Wireless Condition Monitoring

Battery-Powered, On-Line Data-Acquisition

Summary
The application of wireless technology for machine-condition monitoring should come as no big surprise to most maintenance managers. But for many, the question is: Why use wireless? After all, most plants already have hard-wired, on-line monitoring and portable data collectors. This article explores the generic aspects of wireless condition monitoring, and shows a few case studies based on the SKF wireless sensor system. Frequently asked questions and additional resources are included as well.

GS03012 SKF 10 pages December 2003 SKF Reliability Systems @ptitudeXchange 5271 Viewridge Court San Diego, CA 92123 United States tel. +1 858 496 3554 fax +1 858 496 3555 email: info@aptitudexchange.com Internet: www.aptitudexchange.com

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GS03012 - Wireless Condition Monitoring

Introduction
We live in an increasingly wireless world think of cellular phones, cordless phones and pagers. Consequently, the application of wireless technology for machine-condition monitoring should come as no big surprise to most maintenance managers. But for many, the question is: Why use wireless? After all, most plants already have hard-wired, on-line monitoring and portable data collectors.

Addressing Common Concerns

Far from being just the latest gadget made possible by evolving technology, however, battery-powered, on-line data-acquisition devices are the right choice in many industrial settings. These devices, fitted with an accelerometer and capable of sending reliable, analyzable, machine-generated data via a wireless medium, serve well when datacollection points: Are on moving assemblies that might damage power or communications cables, or interfere with assembly or work piece motion. Are inaccessible or hard to reach. Are in restricted or hazardous areas. Require frequent monitoring for a relatively short period of time.

How Wireless Is Wireless?

Battery-operated, wireless units can collect condition-indicating vibration data and transmit that information to other devices. The units are truly wireless in the sense that they require neither power nor data wiring. The only wires necessary are between the sensors and the data acquisition and communication module. In real-world industrial applications, wireless condition monitoring provides optimum results when the sensor and communication module are not located in the same place (although there are systems that combine the two). It is technically feasible to have a conditionmonitoring system that is wireless for communication and hardwired for power. The obvious advantage with this system is its limited need for cabling at the data-collection point.

Figure 1. A wireless monitoring system includes acquisition device(s), accelerometer(s), a base station, and software that configures and runs acquisition devices and interfaces with the diagnostic software.

Figure 2. Wireless conditioning monitoring is ideally suited for areas that are hazardous or inaccessible.

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GS03012 - Wireless Condition Monitoring While the first items are somewhat intuitive, you may be puzzled by the last one. After all, when does a machine require monitoring for a relatively short period of time? As noted maintenance expert John Moubray points out in his book, Maintenance Management - A New Paradigm, 72 percent of machines, components and systems suffer from infant mortality. That is, they are more likely to fail during initial wear-in than during any other time of their service lives. In the latest edition of Reliability-Centered Maintenance, Moubray points out that machine overhauls can actually reintroduce infant mortality into relatively stable systems. Common sense would then dictate that more frequent condition monitoring should take place immediately after commissioning a machine or replacing components. Common sense also dictates that intensive monitoring should continue until the machine is operating at steady state. This period of intensive monitoring would be relatively short compared to the machine's service life. Many of the successful early adopters of this technology are incorporating it as an integral part of their post-maintenance test regimes of critical machinery. Wireless condition monitoring also can be used to troubleshoot potential problems. When a pump or fan sounds bad, for example, a single maintenance worker can quickly set up a wireless monitoring system to assess the situation in about ten minutes. In either case, these installations are understood to be temporary, requiring no hard wiring for either power or communications. They work around the clock, making the data collection automatic and eliminating frequent visits by technicians armed with data collectors.

Figure 3. Temporary wireless on-line system.

Wireless Condition Monitoring

To understand why battery-powered, wireless condition monitoring makes sense, one must understand what it consists of and how it works. The principal component is a data-acquisition device, which collects vibration data from an accelerometer at a specific time (based on an on-board timer) or at the occurrence of a counted event (based on the closure of a dry contact or limit switch). After data collection, the unit sleeps to conserve the battery. Collected data are transmitted to a base station via a RF connection designed to keep the data reliable. One base station can serve multiple data-acquisition devices. The base station links to a computer having diagnostic software, which helps the technicians identify, among other problems, imbalance, misalignment, incorrect gear mesh and bearing wear. As is the case with every condition-monitoring system, the overall goal is to spot trouble before a breakdown occurs. The maximum distance from base station to data-acquisition stage is approximately 100 meters. The outdoor, line-of-sight range is about a kilometer.

