Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with...

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Predictive Maintenance Sensor Parameters for Predictive Maintenance Use Cases Vibration Monitoring Demo Set-up Reference Design Placeholder for picture

Transcript of Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with...

Page 1: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

Predictive Maintenance

Sensor Parameters

for

Predictive

Maintenance

Use Cases

Vibration Monitoring

Demo Set-upReference Design

Placeholder for picture

Page 2: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

Distinctive Sensor Parameters for Predictive Maintenance

Accelerometer & Microphone

Machin

e c

onditio

n

Time

Conditions

start to

change

Vibration

Power

Smoke

Failure

minutes

days

months

weeks

UltraSound

Noise

Heat

Ac

ce

lero

me

ter

Fo

r vib

rati

on

me

as

ure

me

nts

Signal Bandwidth. Frequency Response & FilteringDifferent defects/wears shows up at different frequencies and should

be captured without ambiguity

Noise DensityLower Noise allows to identify earlier defects and wears

Operating Temp RangeSensor should match the operating condition of the monitored

equipment

Number of axis3 axis allows to monitor all kind of defects/wears (imbalance,

misalignment, bearings, etc.)

Power ConsumptionImportant merit figure for battery operated Sensor nodes

Output InterfaceDigital output is the optimal solution for complexity, cost and reliability

Mic

rop

ho

ne

Fo

r U

ltra

so

un

d

& N

ois

e s

en

sin

g Operative Bandwidth Microphone working in standard audio bandwidth as well as in the

ultrasonic domain

Dynamic RangeAOP (acoustic overload pressure) is required to keep sensing

despite of the presence of strong environmental sound emissions

Output InterfaceBoth analog and digital for wide compatibility with processing units

Page 3: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

Operating RangeWide temperature and humidity ranges to cover wide set of use

cases

AccuracyHigh reading accuracy across whole temperature range

Output InterfaceDigital output is the optimal solution for complexity, cost and

reliability

Power ConsumptionImportant merit figure for battery operated Sensor nodes

Environmental sensorsDistinctive Sensor Parameters for conditions monitoring

Pre

ss

ure

se

ns

or

Signal full scaleThe Industrial market covers a broad scope of applications that

range from very low vacuum

Temperature compensationto guarantee sensor’s accuracy over the whole operating

temperature range

Output InterfaceDigital output is the optimal solution for complexity, cost and

reliability

Water and harsh environment resistance featureCompatible with large set of environments where water and

chemicals are present

Te

mp

era

ture

an

d h

um

idit

y

Page 4: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

Symptoms According to Audio FrequencyStandard audio vs ultrasonic

Standard Audio Bandwidth Ultra-Sonic

Audible noise

(CbM, Preventive Maintenance)Predictive

Maintenance

Post processing analysis

Ultrasonic frequencies to detect

and classify leaks

Page 5: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

Motor Control Use CasePredictive monitoring through audio: Minimize damage with early detection

• Most common maintenance applications that could be applied at your plant today

• Air Leak Detection of compressed air equipment

• Vibration monitor: All rotating equipment produces frictional forces with high frequency ultrasonic signatures which are often masked by ambient plant noise and low frequency vibrations

• Compressor Valve Inspections

• Acoustic Lubrication

• Heat Exchanger and Condenser Leaks

• Hydraulic Systems

• Pump Cavitation

Good bearing Failing bearing

Amplitude and

Frequencies matter

Page 6: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

Environmental Sensing Use Cases

Condition-based monitoring examples for Smart Industry

Environmental sensors play critical roles in process and quality

Measure operating temperatures, It’s useful

for detecting loose or improperly terminated

electrical connections, overloading, defective

contacts, phase imbalances and other

electrical problems

Pressure measurements for "air

management” systems, which monitor the

performance indicators and the different stages

of the air compressors connected to the

compressed-air supply grid

Largely adopted in HVAC system control

water vapor level or to help in regulating

parameters such as air temperature and

blowing speed

Page 7: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

Predictive Maintenance Demo

Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The

STM32F4 performs local real-time frequency/time domain analysis for early motor failure detection

• Demo Overview

• #1: Inertial and environmental sensors connected via IO-Link are used

to detect the status of the motor and thus to predict possible failures.

• #2 The demo performs frequency and time domain analysis of a good

motor vs. one unbalanced. Results are shown on a screen thanks a

GUI.

