Condition Monitoring – einfach nachrüsten dank Wireless ... · 2017-06-07 Slide 4 Wireless Sensor Solutions •Wireless Sensors for Industrial Applications –Condition Monitoring,

© Neratec Solutions AG, CH-8608 Bubikon

Condition Monitoring –

einfach nachrüsten dank Wireless Sensoren

Hans Kaufmann, Neratec Solutions AG

2017-06-07 Slide 1


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


Agenda

• Introduction

• Value of Condition Monitoring

• Monitoring System

• Sensor types & examples

• Which wireless technology ?

• Summary

2017-06-07 Slide 3


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


Condition Monitoring & Predictive Maintenance

2017-06-07 Slide 5


Monitoring & Optimizing Cycle

2017-06-07 Slide 6


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


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


Condition Moitoring System

2017-06-07 Slide 9


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


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


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


Wireless Sensors

2017-06-07 Page 13


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


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


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


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


• 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


Thank you for your attention !

2017-06-07 Slide 20

Hans Kaufmann

Managing Director

Condition Monitoring – einfach nachrüsten dank Wireless ... · 2017-06-07 Slide 4 Wireless Sensor Solutions •Wireless Sensors for Industrial Applications –Condition Monitoring,

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