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GS03012 - Wireless Condition Monitoring vendors simply does not exist in the conditionmonitoring arena. Hardware and diagnostic software must be able to interact.

Industries That Need Wireless

Although nearly any industrial plant might employ the troubleshooting capabilities of battery-operated, wireless condition monitoring, several industry segments stand out as likely candidates: In pulp and paper mills, machine components are replaced on a regular basis. Consequently, machines and their components are almost perpetually in the infant mortality mode. Wireless units can be moved and reinstalled easily during the frequent bearing and roll changeovers. In automotive engine plants, wireless condition monitoring can help maintain throughput and capacity. For example, engine plants often have complex drill boxes that bore the cylinders in engine blocks. The wireless monitors are attached to a drill box's gear and spindle boxes. At one engine plant, wireless monitors detected enough problems in a threemonth period to save the company an estimated $25,000 in lost production. Thanks to the significant numbers of pumps and control devices, hydrocarbon and petrochemical plants are wiringintensive. Therefore, being able to monitor machinery without additional wiring should be attractive to maintenance managers and plant engineers. These plants also have many hazardous areas where installing cabling is costly and dangerous. Wireless condition monitoring addresses these concerns, too.

Figure 4. Multiple data-acquisition base monitoring system.

Available accessories include tachometers and limit switches, which can serve as triggers in certain applications.

Implementing a Wireless Monitoring System

Plants performing diagnostics and using either on-line, hard-wired technology or data collectors should contact the providers of their current systems. The plant will need wireless units that are compatible with existing diagnostic software. In this situation, incorporating wireless into the program is relatively easy. Required system components include acquisition device(s), accelerometer(s), a base station, and software that configures and runs acquisition devices and interfaces with the diagnostic software. Plants that outsource condition monitoring will want to consult with their contractors about implementing wireless. Wireless condition monitoring makes it possible for service providers to monitor troublesome machinery, even when service personnel are not on site. Plants not presently using condition monitoring will want to do some careful comparison-shopping. Interoperability among

Limitations

Current wireless condition-monitoring systems have limitations. Temperatures at data-collection points must be between 0 and 175F (actual ranges vary from manufacturer 2004 SKF Reliability Systems All Rights Reserved 4

GS03012 - Wireless Condition Monitoring to manufacturer), and, as noted earlier, the range between data-collection device and base station is limited. In terms of reliability, however, an end-user can realistically expect the same performance from a wireless system as from a hard-wired, on-line system or one using hand-held data collectors.

Pulp & Paper Case Study

The Braviken, Holmen paper mill is one of the most advanced paper mills in Europe. Over several years they have developed a predictive maintenance program and are successfully using SKF Condition Monitoring products to reduce unscheduled downtime. The mills monitoring system is comprehensive, covering all critical areas in the mill. Over time, on-line monitoring equipment is replacing manual, portable vibration measurements. Braviken was one of the first sites to implement the Wireless Sensor System. A wireless system is especially applicable to the pulp and paper industry as bearing and roll changes must be performed quickly, and online system sensor cables are often in the way and interfere with maintenance work, or are damaged as a result of maintenance work. With wireless sensors, the wireless transceiver unit (D-DAQ = Distributed Data AcQuisition unit) is mounted on the roll, and stays with the roll if it is replaced. No time is spent dismounting sensors or disconnecting wires.

Figure 5. Two D-DAQs with tachometer installed on a paper machine.