• #3 The STEVAL-IDP005V1 (ISM330DLC, LPS22HB, HTS221,

STM32F469, L6362A) is fixed on the motors and is connected via IO-

Link to the STEVAL-IDP004V1 (L6360, STM32F2), acting as Master IO-

Link. The two motors are driven using one dual motor control board

STEVAL-IHM042V1 (L6230, STM32F3).

Page 8: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

Predictive Maintenance Demo Setup

FFT

RMS

Peak

STEVAL-IDP005V1

STEVAL for motors drive

STEVAL IO-Link Master board

good unbalanced

knob for speed setting

Page 9: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

GUI Details 1/2

Time Domain

Analysis

Frequency Domain

Monitoring

Good motor behaviour

Motor with anomalies

Motors

speed frequency

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GUI Details 2/2

Environmental

equipment

monitoring

Page 11: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

Local Processing

• STM32F469AI 32-bit ARM Cortex-M4

microcontroller

Condition Monitoring Through IO-LinkReference Platform

EquipmentUse c

as

es

Motors Environment

STEVAL-IDP005V1

Release: Q2’18

Sensing

Processing

Connectivity

• Optimized form factor for industrial M12 connector

• Embedded algorithm for sensors data analysis, detecting

anomalies like unbalance, misalignment, or bad equipment

condition

• Logging of worst working condition events

Main Features

Vibration and Environmental

• ISM330DLC 6-Axis digital MEMS axel and gyro

• MP34DT05-A Microphone

• LPS22HB MEMS Pressure sensor

• HTS221 Humidity & Temperature Sensor

• STTS751 Digital temperature sensor

Wired

• L6362A IO-Link communication transceiver

device IC

Page 12: Predictive Maintenance - STMicroelectronics...Predictive Maintenance Demo Vibration monitoring with cost-effective MEMS accelerometer over IO-Link industrial connectivity. The STM32F4

STEVAL-IDP005V1Reference Eval Platform

• Reference design for predictive maintenance with vibration,

acoustic and environmental monitoring (P, RH, T)

• ARM® Cortex®-M4 core for signal processing and analysis

• Signal conditioning algorithms include:

• Accelerometer data high-pass filter

• IIR exponential filter

• Frequency domain analysis Accelerometer and Speed on three

axes

• Programmable FFT averaging

• Programmable windowing (Flat Top, Hanning, Hamming)

• Programmable overlapping (up to 75%)

• Alarm settings on programmable thresholds

• Time domain analysis (axel on three axes)

• Speed RMS moving average

• Accelerometer Peak to peak

• Data EEPROM Storage (i.e. worst working condition events )

• Pressure, Humidity and temperature environmental monitoring

• Microphone FFT for acoustic emission analysis

• IO-Link connectivity*

• Expansion connector (ADC, I2C, GPIO)

• M12 circular housing compatible* Stack can be hosted by microcontroller but it is not included in STEVAL package

STEVAL-IDP005V1 – Reference Design Features

Next to release: Q2’18

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IO-Link Evaluation Board 4-port Master

• Designed according with IEC and EN standards to address factory automation segment, in particular:

• IEC61000/2-4

• EN60947-5-2

• Several HW interface available on master node to provide more flexibility for data exchange

• IO-Link PHY

• RS485

• CAN

• USB

STEVAL-IDP004V1* – IO-Link 4-port Master

(*) already available on stock

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STEVAL-IDP005V1 communication based on

Master Board

STEVAL-IDP004V1

STEVAL-IDP005V1

Axel spectrum

RMS

Axel Peak

P, T, H parameters

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STEVAL-IHM042V1Motor Control

STEVAL-IHM042V1* –Low Voltage dual motor control demonstration platform

Key Features

• Highly compact dual 3-phase motor control design

• Two L6230 monolithic power stages (PowerSO package), featuring overcurrent and thermal protection

• STM32F303 microcontroller capable of simultaneous driving field-oriented control (FOC) of two PMSM motors

• Designed for sensored and sensorless motor control

• Input voltage from 8 V to 48 V

• Up to 10 W continuous output power for each motor

• 3- or 1-shunt current sensing topology for each drive

• On-board STLink

• USB interface

• Compatible with ST PMSM FOC firmware library and ST MC Workbench

(*) already available on stock