Intelligent Maintenance Systems: Tether-free Multi- Sensing for Performance Assessment. Samir Mekid...

Intelligent Maintenance Systems: Tether-free Multi- Sensing for

Performance Assessment.

Samir MekidMechanical Engineering Dept.

smekid@kfupm.edu.sa

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/Bertil.Stenbom@volvo.com

240-0212 Hydraulic system in A-plant

Possible sensor location on this line

Volvo Technology Corporation06330/Bertil.Stenbom@volvo.com

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 !