CSIR Manufacturing Cluster – Sensor Systems Capability in ...

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CSIR Manufacturing Cluster –

Sensor Systems Capability in the

Industrial Sensors Impact Area

Jeremy Wallis,

Manager: Industrial Sensors Impact Area,

CSIR Manufacturing Cluster

[email protected]

Mobile: +27 83 468 1934

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The CSIR Mandate

CSIR MANDATE

“The objects of the CSIR are, through directed and

particularly multi-disciplinary research and technological

innovation, to foster, in the national interest and in fields

which in its opinion should receive preference, industrial and

scientific development, either by itself or in co-operation

with principals from the private or public sectors, and

thereby to contribute to the improvement of the quality of

life of the people of the Republic, and to perform any other

functions that may be assigned to the CSIR by or under this

Act.”

(Scientific Research Council Act 46 of 1988, amended by Act 71 of 1990)

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CSIR (new) Vision and mission

VISION

We are accelerators of socio-economic prosperity

in South Africa through leading innovation

MISSION

Collaboratively innovating and localising

technologies whilst providing knowledge solutions

for the inclusive and sustainable advancement of

industry and society

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CSIR’s position in the NSI

Technology development

Development of technology

(process, product, service)

Strategic basic & applied research

Generation of new knowledge and application of

existing knowledge

Technology transfer

& implementation

Impact on economyand society

Fundamental research

Understanding fundamental

principles

Industry/public sector

CSIR

Tertiary Education

Institutes

The CSIR spans the research and innovation

value chain but its role is differentiated from

TEIs and industry/public sector

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Contract income: R1 771 m

Royalty and licence income: R4.61 m

*SET base: 1 850

Black South Africans: 1 139 (59%)

Female South Africans: 674 (35%)

The CSIR at a glance

The CSIR is a science council, classified as a national government business enterprise.

Total staff base: 2 619

Staff with PhDs: 348

Staff with M-qualifications: 631

Pipeline development: 725

Total income: R2 506 m

IN NUMBERS:

New technology demonstrators: 60New patents: 19Publication equivalents: 546

Journal articles: 317

years

74

Cape Town StellenboschPort Elizabeth

Durban

JohannesburgPretoria

1945 - 2019

Total investment in

HCD:+ R150 m

*Science, engineering and technology

Figures as at 31 March 2018

Industrial Sensors Impact Area (ISIA)

- Innovation in Inspection & Monitoring -

Jeremy Wallis,


[email protected]

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PRIMARY HEALTH CARE

- POC DIAGNOSTICS

ELECTRO-OPTICAL INSPECTION SYSTEMS

Multi-Spectral Imaging for

power line inspection

Gas leak detection

GUIDED WAVE ULTRASOUND

- RAIL BREAK DETECTION

South African & Foreign Navies

Gun Shot

Detection

SAFETY & SECURITY

Electronics, Firmware, Software, Signal Proc., Num. Modelling, Mech. Design, Opto-Mech Design,Trd Design, Product Development, Quality Systems (9001 & 13485), Small Scale Manufacturing

Small Scale Manufacturing

Technology Platform : Ultrasonics Technology Platform : Electro-Optics

Industrial Sensors – Innovation in Inspection & MonitoringResponding to South Africa’s Challenges with Sensor Innovations

- Targeting Intelligent Sensor Systems Connected Through Advanced Information Networks -

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PRIMARY HEALTH CARE

- POC DIAGNOSTICS




Gas leak detection




SAFETY & SECURITY






Gun Shot

Detection

Skills Areas

• Electronics• Firmware• Software• Signal Processing• Machine Learning• Numerical Modelling / FEM• Electro-Optical design• Mechanical & Opto-Mechanical Design & packaging• Transducer Design• Product Development• Quality Systems (9001 & 13485)• Small Scale Manufacturing

Electro-Optical Systems

for Industrial Inspection

Jeremy Wallis,


[email protected]

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Track record in electro-optical industrial inspection

CSIR has a long history of developing electro-optical inspection systems with Eskom.

CoroCAM 504 (UV) MultiCAM1 (UV & IR)

Uvirco were established in 2008 as a CSIR spin out to commercialise the technology.

Sales of 100’s cameras into 44 countries, substantial world market share. Manufacturing in

Pretoria.

