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Sensors Expo 2013: Condition Based Maintenance, Evigia Systems
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Transcript of Sensors Expo 2013: Condition Based Maintenance, Evigia Systems
Integrated Wireless Multi-Sensor System for Machine Health and Condition-Based Maintenance
Dr. Navid Yazdi CEO, Evigia Systems, Inc.
Sensors Expo 2013 Evigia Systems
Condition-Based Maintenance (CBM)
Reactive maintenance
Preventive Maintenance
Degradation / Alarm-Based Maintenance
Predictive Maintenance
Maintenance Strategies
CBM utilizes information about the present degradation in conditions and performance, and their projected evolution to minimize the downtime.
Sensors Expo 2013 Evigia Systems
Condition Based Maintenance
• CBM Goals:
Automated Fault Diagnosis & Fault Isolation
Determine Remaining Useful Life of the system
Enhance predictability and productivity
Improve operation profitability
sensors Feature Extraction Classification Diagnostics Prognostics Actionable
Information
CBM System Components & Information Flow
Sensors Expo 2013 Evigia Systems
Machine Prognosis Approaches
• Model-Driven – Employ the system physics
model or simulations under normal & degraded conditions
• Data-Driven – Pattern recognition &
machine learning applied to monitored system data
– Detect changes, devise trajectory and estimate RUL
• Hybrid
Prognosis Accuracy
Increase # of Sensors
& Types
Sensor Data Fusion
Customized Data
Processing
Sensors Expo 2013 Evigia Systems
Advanced CBM – Benefits
• Improved reliability & safety
• Reduced downtime
• Synchronized maintenance
• Near-optimal parts logistics
• Reduced life-cycle costs
• Increased profitability
Sensors Expo 2013 Evigia Systems
Advanced CBM – Challenges • Cost!!
– Adding embedded sensors, wiring, instrumentation
– Customization of algorithms
• Sensors disruption of process or affect performance
• CBM sensors reliability
– Accuracy over long-term
– Additional failure points & maintenance
Operations apply preventive, CBM , and reactive maintenance Wireless multi-sensor nodes shift balance to CBM across a larger set
Sensors Expo 2013 Evigia Systems
Wireless Multi-Sensor Node • Flexible and cost effective network • Distributed & large-scale sensing • Less disruptive and easier to embed • Retrofit existing equipment • Reduced size, weight, power and cost • Energy harvesting combined with
improved sensor node energy efficiency • Improved link reliability in industrial
environments – ISO18000-7 low-data rate apps with robust link
and low interference – Variations of IEEE 802.15.4 PHY including
ISA100.11, WirelessHART
Millimeter scale energy harvester Courtesy: Univ Michigan-E. Aktakka, K. Najafi
Evigia RFID-pressure-temperature sensor
Sensors Expo 2013 Evigia Systems
CBM Sensors
Gather high-reliability & accurate in-situ information
Sensor Functions
Environment Structural characteristics Dynamics Performance Monitoring Oil quality & corrosion
Sense Parameters
Temperature, vibration, shock, pressure, acoustic levels, strain, stress, voltage, current, humidity levels, contaminant concentration, usage frequency, usage severity, usage time, power, heat dissipation, corrosion, oil quality
Sensor Data Features
Magnitude, variation, peak level, and rate of change
Sensor Precision
Initial specs, calibration, low-drift, multi-sensor data fusion
Sensors Expo 2013 Evigia Systems
CBM Sensor Example: Chilled-Water System
Source: Secy. to CME/WCR/JBP, 2006 - irsme.nic.in
Parameter Purpose
Water Flow Rate Chiller water flow
Diff. Temperature Heat transfer, tube fouling
Diff. Pressure across Pump & Evaporator
Track pump performance, Chiller tube conditions
Motor Current Motor conditions
Vibrations Condition of pump & structures
Oil condition & wear particle analysis
Lubricant, gears,
Thermography scan Motor control & electronics
Wall-thickness ultrasound
Corrosion & erosion check
Eddy current test Locate leaking tubes
Airborne ultrasonic Air leak
Sensors Expo 2013 Evigia Systems
CH 53-K Chopper CBM • NAVAIR state-of-the-art heavy lift
chopper by Sikorsky (UT)
• Increased complexity while require increased reliability and longer maintenance cycle
• Light-weight and efficient (Low SWaP+C)
• CBM Requirements: – Local & global structural damage detection
– Loads monitoring
– Environmental monitoring
– Fleet Management
Sensors Expo 2013 Evigia Systems
Multi-Sensor Node: Baseline Technology
• 10’s-100’s discrete components including sensors assembled at board level
– Larger size (inches)
– Higher Cost ($10’s-100’s)
– Larger power dissipation & shorter battery life ( months)
Sensors Expo 2013 Evigia Systems
Requirements and Challenges • Embedded multi-sensors and equipment condition monitoring
– 5-10x smaller size & cost
• Multiple sensors – Strain, Temperature, Vibration,
Shock/Mechanical sensors, Humidity
• Size < 0.5 cubic inches
• Weight < 0.5oz
• Energy efficient < 300μW
• Cost $5-20
