external use tm layered intelligence for machine monitoring sensors expo 2014 michael stanley mark...
TRANSCRIPT
External Use
TM
Layered Intelligence for Machine MonitoringSensors Expo 2014
Michael Stanley
Mark Pedley
Maureen Helm
Freescale Semiconductor
TM 2Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Quick Introduction• Employed at Motorola / Freescale Semiconductor from
June 1980 to the present, where I’ve had multiple careers. Most recently:
− SoC Integration / MCU Architecture
− Sensors Architecture / Algorithms / Product Definition
− basically, solving systems level problems
• I blog on sensor related topics at
http://www.freescale.com/blogs/mikestanley and http://memsblog.wordpress.com/
• Download the Xtrinsic Sensor Fusion Library for Kinetis MCUs from http://www.freescale.com/sensorfusionMike Stanley
TM 3Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Freescale SemiconductorSensors Solutions Division - Market Focus
Safe & Efficient AutomobilesSafe driving, front/side impact
Tire information system
Active driver assistance
Passenger occupancy detection
Industrial Sensor NetworksConnected intelligence
Fault monitoring/prognostication
High precision modules
Extreme Portable ElectronicsLow profile packages
Low power consumption
Submersible sensors
Automotive
Consumer
• Standalone sensing systems• Ruggedized packages• Wide sensing ranges
• Accelerometer• Gyroscope• Pressure• Magnetometer• MCU integrated sensors
TM 4Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Courtesy of Volvo Construction Equipment (mages.volvoce.com)
Credit: IBM Research (http://www-03.ibm.com/press/uk/en/photo/43250.wss)
A common thread for all these scenarios is that downtime is very, very expensive.
Predictive maintenance is a must when you cannot afford downtime.
TM 5Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Topics
• Condition-Based Maintenance (CBM)• Condition-Based Monitoring• Prognostics and Health Management (PHM) systems• Machine Monitoring• Predictive Maintenance
In this talk, we will focus on vibration monitoring for CBM
Lowered costs in sensors and communications imply that CBM techniques may be poised to extend into new areas – IF we can simplify the software side of things.
TM 6Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
• General Electric• Techenomics International• Vibrotech reliability services• Condition Monitoring Services
Inc.• Vikon• STI Vibration Monitoring• ALS Limited• Fluke• GeoSonics / Vibra-Tech• Timken• Vipac Engineers and Scientists
Ltd.• Wagner Equipment Co.• KIM Gruppen• Allied Reliability Group• Tezzco Inc.• Sterling SIHI BmbH
• Bentley Nevada Services• Monition Limited• ROZH• GasTOPS Ltd.• Critical Software• Azima DLI• Balmac Inc.• Diagnostic Solutions• Siemens• Prosig• Condition Analyzing Corporation• Metso Corporation• Dresser-Rand• dB Prűftechnik• KCF technologies• Schenck USA• Machine Monitoring Systems
There are lots of players in this field. Many are service companies.
7TM
Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
figure source; http://en.wikipedia.org/wiki/File:Centrifugal_Pump-mod.jpg
This machine includes:• rotating motor• centrifugal pump• linkage between the
two
Each is subject to its own array of problems. These might include:• Bearing failures• load imbalance• shaft misalignment• looseness• gearbox faults• drive belts• resonance
TM 8Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
TangentialAxial
Radial
Aligned
Angular misalignment causes axial vibration at1X running frequency
Parallel misalignment causes radial vibration at2X running frequency
Shaft Misalignment
TM 9Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Pd = pitch diameterBd = ball diameterNb = number of ballsS = speed (revolutions/sec) = contact angleBSF = Ball Spin FrequencyBPFO = Ball Pass Frequency of Outer TraceBPFI = Ball Pass Frequency of Inner Trace
For ball defects:
BSF = ½ (Pd/Bd) x S x [1 – (Bd/Pd x cos)2]
For outer trace defects:
BPFO = ½ Nb x S x [1 – (Bd/Pd x cos)]
For inner trace defects:
BPFI = ½ Nb x S x [1 + (Bd/Pd x cos)]
Bearing faults have specific frequency signatures
Defect signals may be swamped by other noise in the system, in which case enveloping or wavelet techniques may be used to extract the signature.