Latest system from CSIR: Quvir - Quantifiable IR & UV

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1991 - CCI 1994 - CCIII

1999 - CCIV 2005 - CC504

2006 - MultiCAM

2011 – CC6D

2015 – CC8

Night Cameras

Day Cameras

MultiSpectral Cameras

2014 – CC6N

2016 – CC7

CSIR Spin-Out Company – Uvirco

- Product Overview

Uvirco – A CSIR High Tech Start Up

- International clients

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Latest Power Line Inspection System

- Quantifiable UV & IR Sensing

• Adds quantification of UV / Corona sources

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Version 2: GasCAM Prototype Version 3: GasCAM ADM

CSIR, Eskom & TIA have also cooperated on the development of

novel gas detection techniques for Sulphur Hexafluoride leak

detection in electrical switchgear.

The GasCAM technology was expanded to detect and locate

hydrocarbon gas leaks (VOCs)

A GasCAM prototype has been tested at Transnet’s Tarlton depot

Rapid leak detection in plant start up & operations

Version 1: GasCAM Prototype

Gas leak / plume detection

GasCAM

- Gas Leak Detection by Optical Means

Point of Care

Medical Diagnostic Devices

For Low / Middle Income Countries

Jeremy Wallis,


[email protected]

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Umbiflow

- A Point of care medical device that reduces the still-birth rate by 50%

• CSIR and the SAMRC have developed the Umbiflow medical ultrasound system

that has been shown to reduce the still-birth rate at the clinics it is used in by

50%

• Umbiflow, for the first time, puts ultrasound technology into the hands of non-

specialist operators (registered nurses at primary health care clinics) at an

ffordable cost.

Hand-held probe with USB port to

connect to tablet, computer, notebook Self-contained software program to

calculate Resistance Index (RI)

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UmbiflowAll data stored in the cloud in real-time

Umbiflow

- A Point of care medical device that reduces the still-birth rate by

50%

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Umbiflow

- A Point of care medical device that reduces

the still-birth rate by 50%

• Umbiflow is ready for the implementation of national patient health

records in that it can wirelessly communicate diagnostic data to

remote servers for storage and further analysis, in the 4IR paradigm

of health care

• Umbiflow has received international recognition

– Mamelodi trial results presented to Bill Gates of B&MGF in 2016

– B&MGF funded evaluation of Umbiflow in Pakistan

– Canadian Grand Challenges are funding technology upgrades and

transition to scale in low & middle income countries

– The World Health Organisation is sponsoring clinical evaluation in

Rwanda, Kenya, Ghana & India

– The WHO study is being augmented with data from an SAMRC funded

study in all 9 SA provinces

Jeremy Wallis,


[email protected]

Air-Ultrasonic Instrumentation

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Industrial Sensors

Air Ultrasonic Instrumentation

© CSIR

The ‘Airhead’ Ultrasonic Level Measurement Device

• Measures time of flight of sound in air to calculate level & volume

• Two wired, loop powered, 4-20 mA device

• Compact unit used in open channel flow as well as closed vessels

• Real-time temperature compensation

• IP68 (exposure) and EEX ia T6 rated (intrinsically safe)

• Setup procedures for in-situ calibration

• Chemically inert tefzel transducer

• Special algorithms to allow for operation in small diameter pipes

• Can track fast moving level changes (up to 8 m / minute)

• Range of operating frequencies for different distance ranges

• E.g. Dam & river levels, power station coal bins, chemical tanks

• Exported to USA, China, Mexico, Europe, Brazil

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The ‘iSonic’ Intelligent Ultrasonic Meter / Controller / Data Logger

• Measures & logs level, volume & open channel flow

• Low cost PLC replacement, requiring lower skill operators

• Specialised algorithms for different weir / flume geometries

• Accepts dual ultrasonic transducer inputs & 2 analogue inputs

• Totaliser feature (e.g. all throughput over time)

• Choice of power options and range of digital & analogue outputs

• Low power / sleep mode

• Can provide power to external devices

• PID control with 5 relay outputs & event log

• Stores data (max of 1 month data at 1 measurement / minute)

• Setup via graphical LCD display or PC software

• Reporting software

• Remote communication protocols: RS232/RS485, Modem, GSM Modem

• Can network up to 32 iSonics

• E.g. Municipal waste water (Tshwane has ~100 units installed)

Industrial Sensors


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The ‘Loop Controller’ Intelligent Controller & Data Recorder

