Save Money and Decrease Downtime with Vehicle and Equipment Monitoring. Embedded Technology Summit National Instruments

Transcription

1 Save Money and Decrease Downtime with Vehicle and Equipment Monitoring Embedded Technology Summit National Instruments

2 Costa Allegra

3 Types of Vehicle Monitoring Propulsion Task Based

4 Collateral Damage Bearing with problems $5000 repair Bearing with problems not detected $150,000 repair

5 Increasing Equipment Availability Machine Health Preventative Maintenance Predictive Maintenance Acceptable Operating Zone Run to- Failure Time

6 Machine Availability

7 Benefits of Equipment Monitoring Increased uptime Fewer assets needed Increased customer confidence Decrease maintenance costs Prevent catastrophic failure Avoid fines, government penalties

8 Industry Segments Ships Trains Heavy Transport (Mining)

9 Ships Bearings Engine Generators Corrosion

10 Trains Engine monitoring Wheel bearings Rail line monitoring

11 Heavy Transport Drive train Loaders Varying operating conditions

12 What to measure Location (GPS) Temperature Electrical Power Vibration Strain

13 Velocity (ips) Basic Fault Frequency Analysis unbalance misalignment bearing frequencies gear mesh frequencies Frequency (Hz)

14 Order Analysis Resample frequency information to order information 1k 2k 3k 4k 5k Frequency Order

15 Order Analysis 1x 1x 2x Imbalance Misalignment 1x GM 1x 2x 3x 4x Gear Wear Looseness

16 Prognostics Confidence Value for performance degradation assessment (CV ~ 0-1) Health Radar Chart for multiple components degradation monitoring Health Map for potential issues and pattern classification Risk Radar Chart to prioritize maintenance decision

17 Feature 2 IMS Instrumentation Approach CRITICAL ASSET DATA ACQUISITION / SIGNAL PROCESSING FEATURE EXTRACTION & SELECTION 9 8 Baseline Current Data Feature 1 HEALTH VISUALIZATION PERFORMANCE PREDICTION HEALTH ASSESSMENT

18 scales a Signal Processing & Feature Extraction Raw Vibrations Stationary Raw Vibrations Signal Processing & Feature Extraction Time Domain Analysis Frequency Domain Analysis Time-Frequency Analysis Wavelet/Wavelet Packet Analysis Principal Component Analysis (PCA) Non-Stationary Timesynchronous Average FFT + Envelope Wavelets CWT of time synchronous signal for gearbox with broken tooth (File 105) Time (for 1 revolution)

19 Watchdog Agent Prognostics Toolkit for LabVIEW

20 Regime Segmentation

21 Defining the Condition Monitoring Solution Rugged data logging solutions Managing dispersed equipment Integrating the wide variety of sensors

22 Rugged Data Logging Hazardous Environments Ingress Protection Shock and Vibration

23 Managing Remote Equipment Lower Data Transmission Communication Technologies

24 Decision Based Data Logging 8 Accelerometers x 51.2 ks/s x 32 bits 1.64 MB/s 1 Terrabyte/week Reduce volume of data by only recording relevant data based on: Time Measured Parameters User Input

25 Decision Based Data Logging RMS Trend Channel Time Waveform Speed Sensor Location Operating Condition 150 CPM Shaft 90 deg High Load

26 TDMS File Format Read TDMS Files in Excel, Math Packages, C, etc.

27 Wireless Communication Technology Strengths Weaknesses (Wi-Fi) High Bandwidth Short range, susceptible to EMI Broad spectrum (900 MHz) Long Range, Cheap Lower Bandwidth Cellular Higher Bandwidth, Long Range High Cost Zigbee High Bandwidth Short Range Satellite High Bandwidth, Communication Anywhere Equipment size

28 GPS Integration

29 NI CompactRIO Rugged Industrial Form Factor Mixed Measurement Types Onboard Signal Processing Real-Time Computer and Storage Open Communication Standards Module Based Solution for Custom Systems

30 Measurement Modules Accelerometer Strain Gauge Load Cells Digital I/O Microphone DC Voltage Thermocouples 4 to 20mA Time (GPS) RTD Resistance Power (Volts/Amps)

31 Open Pit Mining Shovels Products: Sound and Vibration, LabVIEW, NI CompactRIO The Challenge: Developing a highly specialized continuous monitoring system for electromechanical mining shovels to enable a predictive maintenance strategy for these critical machines. The Solution: Creating a fully functional, tailormade vibration and stress continuous monitoring system using the NI CompactRIO platform and NI LabVIEW software.

32 Train Rail Monitoring Products: LabVIEW, CompactRIO The Challenge: Performing load analysis for train track maintenance at remote sites to determine when to visit the test site to provide necessary maintenance. The Solution: Integrating NI CompactRIO hardware and NI LabVIEW software with a GSM modem and an access point (AP) to monitor track loading in real time, send crucial data via SMS when thresholds are reached, and wirelessly transmit load analysis data via AP to a PDA.

33 Demonstration Embedded Vibration Monitoring Tachometer X Accelerometer Y Accelerometer TCP/IP Communication

34 Thank you for attending the NI Embedded Technology Summit For more information, please visit