Pd
Bd
TM 10Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
10
http://commons.wikimedia.org/wiki/File:NonSynchronousGearBoxSF.jpg
gear mesh speed = shaft speed X # of teeth
So = Si X Ti/To
where:Ti = number of input teethTo = number of output teethSi = input speedSo = output speed
Gears also have specific frequency signatures
11TM
Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
CBM Breakdown
Condition based maintenance
diagnostics prognostics
what went wrong?includes estimation for remaining useful life
data driven
physics-based
require sufficient samples that were run to failure
must understand the physics of expected failure progression and how to get parameters required for the model
more mature than prognostics
statistical
machine learning
We should differentiate between:• rotating vs linear motion• constant rotation versus step
oriented
TM 12Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Maintenance Scenarios
maintenancepreparation
actualmaintenance
scheduledmaintenance
maintenancepreparation
continuous RUL estimation
Fault DetectionDown Time
Down Time
Unscheduled Maintenance
Managed Maintenance
From “Major Challenges in Prognostics: Study on Benchmarking Prognostics Datasets” by Eker, Camci and Jennions
Preventive maintenance can be scheduled when downtime is cheapest.Notice that in the 2nd scenario, we can minimize inventory and do prep work while still “line-up”
TM 13Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
ISO 13374 Provides a Standard Architecture for Condition Monitoring & Diagnostics
Sensor / Transducer / Manual Entry
Data Acquisition (DA)
Data Manipulation (DM)
State Detection (SD)
Health Assessment (HA)
Prognostic Assessment (PA)
Advisory Generation (AG)
External systems, data archiving and
block configuration
Technical displays and information presentation
DA Basically a “server of calibrated digitized sensor data records”. Outputs include digitized data, timestamps, data quality indicators
DM Extracts features from digitized sensor data. Examples: FFT, wavelet, virtual sensor, filtered data, normalized data, etc.
SD Compares DA & DM outputs against expected baselines / operational limits to determine health indicators. Outputs might include enumerated state values, threshold alerts, rate of change alerts, deviation severities, etc.
HA Determine the current health of the system and diagnose fault conditions
PA Estimate remaining useful lifePredict faults / failuresGenerate recommendations
AG Integrate outputs from all other blocks and provide optimized recommendations, courses of action, advisories, prioritized operational & maintenance actions, etc.
TM 14Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Let’s explore a very simple example…a basic servomotor
Motor Control Electronics
1ms to 2ms pulse every
20ms
Accelerometer Sensor Board
Laptop with interface program and Matlab
samples at 400Hz rate
and REPEAT
accelerometer readings over time
TM 15Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
340 350 360 370 380 390 400 410 420-6000
-4000
-2000
0
2000
4000
6000Z acceleration vs time
340 350 360 370 380 390 400 410 4200
200
400
600
800
1000
1200
1400
1600
1800
2000
time (seconds)
rms
rms of accZ moving window of size 89
Looking at actual Z-axis accelerometer readings
These spots are where the motor does the wide swing back to its original position
motor is stationary for 1 second between movements of ~15 degrees at each step
TM 16Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Compare a Good vs “Marginal” motor
20 40 60 80 100 120 140-1.5
-1
-0.5
0
0.5
1
1.5x 10
4 Z acceleration vs time
20 40 60 80 100 120 1400
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
time (seconds)
rms
rms of accZ moving window of size 89
340 350 360 370 380 390 400 410 420-6000
-4000
-2000
0
2000
4000
6000Z acceleration vs time
340 350 360 370 380 390 400 410 4200
200
400
600
800
1000
1200
1400
1600
1800
2000
time (seconds)
rms
rms of accZ moving window of size 89
Good
Marginal
Motor sometimes “chatters”
TM 17Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
How does a computer tell a healthy motor from a sick one?
Steps are:
1. Sample data
2. Filter
3. Extract features
4. Segment data stream
5. Extract states
0 20 40 60 80 100 120 140 160 180 200
5
10
15
20
25
Frequency
FFT(
accZ
)
accZ FFT
0 20 40 60 80 100 120 140 160 180 200
100
200
300
400
500
600
accZ PSD
Frequency
PSD(
accZ
)
Possible features include:• FFT• PSD• AutoCorrelation• Wavelet• RMS value• Peak to RMS• Mean• Crossing Rate• Standard Deviation• Variance• Skew Factor• Kurtosis• Shape Factor
TM 18Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Variances Plots for Good vs Marginal MotorNote the differences in scale
20 40 60 80 100 120 1400
0.5
1
1.5
2
2.5x 10
7
time (seconds)
varia
nce
variance of accZ moving window of size 89
340 350 360 370 380 390 400 410 4200
0.5
1
1.5
2
2.5
3
3.5
4x 10
6
time (seconds)
varia
nce
variance of accZ moving window of size 89
A Good Motor A Marginal Motor
red line = threshold used to break continuous data stream up into “frames”
TM 19Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
20 40 60 80 100 120 1400
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
time (seconds)
std
std of accZ moving window of size 89
340 350 360 370 380 390 400 410 4200
200
400
600
800
1000
1200
1400
1600
1800
2000
time (seconds)
std
std of accZ moving window of size 89
A Good Motor A Marginal Motor
Standard Deviation Plots for Good vs Marginal MotorNote the differences in scale
red line = threshold used to break continuous data stream within frames into a sequence of “symbols”
TM 20Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
0 20 40 60 80 100 120 140 160 180 200
5
10
15
20
25
Frequency
FFT(
accZ
)
accZ FFT
0 20 40 60 80 100 120 140 160 180 200
100
200
300
400
500
600
accZ PSD
Frequency
PSD(
accZ
)
A Good Motor
0 20 40 60 80 100 120 140 160 180 200
5
10
15
20
Frequency
FFT(
accZ
)
accZ FFT
0 20 40 60 80 100 120 140 160 180 200
100
200
300
400
accZ PSD
Frequency
PSD(
accZ
)
A Marginal Motor
FFT and PSD Plots for Good vs Marginal Motor
These motors are made by two different manufacturers – the difference is clear when viewing the spectrum
TM 21Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Auto-Correlation Plots
-80 -60 -40 -20 0 20 40 60 80-0.2
0
0.2
0.4
0.6
0.8
1
1.2
lag
auto
corre
latio
n of
accZ
A Good Motor
-150 -100 -50 0 50 100 150-0.2
0
0.2
0.4
0.6
0.8
1
1.2
lag
auto
corre
latio
n of
accZ
A Marginal Motor
It makes sense the that device on the left would show better auto-correlation, as it has significantly less “chatter”.
