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www.arrowhead.eu

Arrowhead Task 1.6: Case: Mining industry condition monitoring

Mika Karaila, D.Sc. (Tech.)Research Managermika.karaila@metso.com, +358 40 761 2563

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WP 1.6 Participants (FINLAND)- Metso Automation (task leader)

Mika Karaila, Yiqing Liang- Outokumpu

Petri Vuolukka, Pasi Lassuri- VTT Technical Research Centre of Finland

Erkki Jantunen, Ventä Olli, Määttä Kalle - Wapice Ltd.

Laurentiu Barna, Veli-Pekka Salo, Pasi Tuominen- Tampere University of Technology

David Hästbacka, Seppo Kuikka- University of Oulu

Esko Juuso, Antti Koistinen, Jouni Laurila

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OutokumpuMultiple challenges in mining:

Optimal and correct system operationo Reduced riskso Remote control

Large number of devices from different vendorso Cost-effective on-time maintenanceo Maintenance strategyo Condition monitoring of devices and equipment

ERP integration

Kemi Mine

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STAVANGER

Information Services for Condition Monitoring and Maintenance

Data Aggregation and Unified Access Information Model and Interoperability Events and Notifications OPC UA Client/Server Architecture

WAPICE REMOTE MANAGEMENT (WRM)

OPC UA Servers / Clients Generic Data Model & Databases Terminal Communication REST API VPN, Security Gateway

WRM TERMINAL (WRM247+)

Data Acquisition Device Control Accelerometer, GPS RS-232, RS-485, USB Digital I/O, Analog Output 1-Wire, CAN Ethernet, GPRS, 3G

WRM Desktop

User Interface (web based)

WP 1.6 Demonstration

Automation System Metso DNA

Beckhoff OPC UA Server

Beaglebone Black OPC UA Server

OPC UA (alarms & events)Generic Information Model

process and control data(e.g. from/to the Kemi mine)

OPC UA process and control data(e.g. from/to the Kemi mine)

OPC UA process and control data(e.g. from/to the Kemi mine)

TAMPERE

KEMI

ESPOO

OULU

VTT Node (Acceleration Sensor) Acceleration Data MIMOSA

condition monitoring data(from the Kemi mine)VAASA

Enterprise Applications and Mobile Clients

Condition monitoring Condition and stress indexes Vibration analysis

condition monitoringdata (from the Kemi mine)

Grinding mill (Kemi) Wear part monitoring Hoisting rope damage Fine concentrate machine vision

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Demo session: Metso

BeagleBone Black:OPC UA server

Node-red:Sensortag

OPC UA client

Raspberry PI:Camera

Node-red:Cloud storage

Windows:OPC UA client

Cloud:Big Data

Beckhoff PLC:OPC UA server

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Demo session: WapiceWapice Remote Management (WRM) System, OPC UA

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Demo session: Tampere University of Technology

OPC UA based aggregation of heterogeneous device data for maintenance information systems

Dynamic system structure enables scalability to data gathering and propagation of event notifications from a multitude of devices

OPC UA information modeling for declaring data relations and semantics as well as views for different purposes

Consolidating information model e.g. for device, segment or site level services (i.e. Arrowhead framework)

Adaptation of legacy system structures for improved interoperability

Built-in support for information security for a multi-vendor environment

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Demo session: VTT Technical Research Centre of Finland

CMMS:Registry

Work management

VTT Little Node:Vibration acceleration

dataWear plate monitoring

Windows:Mimosa

Cloud:Big Data

Maintenance centre:

Wear plate diagnosis

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Preliminary results from the first test

NaturalFrequencyOF_AveragedFTT

0.68

0.70

0.72

0.74

0.76

0.78

0.80

0.82

0.84

0.86

0.88

0.90

0.92

0.94

0.96

0.98

1.00

1.02

1.04

1.06

1.08

kH z

0.0 0.5 1.0 1.5 2.0 2.5

10^3

Change of natural frequency (1050 -> 710 Hz) of a wear plate during a 2 month period 19.4–24.5.2014

Demo session: VTT Technical Research Centre of Finland

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• Wireless data acquisition system using BT-LE sensor nodes, smartphones and gateway units.

• Intelligent distribution of data pre-processing in node, in phone and in gateway-nodes to optimize energy, bandwidth and capacity usage

• Use case/next steps: Implementation of distributed data analyzing system for wear plate analysis utilizing distributed WSN architecture

Distributed analysis in WSN Smartphone data analysis

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Demo session: University of Oulu, Overview• On-site data processing• FFTDerivationIFFTNorms and describing indices

Finding the degreesMatlab demonstrationLocation and setup

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Thank you!