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© Neratec Solutions AG, CH-8608 Bubikon
Condition Monitoring –
einfach nachrüsten dank Wireless Sensoren
Hans Kaufmann, Neratec Solutions AG
2017-06-07 Slide 1
© Neratec Solutions AG, CH-8608 Bubikon
Why wireless ?
2017-06-07 Slide 2
• Easy to retrofit – no cables
• Connection to moving or rotating parts
• Easily expandable
• User Interface from mobile terminals
© Neratec Solutions AG, CH-8608 Bubikon
Agenda
• Introduction
• Value of Condition Monitoring
• Monitoring System
• Sensor types & examples
• Which wireless technology ?
• Summary
2017-06-07 Slide 3
© Neratec Solutions AG, CH-8608 Bubikon
Neratec Solutions AG – a Swiss KMU
2017-06-07 Slide 4
Wireless Sensor Solutions
• Wireless Sensors for Industrial Applications
– Condition Monitoring, Predictive Maintenance
• Customized products
– tailored to your application
• Connectivity Management: IoT, M2M, Cloud
Industrial WLAN Products
• Wireless LAN Stations
– Very robust, for mobile use, railway certified
• WLAN Access Points
– For outdoor use, railway certified
• WLAN Modules
– high performance, long distance
© Neratec Solutions AG, CH-8608 Bubikon
Condition Monitoring & Predictive Maintenance
2017-06-07 Slide 5
© Neratec Solutions AG, CH-8608 Bubikon
Monitoring & Optimizing Cycle
2017-06-07 Slide 6
© Neratec Solutions AG, CH-8608 Bubikon
For the End User:
• Reduce unexpected downtime
• Increase asset availability
• Optimize performance
• Improved planning of O&M services
• Convenience and safety
For the Device / Machine Supplier:
• Increase value of machine
• Machine health monitoring
• Optimize business processes
(e.g. spare parts stock, service interventions)
• Enable new service offerings & revenue streams
Condition Monitoring & Predictive Maintenance –
Value Proposition
2017-06-07 Slide 7
© Neratec Solutions AG, CH-8608 Bubikon
Potential Applications
• Intra-Logistics
commissioning, warehouse and automated logistics
applications
• Motors, Pumps, Drives …
Vibration sensors for mechanical components and drives
• Industrial Process Monitoring
wireless sensors for temperature, humidity, flow, pressure, …
• Optimization of Cold Chain
monitor the conditions to save energy and reduce life cycle
costs
2017-06-07 Slide 8
© Neratec Solutions AG, CH-8608 Bubikon
Condition Moitoring System
2017-06-07 Slide 9
© Neratec Solutions AG, CH-8608 Bubikon
Gateway
• Interface to sensors
• Managing wireless network
• Pre-processing of sensor data (Applications):
– Statistics
– Thresholds
– Alarms
• Cloud connection:
– Interface to cloud protocols
– Administration & Configuration
– Security
2017-06-07 Slide 10
© Neratec Solutions AG, CH-8608 Bubikon
Communcation & Cloud Connection
• Connection to server or cloud
– LAN
– WiFi
– 3G / 4G Mobile
• Cloud Server
– Data integration from several sources
– Device management, Web GUI
– Connectivity management (e.g. SIM)
– Data buffering and simple presentation
Data Integration
Device Management
Connectivity
Management
Gateway Server / Cloud
Sensor drivers
Edge processing
Cloud connection
LAN, WiFi
3G/4G
2017-06-07 Slide 11
© Neratec Solutions AG, CH-8608 Bubikon
Applications
2017-06-07 Slide 12
• Applications connect to data base
• Applications may include:
– Statistics
– Trending
– Monitoring of thresholds and alarm values
– Data fusion and analysis
– Prediction of expected lifetime / failures
– Interface to processes triggering
maintenance actions
WEB API
ApplicationsServer / Cloud
Data Integration
Device Management
Connectivity
Management
© Neratec Solutions AG, CH-8608 Bubikon
Wireless Sensors
2017-06-07 Page 13
© Neratec Solutions AG, CH-8608 Bubikon
Wireless Sensor Types
• Temperature
• Vibration, Shock
• Acceleration, Movement
• Humidity
• Light detector
• Air quality
• Analog and digital inputs/outputs
Tailor made sensors with selection of:
• Sensor type
• Form factor, size
• Low power
2017-06-07 Slide 14
© Neratec Solutions AG, CH-8608 Bubikon
Example: Wireless Vibration Sensor
• VibroSens: Vibration/Temperature Sensor
– 3-axis MEMS accelerometer
– ±2g …±16g per axis
– usable bandwidth up to 1.6kHz
– accurate Si temperature sensor
– wireless interface
– low-power battery operation
– IP68 housing
• Wireless Connector
– Manages the wireless sensor network
– Interfaces to gateway
– Connectors to cloud services via gateway
2017-06-07 Slide 15
Wireless
Connector
© Neratec Solutions AG, CH-8608 Bubikon
Wireless Technologies
2017-06-07 Slide 17
Technology Bluetooth low-
energy
WiFi 802.15.4
Range (typ. usable) 10 … 30 m 20…100 m 50 … 250 m
Power
Consumption
Very low Medium Low
User Data Rate 30 … 240 kbit/s several Mbit/s 10 … 200 kbit/s
Topology Star (Mesh) Star Star, Mesh
© Neratec Solutions AG, CH-8608 Bubikon
Battery Life BLE vs. WiFi (typ.)
2017-06-07 Slide 18
BLE WiFi
Vibration sensor, 5 min. interval, 2.4Ah 1- axis 3-axis
BLE 4.9 years 2 years
WiFi 15 months 7.7 months
© Neratec Solutions AG, CH-8608 Bubikon
• Condition Monitoring & Predictive Maintenance Systems offer
manifold benefits
• Wireless Sensors promise easy integration for retrofit or
mobile/moving components
• Low-power technologies are a must to achieve long battery life
• Applications with medium to long measurement intervals are
best suited
• Wireless Systems need a careful system design to meet all
required parameters: range, data rates, battery life time, …
Summary
2017-06-07 Slide 19
© Neratec Solutions AG, CH-8608 Bubikon
Thank you for your attention !
2017-06-07 Slide 20
Hans Kaufmann
Managing Director