• Similar to iSonic except designed to work with up to 4 analogue

(loop powered) measuring devices

• E.g. Swiss hydro-electric power facilities, sewerage processing stations

Airhead Loop ControlleriSonic

Level / flow industrial instrumentation

Industrial Sensors


Real-time, Distributed

Infrastructure Monitoring / NDT

Using Guided Wave Ultrasound

Jeremy Wallis,


[email protected]

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The Ultrasonic Broken Rail Detection SystemReal-time detection & alerts of rail breaks on welded lines

• CSIR has an R&D capability in a specialised NDT technology: Guided Wave Ultrasound

• Ultrasound injected into structures to travel long distances

UBRD V4

• CSIR has jointly, with the Institute for Maritime Technology,

developed a heavy freight railway monitoring system for Transnet

Freight Rail (TFR)

• GWU useful for structural health monitoring

• Over distance – e.g. continuously welded railway lines,

pipeline corrosion

• Buried structures – e.g. foundation rods, anchor bolts

• The railway system is a world first achievement & operates on the

entire Sishen-Saldanha (iron ore) line as well as tunnels & bridges on

the coal line

• Test sections currently under evaluation in India

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Remote, solar powered

sensor station

UBRD System currently on the 860 km Sishen-Saldanha Iron Ore Line


Ultrasonic Transducer

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Real-time condition monitoring of heavy freight

railway lines

• Research is underway to develop a next generation technology that detects defects in the rail before they become breaks and preliminary findings are positive for the concept.

• This technology would see individual sensor stations every ~2kms which analyse 1000’s of kms of railway line ultrasonically, conduct signal processing to detect and classify defects and then communicate the status wirelessly to a control centre.

• The provision of real time sensor data in a usable form is at the heart of the 4IR paradigm and would enable development of an intelligent hardware / software system as well as a management information function conducting real-time data analytics that would provide rail network operators with the ability to conduct planned / predictive maintenance.

Underwater / Sonar

Jeremy Wallis,


[email protected]

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CSIR’s Role in Sonar

Maintain a local expert knowledge & resource base in sonar wet-end technology

By partnering with the SA Navy &

Armscor on SAN’s current & future

sonar needs

By conducting R&D

in the sonar domain

Support naval

acquisition

processes

Maintain local

skills level in

wet-end sonar

Contribute to local

content goals

Provide quicker

reaction times & do

so at local rates

Sonar consultation

/ troubleshooting

Provide support to

keep SAN sonars

operational

Local T&E

according to OEM

requirements

Local 9001 sonar

manufacturing

capability

Transducer &

array development

for special needs

Explore future

sonar concepts /

technologies

SA Defence Review 2015:

Asks for local support, maintenance & repair of critical equipment & systems

Trd & Array refurb.

- local & overseas

navies

SA’s Local Wet-End Sonar Capability at CSIR

Research Development Manufacturing Logistics

Next Generation Sensor Materials & Sonar Systems

Includes design & prototyping of sonar transducers,

electronics, signal processing and display software

Test & Evaluation: Electrical, Piezoelectric, Acoustic, Pressure / Depth, Polymer Materials, ISUS DAP

ISO 9001 Quality System / Configuration Management

Sonar Transducer

Manufacturing

Including training on Atlas

& Thales sonar suites on

SA vessels (REWA, FAS,

ONA, PRS, CHA, HMA)

Sonar Transducer

Refurbishment /

Obsolescence Replacement

SA & foreign navy experience

Piezoelectric sensor

materials

Mechanical design / materials processing: Full Workshop, Mould Design, Polymer Casting of sonar transducers

Electronic design & testing: Analogue & digital electronics

CSIR’s Sonar Related Facilities

Underwater acoustic (~120 m^3)

Pressure / depth to 1,000 m

Electrical characterisation

Prototyping / machine workshop

Mechanical testing (metals, polymers)

Piezo Ceramic & Composite Manufacturing

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Underwater Acoustic Test Facility

©CSIR

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Pressure Testing Facility to Simulate High Depth(up to 1 km)

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Piezoelectric Ceramic Processing

© CSIR

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Piezoelectric Composite Processing

© CSIR

Patterned linear

arrayPatterned electrode &

curved sector

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Plasma Cleaner

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Manufacturing Facility(mechanical assembly, workshop, priming, casting, stores, electronic assembly etc)