In the Braviken mill, four D-DAQs, each one connected to a conventional accelerometer, were placed in critical locations on one of the paper machines. Two were placed in the wet section, the other two in the calendar. The base-station, which receives vibration signals from the D-DAQs and routes them into the computer system, was located near a PC in a control room that overlooks the paper machine. During a three-month period, vibration measurement results were collected every hour around the clock, without disturbance or lost information. The predictive maintenance personnel could confidently follow problem bearings through the four bearing failure stages. In this application, the speed of the machine in question is important as bearing defect frequencies are plotted as a function of the machine speed. The D-DAQs innovative design includes an input for a tachometer and a trigger. Several D-DAQs can share a single tachometer when performing measurements on the same machine. The RPM reading is wirelessly transmitted along with the vibration data, and displayed in the software. The vibration analyst monitored the machine from his office PC using the mills internal computer network. Typically, for thorough analysis purposes, spectral measurements

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GS03012 - Wireless Condition Monitoring were analyzed, but the Wireless Sensor Systems trend displays were also used. One of the biggest advantages of having SKF's Wireless Sensor System is the time and ease of installation. Since there are almost no cables to be installed or potentials to pay attention to, the installation is done in no time. All to be done is: 1. Install your accelerometer as usual, 2. Put the wireless transceiver unit (D-DAQ) at a convenient location nearby and, 3. Connect the accelerometer to the D-DAQ. Not only provided the Wireless Sensor System the predictive maintenance personnel with useful information about the machine condition, it also shortened the machine downtime because no cables had to be disconnected, the D-DAQ stays with the roll. reassembled with unhardened parts to avoid additional downtime. When the hardened parts arrived and production allowed, the correct parts were installed. The machines in question were only monitored on weekends, once or twice a month, using a portable data collector. As wear propagation in this situation is very fast (with only a few days between an incipient defect to the machines break down) this monitoring method was unsatisfactory for this application.

Automobile Manufacturing Case Study

An automobile industry manufacturing plant was experiencing problems with their cylinder head production. Problems with drill boxes were resulting in unscheduled downtime. These drill boxes had a large number of spindles (up to 26) and gear wheels, and were experiencing problems due to high operating temperature and poor lubrication. Monitoring the machine with conventional, cable-based vibration monitoring equipment proved nearly impossible, as every time the line changed engine types, for example from a 4-cylinder to a 6-cylinder, the machine in question rotated to change drill boxes. A breakdown resulted in total disassembly of the machine and close examination of the cause. The components in question were ordered and manufactured externally (two of each) as it was deemed too expensive to stock all the necessary types of spares. While waiting for the ordered parts, the drill box was

Figure 6. Two D-DAQs (prototypes) on one of the drill boxes. Machine is in a service position. Trigger (green switch) is located in the pictures top centre.

Two D-DAQs, each connected to a conventional accelerometer, were mounted on the machines with the highest failure probability. One D-DAQ monitored the gearbox, the other monitored the spindle box. The D-DAQs superior design allows measurements to be triggered by external events and/or on a user-defined schedule. In this application, measurements where triggered by the machines horizontal movement. When the D-DAQs counted 60 machine cycles (approximately once per hour), they would wake up and perform their user defined vibration measurement(s).

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GS03012 - Wireless Condition Monitoring The acquired vibration data was transmitted automatically and wirelessly to the systems base-station. The base-station is connected to a host computer conveniently located more than 100 meters (300 feet) from the drill box. The host computer runs analysis software to aid the analyst in predicting bearing failures and in identifying mechanical problems. The SKF Wireless Sensor System was put to the test shortly after installation: One of the spindle boxes developed a rapidly increasing enveloped acceleration overall trend. This is typically caused by higher than normal energy in the bearing. In a two day time period, the overall value rose from 1 gE to 4.2 gE. After changing the bearing in question, trend levels returned to normal.

Train Derailment Case Study

A passenger train coach can derail without creating any real damage or risk. The coach can continue for quite a distance with at least two wheels off a rail. If the derailment is detected in time, the situation can be corrected. However, if left undetected, the situation can easily evolve to a full derailment when the train encounters a switch or curve. To learn more about derailment situations, analysts analyze the amplitude and characteristics of an acceleration signal. Acquiring accelerometer signals as the couch derails should provide the necessary derailment detection information. The acceleration level is expected to be in the range of several hundred G's, and the measurement data should be delivered as data files to be filtered and analyzed in various systems. The tests include: 1. The coach rolls on a rail with several jumps (steel ramps). The coach will be pushed onto these jumps at different speeds. 2. One coach will be derailed (with two wheels off the rail); the coach will be pulled by the locomotive at different speeds. Using two wireless sensors, it was possible to start the measurements and collect data from a car stationed close to the test rail. Naturally, this was safer than having personnel operating a data collector on the test train. Acceleration in the vertical direction was found to be close to 200 Gs during derailment (at 30 Km/h). This information has been used in the development of a coach monitoring system that will be able to detect and alert when a derailment occurs.

