTD Resistance Power (Volts/Amps)
Accelerometer Strain Gauge Load Cells Digital I/O Microphone DC Voltage
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Online Monitoring of Nuclear Power Reactors
• Products: Sound and Vibration, LabVIEW, NI CompactRIO
• The Challenge: Developing an online monitoring (OLM) solution for boiling water reactors, which contain machinery in hazardous and difficult-to-access areas.
• The Solution: Using an integrated, embedded NI CompactRIO system to develop the EWV-1 and OLM-32 hardware to provide live, wireless monitoring of plant assets in conjunction with AMS’ monitoring software
Wireless
Receiver
Wireless
Repeater
Data Acquisition and
Analysis Workstation
Wireless
Transmitter
Wireless
Transmitter
Temperature SensorT
AccelerometerA
Speed SensorS
WRLSS059-2
Wired
Network
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Open Pit Mining Shovels
• Products: Sound and Vibration, LabVIEW, NI CompactRIO
• The Challenge: Developing a highly specialized continuous monitoring system for electromechanical mining shovels to enable a predictive maintenance strategy for these critical machines.
• The Solution: Creating a fully functional, tailor-made vibration and stress continuous monitoring system using the NI CompactRIO platform and NI LabVIEW software.
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Demonstration • Embedded Vibration Monitoring
Tachometer
X Accelerometer
Y Accelerometer
TCP/IP Communication
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Thank you for attending the NI Embedded Technology Summit
For more information, please visit www.ni.com/embeddedsystems