intelligent maintenance systems: tether-free multi- sensing for performance assessment. samir mekid...
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Intelligent Maintenance Systems: Tether-free Multi- Sensing for
Performance Assessment.
Samir MekidMechanical Engineering Dept.
3rd Symposium on MaintenanceKFUPM, Dhahran 20th April 2009
Jay Lee
Cutting Tool Life
Complete process of tool change
Signature of the failure!
Wireless com see jay leees
Jay Lee
e-Maintenance components
Smart Tags: RFID + PDASmart Tags: RFID + PDA– Hardware & Software– Tests on functionalities– Connection or interface with MIMOSA data base– Man/machine interface– PDA services (functioning and not added value)
WirelessWireless Communications Communications– Hardware and Software – Multi sensing platform– Communication issues – Interface with MIMOSA ( +/- “Translator”)
WebservicesWebservices– Tests from MIMOSA Translator– Tests from PDA – Tests on Man/Machine interface from agent interface and CMOpS
Why use wireless?
ZigBeeCollector
Zig
beeA
rea
Zig
beeA
rea
PRISMAGateWay
Wifi
/ Eth
ern
et A
rea
Wifi
/ Eth
ern
et A
rea
WifiAccessPoint
Internet
WebServices-CM-Diagnosis-Prognosis-Advanced scheduling
TEKNIKERZENON
Maintenance Crewwith PDA
Angular PositionAngular PositionSensorSensor
VOLVO- FIATGurato
MIMOSAdatabase
MIMOSAtranslator
VTT
TESSNET
Overall monitoring scenario
AccumulationAccumulationMotor TorqueMotor Torque
Manchester
GatewayThe roles:
• Coordinator of the ZigBee Network with frequency agility.• Receives data and orders from the server through the WLAN and send them
to the smart sensors through zigbee.• Sends the received zigbee packages to the server through WLAN.• Sends some selected zigbee packages to another device in the WLAN (like
PDA) with specific IP Address.
Collector
Gateway/Black Box
Maintenance Information System
- All exchanges through MIMOSA
- Some actors are not able to communicate directly with the Database
It needs a common interface
(Mimosa translator)
Current solution: mobile sensors
Wireless Multi-Sensing Platform
Functionality of the internal sensor control system also called “House keeping” and its capability with:
a. Measurement with specific strategiesb. Transmission of datac. Sensor control systemd. Self diagnostic possibilitye. Power management
Target: the experience in the application and identifying better procedures for the hardware and software configurations.
‘House keeping’
A system has been developed to be able to add intelligence to measurement, communications and housekeeping functions. The system specification includes:
a. Measurement and sampling data from the transducers at predefined intervals, log the data, and perform basic diagnostic functions such as comparison with programmed thresholds and event triggering;
b. Receiving instructions from a programmer including changes to logging and diagnostic functions;
c. Transmission of data packages at required intervals and events;
d. Management of system start-up and power management.
Algorithm of the embedded Program
Initial setup of the sensor data packet
Implement routines for the alarms and reading shedule
Start data collection process
Analyse data
Any alarm indication?NO
YESScheduled transmission?
Send data packet
Is it time to take readings? Or new external request for reading?
YES
NO
Run watch dog timer
Read the network for new messages i. The change in database would be
picked up by the acquisition software,
ii. send request to the sensor,
iii. wakes up,
iv. takes measurements,
v. Process data (thresholds, FFT, …etc)
vi. Analyse data/ Alarms
vii.sends data to receiver. The data will be stored and available to remote access.
Data acquisition process
16
Transfer on Remote Request
Hardware
ADC interface
Signal connection
Vibration Sensor Calibration
• Designed sensor: ADXL 811 JE with biased amplifier.• PCB Sensor: PCB 352C22 with Gain=10.
Presence of the sensors on the network and alarms indication
Monitoring Software, selection of the sensors
Vibration local processing
• 2 examples
100 200 300 400 500 600 7000
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
Spectrum
Frequency [Hz]
Am
plitu
de
100 200 300 400 500 600 700 800 900
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
Spectrum
Frequency [Hz]
Am
plitu
de
Power Harvestingvoltage
3.13.23.33.43.53.63.73.83.9
44.14.2
0
2156
4312
1327
3483
5639
7795
9951
1210
7
1426
3
1641
9
1857
5
2073
1
2288
7time (s)
Vo
ltag
e (v
)
voltage
Voltage Waveform of Battery_Set1 for Powering Imote2
012345
8.33
8.75
9.17
9.59 10
10.4
10.9
11.3
11.7
12.1
12.5 13
13.4
13.8
14.2
14.6
time (h)
volta
ge (v
)
Voltage Waveform of Battery_Set2 for Powering Imote2
0
1
2
3
4
5
8.33
8.62 8.9 9.19
9.48
9.76 10
10.3
10.6
10.9
11.2
11.5
11.8 12
12.3
12.6
12.9
13.2
13.5
13.8 14
14.3
14.6
time (h)
volta
ge (v
)
Using solar cells
Modified Platform
Power UnitPower
Generator
Transceiver
Processor
StorageSensor ADC
Processing unit
Sensing unit Communication unit
How PDA communicates?
Interconnections
• RFID Technology– PDAs with assets, parts, inventory, product,
location awareness
• Wifi (802.11 b/g)– Connects: PDAs with Server components
• Ethernet– Connects: Clients with Server
Main Screen Map Screen
User Interface
283-9043 Hydraulic system in foundry
Possible sensor location on this line
Sensor demonstration at Volvo Powertrain Skövde
Volvo Technology Corporation06330/[email protected]
240-0212 Hydraulic system in A-plant
Possible sensor location on this line
Volvo Technology Corporation06330/[email protected]
Mobile platforms
Conclusion
i. Two types of hardware are proposed for intelligent maintenance.
ii. Multiple & varied types of sensors for monitoring several parameters.
iii. ‘Watch dog’ development either internally or outside (MIMOSA)
iv. Monitoring single or several machines in a production line.
v. Power management for stand alone sensors.
Thank you !Thank you !