Figure 7. Trend of overall vibration.

Using SKFs Wireless Sensor System, predictive maintenance personnel were able to detect problems early and thus avoided several breakdowns within three months of the systems installation, saving the customer an estimated $25,000 in production losses due to avoided unscheduled downtime. The wireless technology used to transmit the data proved suitable for industrial environment. Although the base-station was located in a corner of the plant, it successfully monitored the entire plant floor (more than 100 x 100 meters). Note that the plant does not have floor to ceiling walls, but line-of-sight was not available due to large machinery.

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GS03012 - Wireless Condition Monitoring is needed the most, for example on machinery that just became critical and need further monitoring. Obviously using the Wireless Sensor System allows you to benefit from condition monitoring on machinery that was once off limits, or too dangerous to monitor. Machines that are moving, out of reach, or located in hazardous areas can be easily incorporated into your reliability program. It also eliminates the need for technicians to risk taking measurements in perilous locations. The wireless system does the hard work for you, sending the data directly to the basestation that is connected to PC and software. What types of measurements can be taken? You can easily monitor acceleration, velocity and enveloped acceleration measurements in combination with speed and trigger inputs. Multiple point-type acquisitions are also implemented. These enable the user to take more than one type of measurement, such as velocity and enveloped acceleration, at the same time, from the same point without changing the point set up. What is Enveloped Acceleration? Enveloped acceleration, or demodulation, is a signal processing technique that enhances repetitive signals of the impact type, providing early warnings of developing component damage. This greatly enhances an analysts ability to determine the condition of rotating equipment. The acceleration process first filters out the machines low frequency vibration signals, then looks for harmonics of repetitious signals occurring in a higher frequency band specified by the user. How do I read measurements taken by the D-DAQ? The base-station, that receives the data from the D- DAQ, is connected to your PC and software. With the data being sent, users navigate the software interface just as if the 8

Figure 8. D-DAQs monitoring horizontal and vertical acceleration on the rear bogie of a passenger coach.

Frequently Asked Questions on SKF's Wireless Sensor System

What is the Wireless Sensor System? It is a complete on-line system with no need for long wires and extensive cabling. This enables the monitoring of machine points that are moving, out of reach, located in hazardous areas, or temporary for any critical machinery. What are the components of wireless system and how do they work? A battery-powered transceiver unit called DDAQ (Distributed Data AcQuisition Unit) is linked to a conventional accelerometer at each point monitored. In addition, the D-DAQ provides input capabilities for a tachometer and a trigger. After taking the measurements, the D-DAQ transmits the information wirelessly to the systems base-station, which is connected to a personal computer where the data can be analyzed and recorded in analysis software. What are the benefits of using a wireless system? The Wireless Sensor System is the complement to existing cable based on-line system (LMU) and/or manual data collection (Microlog). The flexibility and the ease of installation of the Wireless Sensor System gives you the opportunity to deploy it where it

