WiBeaM : Design and Implementation of Wireless Bearing Monitoring System
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1 WiBeaM : Design and Implementation of Wireless Bearing Monitoring System VMD Jagannath Supervisor: Dr Bhaskaran Raman Department of Computer Science & Engineering Indian Institute of Technology, Kanpur 29th June 2006 WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 1/36
2 Outline 1 Introduction 2 Background Types of Bearing Defects Existing Methods Necessity of Automated System Proposed Solution Theory of Bearing Measurement 3 Related Work 4 Design Overview Operation Cycle of Motors Hardware Selection Software Selection 5 Implementation Implementation Details Software Implementation 6 Performance Single Vs Multihop Data Transfer Vibration Measurements 7 Future Work WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 2/36
3 Wireless Sensor Networks A collection of sensor nodes that are deployed to perform a specific action. Characterestics/Challenges of WSN Small Processing power. Limited Memory. Radio to transmit /Recieve data. Ability to run on batteries. WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 3/36
4 Wireless Sensor Networks A collection of sensor nodes that are deployed to perform a specific action. Characterestics/Challenges of WSN Small Processing power. Limited Memory. Radio to transmit /Recieve data. Ability to run on batteries. WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 3/36
5 Condition Based Maintenance To Monitor and assess the health of an equipment Common Parameters Measured temperature vibration various other machine specific parameters WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 4/36
6 WiBeaM Bearing Monitoring WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 5/36
7 WiBeaM Thesis Definition Develop a cheap and reliable sensor network application to monitor the bearing vibration of induction motors in a ship Thesis Goals Find a suitable vibration sensor Form a network of sensor nodes Ensure reliable transfer of data Storage of measured readings on the node Conserve the battery power Process the measured signal and capture relevant vibration data WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 6/36
8 Types of Bearing Defects Background Bearing Anatomy Defects in Ball Bearings Outer race defect Inner race defect Ball defect WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 7/36
9 Existing Methods Manual Methods Automatic/semi-automatic Methods Shock Pulse Measurement Vibration measurement Stator Transient current analysis WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 8/36
10 Necessity of Automated System Drawbacks of Manual Methods Large number of machinery Hidden costs More man hours expended No lead time Book keeping Costly Hand held scopes WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 9/36
11 Proposed Solution Proposed Solution Develop a network of Wireless Sensor Nodes Should measure the vibrations automatically WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 10/36
12 Theory of Bearing Measurement Theory of Bearing Measurement Outer,inner and ball race defects [ { } { ( ) }] N RPM dball F ord = 1 cosα 2 D pitch [ { } { ( ) }] N RPM dball F ird = 1 + cosα 2 D pitch Bearing Geometry [ { } {( ) ( ) }] RPM Dpitch dball F ball = (cosα) 2 2 d ball D pitch WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 11/36
13 Related Work Structural Monitoring Monitor Structures Habitat Monitoring Great Duck Island CodeBlue Application for hospital care North-sea Deployment Similar to what we have done BriMon Bridge Monitoring System for railway bridges WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 12/36
14 Comparison Table Habitat WISDEN North Sea BriMon CODEBLUE WiBeam Monitoring Deployment Deployment Long Term Short Term Long Term Long Term Long Term Long Term Hardware Mica2 Mica2 MicaZ Tmotes Mica2,MicaZ Tmotes MicaZ Telos System manual wired Expensive manual Medical manual Replaced wireless Electronics Architecture Tiered Flat Tiered Tiered Tiered Tiered Sensor Temp accelero accelero acclero Pulse accelero erature meter meter meter oximeter meter Pressure MEMS EKG MEMS Compression YES YES NO NO NO NO WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 13/36
15 Operation Cycle of Motors Design Overview Operaton Cycle of Motors Important - Fire fighting system, AC Plant, Ref plant etc. Less Important - Cooling motors, Fuel supply motors for Engines Unimportant - Ventilation, Sewage Motors WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 14/36
16 Operation Cycle of Motors Duty Cycle Motors are run in a cycle of 6 hours on/off in a day Nodes may wakeup once in every four hours and check for activity One measurement in a day is sufficient Latency upto one day is acceptable WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 15/36
17 Hardware Selection Design Overview Comparison between various Accelerometers Power Range Freq Band Sensitivity Noise Cost ADXL105 MEMS 2 5V ±5g 0 12Khz mv/g 225mg 14USD CXL04 XBow ±5V ±4g 0 100Hz 500mv/g 10mg 185USD SKF CMSS786A 18 30V ±80g Khz mv/g 20mg 120USD CMCP V ±50g Khz 100mv/g 4 8ug 130USD Wilcoxon 786A 18 30V 80g 30Khz 100mv/g not 185USD specified WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 16/36
18 Hardware Selection Comparison between various Sensor Nodes Model Radio Data Rates RAM Processor I/OInterface Tmote Sky 2.4Ghz 250kbps 10KB msp Pin Intel Bluetooth 750kbps 64KB ARM7TDMI USB-slave mode Mica2 916MHZ 38.4kbps 4KB Atmega pin Micaz 2.4Ghz 250kbps 4KB Atmega pin WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 17/36
19 Software Selection Design Overview Operating System TinyOS Component based operating system Developed by U/C at Berkeley Has lot of sample applications and code Freely downloadable WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 18/36
20 Design Overview Software design Figure: Layered design WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 19/36
21 Design Overview Overall System design WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 20/36
22 Implementation Details Hardware Implementation WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 21/36
23 Implementation Details WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 22/36
24 Software Implementation Implementation Details Data Measurement WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 23/36
25 Software Implementation Reliable Data Transfer Sender Node Base Station header header ack data msg 1 data msg 2 data msg n data ack tail msg tail ack WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 24/36
26 Software Implementation Flash Storage WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 25/36
27 Software Implementation Power Consumption WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 26/36
28 Single Vs Multihop Performance Analysis Singlehop Vs Multihop WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 27/36
29 Single Vs Multihop CC2420 Transmit Power Vs Power Consumption TinyOS Transmit Current Power Value Power(dBm) Consumption(mA) Table: Source - CC2420 Datasheet WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 28/36
30 Single Vs Multihop Powers After running Power Negotiation Algorithm Node ID Transmit Power(dBm) WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 29/36
31 Data Transfer Data Transfer with 4 nodes Delay(msec) Throughput(kbps) %Packet Loss(per file) Table: Throughput and Packet loss at various delay intervals WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 30/36
32 Vibration Measurements Testbed for Trials WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 31/36
33 Vibration Measurements Measurement Settings Sampling Frequency = 20KHz No of data points measured = 4096 δf = 1 (δt N) δf is the desired frequency resolution δt is the time between two samples(depends on the sampling rate) δf = 1 ( ) = 4.88Hz No of Frequencies checked = 7 No of measurements obtained at each frequency = 5 WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 32/36
34 WiBeaM : Wireless Bearing Figure: Monitoring Vibration System readings measured VMDwith Jagannath ADXL105 33/36 Vibration Measurements
35 Future Work Data Compression Packaging Industry Trials Site Survey Security Low power operation (switch off Microcontroller) User Interface WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 34/36
36 Conclusion Wireless solutions are ideal to ships environment Extendable to other equipment like Engines and Generators etc WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 35/36
37 Questions? Please ask, it may improve the standard of my work WiBeaM : Wireless Bearing Monitoring System VMD Jagannath 36/36
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