Predictive Maintenance using IRT.pdf
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Predictive Maintenance Using Infrared Thermography (IRT) Analysis of Cables/Connectors 11 July, 2013 Scott McWilliams Andrew C. Rudack The data contained in all slides of this presentation is protected data produced under agreement no. DE-EE0004947 with the U.S. Department of Energy and may not be published, disseminated, or disclosed to others outside the Government until five (5) years from the date the data was produced, unless express written authorization is obtained from the recipient. Upon expiration of the period of protection set forth in this Notice, the Government shall have unlimited rights in this data. This Notice shall be marked on any reproduction of this data, in whole or in part.
Transcript of Predictive Maintenance using IRT.pdf
Predictive Maintenance Using Infrared Thermography (IRT) Analysis of Cables/Connectors 11 July, 2013 Scott McWilliams
Andrew C. Rudack
The data contained in all slides of this presentation is protected data produced under agreement no. DE-EE0004947 with the U.S. Department of Energy and may not be published, disseminated, or disclosed to others outside the Government until five (5) years from the date the data was produced, unless express written authorization is obtained from the recipient. Upon expiration of the period of protection set forth in this Notice, the Government shall have unlimited rights in this data. This Notice shall be marked on any reproduction of this data, in whole or in part.
Agenda
Outline
Overview • U.S. Photovoltaic Manufacturing Consortium
Preventive (PM)/Predictive Maintenance (PdM) • PdM toolbox
• SEMATECH PdM program
• Case Study in Infrared Thermography
PV Cables/Connectors • January, 2010 article in Photonics International
Summary
U.S PVMC Overview
• Mission of DOE SunShot Initiative - ~75% reduction in cost of PV systems. Advance large-scale US solar manufacturing. Drive
national deployment of solar energy
• SunShot Initiative – focused on R&D, cost reductions PV Cells / Modules – 3 recipients
Balance of System
Power Electronics
• April 11, 2011 – award recipients of solar cell/module – Industry-led consortium, SEMATECH – PVMC
Copper indium gallium selenide (CIGS) pilot line, in partnership with CNSE
c-Si metrology and wafering technologies, in partnership with UCF/FSEC in Florida
– PV manufacturing development facility – Solar Rochester
– University-led consortium – BAPVC (Stanford/Berkeley)
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Consortium
Management CIGS c-Si
U.S. Photovoltaic Manufacturing Consortium (PVMC)
PVMC is part of the DOE SunShot Initiative
IR Thermography
PM versus PdM
PM versus PdM
Preventive maintenance (PM)
Time-based (routine)
– Down time required
Predictive maintenance (PdM)
– Condition-based (tested)
– Inspection while running • portable or tethered instrumentation
Predictive Maintenance (PdM)
Equipment Engineer’s PdM toolbox
– Oil analysis • Including ferrography (wear particle analysis )
– Vibration
– Acoustic • Audible, ultrasonic, dB
– Corona detection (UV, ultrasound, EMI, nose)
– Electrostatic audit (ESC monitor, ESD event)
– Infrared Thermography (IRT)
Predictive Maintenance (PdM)
SEMATECH PdM program (1994 – 2003) • Manufacturing Methods Division
• Equipment Engineers: champions for PdM technique – e.g. Oil Analysis, Ferrography and Electrostatics
PdM tool box established • Equipment technicians trained
• Supported all cleanroom tools
• Supported all Facilities systems
Case study – Semiconductor Fab tool • 4-Tube Horizontal Furnace
Case Study – Semiconductor Fab Tools
1980’s vintage - 4- tube horizontal furnace • 150 mm upgraded to 200mm wafer size
• EMI sensitivity previously established – walkie talkie cell phone ban
Intermittent “happy stop” • EMO?
• Gremlins?
• Assumed EMI related
Weekend coverage with happy stop • “go get the camera”
Case Study – Semiconductor Fab Tool
• One leg of 480 VAC “hot”
• Heater in contactor opened over-temp
• Similar to EMO, drops contactor
• Demonstrated IRT as effective part of PdM tool box
Source: Fluke Corporatiion
PV Cables/Connectors
PVMC, Inc. Confidential
PV Connector Survey Photon International January, 2010 article
Evaluation Included • Electrical • Mechanical • Climate
Source: Photon International, January 2010
Cable – Connectors Graded
Force • Insertion
• Release (locking, non-locking)
• Withdrawl (cable separation)
Insulation • Submerged
Contact Resistance and IR Thermography • Connectors, crimping
Source: Photon International, January 2010
Thermographic Examination
• Cables/Connectors at full rate (A)
• Measured Power loss
Source: Photon International, January 2010
Contact Resistance and IR Thermography
Source: Photon International, January 2010
Summary
• IRT effective part of PdM Tool box
• Demonstrated successful trouble shooting in Semiconductor tools
• Electricity converted to heat due to contact resistance identified using IRT
• Installation, maintenance opportunity in PV