Examples of Sonars

- Active Service

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Tracker Array for the SA Daphne Class Submarines(local refurbishment & performance improvement by IS)

© CSIR

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Sonar Systems on board the SA 209 class Submarines(90% of transducers and arrays manufactured by CSIR-IS)

© CSIR

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CTA Array for the SA 209 class submarines(South African technology, developed and manufactured by CSIR-IS)

© CSIR

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Submarines – Past and Present

• ATLAS Elektronik partner for ISUS wet-end

• Custodian of ISUS wet-end IP in South Africa

• Manufacturing, technical support and assistance

– ISUS wet-end

– UWT wet-end

• Investigations on failed sonar transducers

• Manufacture replacement sonar transducers

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Hull Mount Sonar Array on board the SA Meko class frigates

(manufactured by CSIR-IS)

© CSIR

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Corvette – Past and Present

• Thales Defence Mission Systems partner for HMS wet-end

• Custodian of HMS wet-end IP in South Africa

• Manufactured original HMS arrays

• Investigations on failed sonar transducers

• Investigations on operational aging and corrosion

• Manufacture replacement sonar transducers

Receive Array for

Sub-Bottom Profiler

(offshore mining AUV

for DeBeers Marine)

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Sub-Bottom Profiler – Receive ArrayOffshore Mining AUV

Omni-Directional

Underwater Telephone

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Uderwater Telephone Omnidirectional Transducer

© CSIR

Examples of Sonar

Research & Development

Activities

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SONAR TECHNOLOGY PLATFORMS

Broadband Underwater Data Communication

Broadband 2D & 3D multifunctional Imaging Sonar

Broadband Synthetic Aperture Sonar

Broadband Underwater

Data Communication

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Broadband Underwater Data Communication

Broadband 2D & 3D

Multifunctional Imaging

Sonar

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3D Underwater Imaging Sonar for the SA NavyFirst Field Demonstrator Tested in Harbour

Sensor Array

Prototype

Transmit / Receive Electronics

Prototype

Display / Interface

~250 kHz bandwidth ultrasound system, provides feature resolution ~ 3 mm

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3D Underwater Imaging Sonar for the SA NavyFirst Field Demonstrator Tested in Harbour

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Example of 2D Image

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Example of 3D Image from Prototype System

First field test of prototype

2D image

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Ladder was placed vertically in

the tank but skew

N.B.: It is significant that this imaging example was in the acoustic near-field

High Resolution Sonar System - Example

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Broadband 2D & 3D multifunctional Imaging Sonar

Broadband

Synthetic Aperture

Sonar

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Broadband Synthetic Aperture Sonar

Side-Scan

Sonar System

Demonstrator

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Side Scan Sonar Demonstrator

Side Scan Sonar Demonstrator

Example specs of demonstrator version:

• Transmit frequency: 100-450 kHz

• Beam widths

• Transmit

• Horiz: 0.7 – 3.0

• Vert: 30-56 deg

• Receive:

• Horiz: 0.3-1.5

• Vert: 30-56 deg

• Source level: 210 dB

• Receiver: -190 dB

High-Frequency

Sonar Arrays

(piezo-ceramic & piezo-composite based)

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High Frequency Arrays developed by IS(SA & Overseas Navies)

Upper : 100 kHz Detection Array

Lower : 400 kHz Classification Array

270 kHz piezoelectric composite

transmit / receive array

(curved transmitter)

© CSIR

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Application of Acoustic Sensing &

Signal Processing Capabilities to GunShot Detection

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GunShot Detection & Classification - System Overview

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GunShot Detection & Classification - System Hardware

Vehicle-mounted microphone array Computing and acquisition hardware with display

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GunShot Detection & Classification - User Interface

Graphical User Interface

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PRIMARY HEALTH CARE

- POC DIAGNOSTICS




Gas leak detection




SAFETY & SECURITY






Skills Areas

• Electronics• Firmware• Software• Signal Processing• Machine Learning• Numerical Modelling / FEM• Electro-Optical design• Mechanical & Opto-Mechanical Design & packaging• Transducer Design• Product Development• Quality Systems (9001 & 13485)• Small Scale Manufacturing

Thank you

Jeremy Wallis,

Manager: Industrial Sensors Impact Area,


[email protected]

Mobile: +27 83 468 1934

CSIR Manufacturing Cluster – Sensor Systems Capability in ...

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