Machinery Health Monitoring and Power Scavenging. Prepared for WMEA. Presented by Lewis Watt November 15 th, 2007
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1 Machinery Health Monitoring and Power Scavenging Prepared for WMEA Presented by Lewis Watt November 15 th, 2007 RLW, Inc All Rights Reserved
2 An Open Platform for Condition Monitoring Any Transducer LAN, WAN, Wired, Wireless, S 2 NAP Any Embedded Algorithm Any Network OSA-CBM XML Schema Any Analysis or Display Model or External System (e.g., ERP, MEP, Decision Support, e- Commerce, The Analog World 2
3 S X NAP Concept Small, smart, networkable appliance to connect the physical world to the Internet Power Supply Communications Processor Signal Processor Micro-Generator, Battery, Line- Power Any wireless/wired network + Internet Local processing reduce data to information Transducers Wide variety of analog inputs RLW, Inc All Rights Reserved. 3
4 S 2 NAP System Architecture Connecting the Physical World to the Internet RLW, Inc All Rights Reserved.
5 S 2 NAP - Baseline Product S 2 NAP Shipboard Shipyard XML Interfaces [S 2 NAP XML Schema] 8 Sensor Channels Tachometer Input 2 Analog Output Channels 1 Relay Contact Output 2 EIA-232 Serial Ports. (Optional EIA 422/485) Dual Processor Architecture Wi-Fi (IEEE b) Wireless Network Mil-Qualification achieved 7/07 RLW, Inc All Rights Reserved. 5
6 wsim (wireless Sensor Interface Module) Dual sensor: Accelerometer Temperature Power options: Power harvesting micro generator Battery Network layer: Wireless mesh topology Compatible with emerging standards Signal Processing: Static and Dynamic data Configurable Scanning rates Acceleration Enveloping, Velocity RLW, Inc All Rights Reserved. 6
7 Top Level Architecture 7
8 249 Motes Simulation 8
9 7 Mote Network (from repeater RLW) 9
10 Client Site 10
11 Recovery of Network These graphs exhibit a scheduled power outage at client site in which the network power was lost and all sensors departed the network. Within 12 hours of power restoration, the entire network had reformed and was reporting data. 11
12 Natural Gas Facility Under Construction 12
13 Pre- Installation Testing 13
14 wsim Connected for Comparison 14
15 Harvester unit inside compressor room 15
16 2 wsim 1-vibration/ 1-Battery 16
17 Repeater on top of compressor building - magnetic 17
18 Energy Harvester on a Compressor 18
19 wsim inside enclosure (Pit) 19
20 Repeater 20
21 Fan Application 21
22 Fan Application 22
23 Fan Application 23
24 Info-Sensor Phase I Goal is 1 cubic inch with ~5 year life at the end of year 3 9/09 Evolve through increasing integration of Info- Sensor IC and with Mesh Network IC Antenna with Integral Ground Plane Coin Cell Batter CR2477N 950 mahr Wireless Platform board Dust Mote-on- Chip Sentry Circuit Board includes Risk Mitigation Design Height 2.93 Diameter 2.90 Design for standard ¼-28 accelerometer studmount Charge mode accelerometer no power required RLW, Inc All Rights Reserved. 24
25 Info-Sensor Capabilities Wireless Sensing Node dynamic sensing applications (vibration, sound...) Battery Powered MESH Radio Network Vibration and Temperature Sensing versions Reconfigurable Architecture supports Dual Mode Data Acquisition Info-Sensing Sentry circuit provides continuous frequency domain sampling with analog circuitry. Provides estimate of power spectral density Conventional Mode Full Waveform, FFT Spectrum User Configurable, On-The-Fly Frequencies of interest and bandwidth Sample, report rates for sentry and conventional modes On demand waveform, spectrum Data triggers- report, alert, full waveform/fft sample RLW, Inc All Rights Reserved. 25
26 Vib Info-Sensor Phase I Accelerometer Vibration Info-Sensor Sentry Circuit Board WMB Board ABB Board Height 2.93 Diameter ounces (9.4 w/ mag mount) RLW, Inc All Rights Reserved. 26
27 S5NAP Ready for Install 27
28 Nuke Plant RTD Application 28
29 Data from Nuke Install 29
30 Current State of Development S2NAP Commercially available Extending applications / channel count from 8 to 16 FIPS Wireless Security wsim / S5NAP TM In production GE Energy co-developer Info Sensor Derives from wsim / S5NAP Miniaturization Goal = 1 cubic inch Collective Intelligence thru highly interactive network RLW, Inc All Rights Reserved. 30
31 Back Ups RLW, Inc All Rights Reserved. 31
32 Info-Sensor SBIR Phase III Contract # N C-0041 Develop and demonstrate low power analog signal processing circuits in CMOS, integrated with wireless mesh networks to enable distributed complex signal processing and analysis at the lowest level. RLW, Inc All Rights Reserved
33 System Engineering Requirements and Design Document Technical Progress Sentry Circuit IC designed, fabricated, integrated with PC board Control logic design/approach completed Board designed, fabricated, populated Design includes IC chip, ADC, risk reducing discrete components Sentry Circuit chip operation tested Info-Sensor Platform (S5NAP) WMB board re-spun - support Sentry Circuit interface/ control incorporates next generation low power, Dust mesh radio IC Software Sentry Circuit/Board operation/control firmware Info-Sensor platform configuration, control (on demand request) and viewing software modifications added spectrum bands Packaging Designed and Fabricated Integral accelerometer, antenna/battery board, Sentry Circuit board (interface to accel), wireless microcontroller board, and enclosure. RLW, Inc All Rights Reserved. 33
34 Technical Progress In Progress Component Test and Assembly Initial board DVT - complete Initial unit assembly/ issue identification - complete Testing Unit hardware and software config, control, data collection Sentry Circuit operation, power usage Data Viewer integrated configuration, control, data viewing (spectrum bands) Demonstration Date TBD 10 nodes mesh network - laboratory 1+ nodes on Marine test/demo vehicle (ARL) RLW, Inc All Rights Reserved. 34
35 Lead Times and Delays - Challenges / Solutions Limited Sentry Circuit Foundry Runs submission deadline soon after project start (1.5 months) Impact - One Shot at Sentry IC fabrication Discrete components added to Sentry Circuit board to duplicate IC function Dust Radio Shield lead time Impact delay in WMB board assembly Fabricate initial 8 boards w/o shield hand solder later Install on remaining boards during normal board build Sentry and Dust Chip delivery delays Impact - delay in board assembly, component and unit test (software and hardware), lab testing and demo Considered install after board built - IC design requires install at time of board fab Initial 8 board built pending receipt of all radio chips Board Completion Impact - delay demonstration, time to test hardware and software Tight schedule, testing conducted to the extent possible Problem compounded by multiple part delays on different boards the addition of hardware and software to previous designs RLW, Inc All Rights Reserved. 35
36 S 6 NAP Battery-Powered 2 Year Life b Wireless 2 Channels: Vibe/Vibe or Vibe/Temp Raw Data to host computer via connector software Network host interface - XML in/out RLW, Inc All Rights Reserved. 36
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