TM 22Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
After segmentation and feature extraction
350 360 370 380 390 400 410
-5000
0
5000
time (seconds)
accZ
Z Acceleration vs Time
350 360 370 380 390 400 410-2
-1
0
1
2Computed States
Time
1=hi
gh n
oise
, 0=u
nkno
wn, -
1=lo
w no
ise
A Good Motor
30 40 50 60 70 80 90 100 110 120 130
-1
-0.5
0
0.5
1
x 104
time (seconds)
accZ
Z Acceleration vs Time
30 40 50 60 70 80 90 100 110 120 130-2
-1
0
1
2Computed States
Time
1=hi
gh n
oise
, 0=u
nkno
wn, -
1=lo
w no
ise
A Marginal Motor
For lower plots:1 = high noise or start of frame0 = not computed (partial frames)-1 = low noise
TM 23Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Close-up on the Marginal Motor
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accZ
Z Acceleration vs Time
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1=hi
gh n
oise
, 0=u
nkno
wn, -
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w no
ise
We could also use “# of recognized symbols/frame” as a figure of merit
TM 24Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Scaling it up to real life
• We are consulting with our in-house wafer fab to use these techniques to provide early warning indicators of “maintenance required” for wafer handling equipment (shown to the right).
• Initial results are promising. Primary limitation is getting production engineers to take time out of their day for data collection.
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TM 25Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Freescale is developing collateral designed to simplify implementation of condition monitoring systems.
Data Acquisition (DA)
Data Manipulation (DM)
State Detection (SD)
Health Assessment (HA)
Prognostic Assessment (PA)
Advisory Generation (AG)
Sensor / Transducer / Manual Entry
DevelopmentBoard
Matlab
Choices include: • Sensor Type• Axis (X, Y, Z, temp, etc)• Sample Rate
Feature Extraction choices include:• FFT• Wavelets• Entropy• RMS noise• peak value• etc.
Use Freescale supplied GUIs and embedded apps to experiment with data capture and feature selection, then utilize Matlab machine learning algorithms to develop higher level ISO 13374 functions.
TM 26Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
In real time, the user can change:• Sensor• Axis• Window• Filter
All FFT computations are done on the sensor board.
Data can be logged, replayed, and transferred to Matlab.
Freescale Xtrinsic Vibration Monitoring
TM 27Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Also under development – Wavelet Analysis
TM 28Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
Conclusions
• Useful vibration analysis work can be done with consumer grade MEMS given the right enablement tools and libraries.
• Some problems will require wider dynamic range and bandwidth sensors.• We don’t have to re-invent the wheel. There is a mature industry doing
machine monitoring. Re-use of existing techniques can bootstrap new applications.
• Freescale Semiconductor is actively working to bring hardware and software components together to make adoption of these techniques easier.
29TM
Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, ColdFire+, C-Ware, the Energy Efficient Solutions logo, Kinetis, mobileGT, PEG, PowerQUICC, Processor Expert, QorIQ, Qorivva, StarCore, Symphony and VortiQa are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. Airfast, BeeKit, BeeStack, CoreNet, Flexis, Layerscape, MagniV, MXC, Platform in a Package, QorIQ Qonverge, QUICC Engine, Ready Play, SafeAssure, the SafeAssure logo, SMARTMOS, Tower, TurboLink, Vybrid and Xtrinsic are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2013 Freescale Semiconductor, Inc.
To Learn More
Organizations:• Open Operations &
Maintenance Initiative (http://www.openoandm.org)
• Machinery Information Management Open System Alliance (http://www.mimosa.org)
• International Organization for Standardization (http://www.iso.org)
• Center for Intelligent Maintenance Systems (http://www.imscenter.net)
References:
1. “Commercialization of Prognostics Systems Leveraging Commercial Off-The Shelf Instrumentation, Analysis and Data Base Technologies”, Preston Johnson
2. “Vibration Diagnostic Guide”, SKF Reliability Systems
3. “Harris Shock and Vibration Handbook”, 6th edition, Allan G. Piersol & Thomas L. Paez, McGraw Hill
4. “A Review of PHM System’s Architectural Frameworks”, Surya Kunch, Chaochao Chen & Michael Pecht.
5. “Review of Vibration Analysis Methods for Gearbox Diagnostics and Prognostics”, Mitchell Lebold, et. al.