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GS03012 - Wireless Condition Monitoring measurements had been collected manually with a portable data collector or with a cable based on-line system. The data can be thoroughly analyzed, checking vibration diagnostics to identify problems such as imbalance, misalignment, gear mesh, bearing wear, and more. Is installing the wireless sensor system complicated? The installation process is faster, more efficient, and less costly than traditional methods because there is almost no cabling required. This convenience allows for easy movement should a sensor need to be relocated, and is especially significant and cost effective for temporary installations when troubleshooting or testing machines. What is the range of the transmissions? The Wireless Sensor System has a range of at least 100 meters (300 feet) inside industrial environment buildings and several times further with line-of-sight. How reliable is the data collected from a wireless system? The Wireless Sensor System is equipped with advanced communication protocols and several other integrity processes to help ensure the accuracy of the transmitted data. Because the analog vibration signals are converted to digital signals before being sent to the base unit, sensitivity to disturbance is virtually eliminated. What are the data rate and bandwidth? Do I need to purchase a license for the transmissions to radios? Licenses are not required since data transmissions are carried on the license-free ISM (Industrial-Scientific- Medical) band, reserved by the Federal Communications Commission for applications in these areas alone. What areas of industry are best suited for a Wireless Sensor System? The Wireless Sensor System can be used for predictive maintenance in any industry with rotating or moving machinery, or with monitoring points located in hard to reach or hazardous locations. Any critical machine where conventional cabling was not possible can now be monitored using the Wireless Sensor System. Can I monitor high-speed machines with wireless technology? Even machines that are operating at 10,000 rpm and more can be monitored using the Wireless Sensor System.

Additional Resources
http://www.bluetooth.com/ "Founded in 1998 by Ericsson, IBM, Intel, Nokia and Toshiba, Bluetooth is an open standard wireless technology used for shortrange transmission of digital voice and data. Bluetooth covers a range of ten meters to 100 meters and eliminates the need for almost all cables and attachments for connecting computers, mobile phones, mobile computers and handheld devices. The greater mobility and responsiveness that this will allow, will enable a whole range of data, voice and content-centric industrial applications, from remote operation to sales and service support.

The maximum data rate of the radio is 2 Mbps. At this rate, the wireless transceiver sends 2 million bits (ones and zeros) per second to the base-station. This high data rate lays the ground for a bandwidth from DC to 30 kHz, which allows the implementation of What makes Bluetooth unique is that it can be SKF Condition Monitorings enveloped used for so many different applications. Its acceleration technique. 2004 SKF Reliability Systems All Rights Reserved 9

GS03012 - Wireless Condition Monitoring low cost and built-in security opens up new connectivity opportunities for wireless communication in industrial environments. In addition to eliminating communication cables, it offers flexible topology and the possibility of mobile applications." http://www.abb.com "ABB leads the pack in wireless technology research for industry. As this wireless boom starts to affect industry, ABB is getting close to commercial applications. A wireless communications pilot project, in cooperation with Ericsson, has removed all the cables from a point-welding robot on a Volvo production line in Sweden, cutting installation costs and the need for replacing cables in the robots arm joints. The wireless ABB research team is also working with Bluetooth technology. A tiny Bluetooth microchip, incorporating a radio transceiver, is built into digital devices at ABB this can be embedded on a robot or control device. The microchip enables secure transmissions of both voice and data, even when the devices are not within line-of-sight." http://www.wilcoxon.com/ Various white papers on wireless: Bluetooth gets a filling, May 01, 2003 Bluetooth gets greasy and gritty, July 28, 2003 Security Comparison: Bluetooth Communications vs. IEEE 802.11, February 01, 2002. "The basic differences between the two wireless communications standards are power consumption and, as a direct result, communications range". Bluetooth Applications in the Industrial Environment, July 10, 2002. "The announcement of Bluetooth wireless in the late 1990's promised a low cost, low 10 power, small size technical solution for immediate vicinity information exchange between personal computers and peripherals. One of the stated goals of the system was to replace the wires and cables linking personal computer equipment on the desktop. The Bluetooth technology would enable wireless interconnection of the equipment and would enable portable equipment to link to the stationary equipment without connecting cables or using the very limited range and occasionally "fussy" infrared optical links." http://www.techkor.com/ Various white papers like: An Intelligent Wireless Data Gathering System for Condition Based Maintenance

"Advances in wireless technology, battery chemistry, and miniaturization have made large-scale wireless CBM data gathering systems practical. Wireless sensing no longer needs to be relegated to locations where access is difficult or cabling is not practical. Wireless CBM data gathering can be cost effectively implemented in extensive applications that were historically handled by route running. This publication will detail the major issues surrounding the development of a wireless surveillance system for practical application in the factory environment. A wireless surveillance system must address the reliability of the wireless communication network, cost, battery life, ease of configuration, miniaturization and intelligence, all while retaining the accuracy and bandwidth of traditional sensors."

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