• Standard based rugged wireless data link
Sensors Expo 2013 Evigia Systems
Solution • Chip-scale multi-sensor prognostic sensor system
– Integration of energy efficient sensors and electronics on chip
– Mass-volume manufacturing technologies
Sensor Interface & Control Circuitry
Digital Interface Bus
Digital Memory
SPI/I2C Serial Interface
Sensor Event Management &
Real-Time Clock
IC-MEMS Micropackaged Prognostic Sensor Chip
Shock/Acceleration Sensor
Strain Sensor
Vibration Sensor
Temperature Sensor
Low-power ICs MEMS Sensors Wafer-Level Micropackaging
Sensors Expo 2013 Evigia Systems
Features, Advantages, Benefits Feature Advantage Benefit
Multiple sensors (Strain, Vibration, Temperature, Shock)
Multiple condition parameters Provide full suite of parameters
Compact size (<0.5 cubic inches) Reduces size by 10x Enable embedding of the prognostic sensor in equipment
Light weight (< 0.5 ounces) Reduces weight by 10x Enable embedding of the prognostic sensor in equipment
Energy-efficient (20-300 micro watts average depending on mode of operation)
Reduces power draw Extend module power up option, Extend battery life
Manageable cost ($5 to $20, vary by sensor mix) Reducing cost by 10-50x Cost savings; Broaden usage in
submodules and systems
Optional Wireless link compatible with the DoD infrastructure
Ease of integration in military systems
Leverage from the installed infrastructure; Reduce the installation and operation costs
Sensors Expo 2013 Evigia Systems
Prognostic Sensor Microsystem
TemperatureSensor
Wired Serial Data Interface
HumiditySensor
StrainSensor
VibrationSensor Event-Management
And Logic Control
Memory
MUX
ShockSensor
CapacitanceReadoutand ADC
Wireless Data Link
Prognostic Sensor Module
Prognostic Chip PMSC-A
Flash Card Memory
1Gb+
• Strain-Vibration-Shock-Temperature sensors with wireless data link
• Target military rotary wing aircraft (CH-53), and other defense and industrial equipment prognostics applications
Sensors Expo 2013 Evigia Systems
Multi-Sensor Wafer
Shock Sensor
Strain Sensor
Vibration Sensor
Sensors Expo 2013 Evigia Systems
Sensor Specifications
Sensor Range Resolution Accuracy
Strain 1-1000µε 1µε 1% of full-scale
Vibration ±10g 50mg 2% of full-scale
Shock/Impact 50g-800g depends on the array design
5% of shock switch threshold
Temperature -55 ºC to 85ºC 0.1 ºC 0.5ºC
Humidity 0% to 100% RH 0.1%RH 3%RH
Sensors Expo 2013 Evigia Systems
Prognostic Sensor ASIC
Evigia Multi-Sensor Prognostics ASIC
Sensors Expo 2013 Evigia Systems
Specifications Sensor
Sensor types supported Low bandwidth: temperature, strain, shock; High-bandwidth: Vibration Sensor integration 4 shock, 1 strain, 1 vibration, temperature External Sensor Support 11 shock, 1 strain, 2 vibration
Memory Internal EEPROM Size 16 kbit (167 to 375 low-bandwidth sensor events)
External Flash Supported 2 Gbits (> 44 million low-bandwidth sensor events, 134 million vibration sensor samples [70 minutes total])
External Flash Interface Serial (SPI) , 2 master SPI flash memory interfaces Timing
Input Clocks 32kHz RTC Length 17 years RTC Resolution 30 bits
Performance ADC Resolution 11-bit
Sampling rate Low-power mode: 0.125Sec-4hrs Vibration Active: Up to 10kSPS
Digital Interface Communications Interface 4-wire SPI slave Supply
Voltage 2.5V - 3.3V
Current Low-power mode (@3.3V): <30µA Instantaneous Sensors , On-Chip NVM <320µA Instantaneous , Average : 1 sample per minute: <2µA Vibration Active: <100µA not including external flash memory
Battery Life [500mAHr cell] >25 years in low-power mode , 1 Samp/min (not including self-discharge)
Sensors Expo 2013 Evigia Systems
Development and Deployment
• Energy-efficient integrated strain sensor, vibration sensor, and 3-axis mechanical shock sensor are complete
• Manufacturing process being qualified (MRL4)
• Sensor & electronics IC rev 1 (TRL5)
• Single chip sensor-electronics Q1’14 (TRL 6)
• Module with wireless link Q2’14 (TRL6)
Sensors Expo 2013 Evigia Systems
CBM Case Study: Army TACOM
Condition Based Maintenance Plus, Return on Investment Analysis Ken Fischer (01/12/11) US Army RDECOM-TARDEC
• Army TACOM Life Cycle Management Center is responsible for the sustainment of all ground vehicle platforms and supporting equipment.
• CBM+ Initiative to transition military from traditional reactionary and time-based preventative maintenance to deliver maintenance only upon evidence of need (CBM).
• CBM+ potential savings in: – Reduction in direct costs of part replacement and associated
maintenance labor costs
– Reduction in inspection times, reduced logistic down times, and ability to change the level of repair for diagnosable failure modes
– Reduction in maintenance costs due to reduced mean time to repair (MTTR)
– Reduced mean logistics down time (MLDT) due to improved forecasting and advanced reporting of impending failures
– Savings from logistics efficiencies as repair parts are better staged where most needed.
HEMTT Heavy Transport Introduced 1982 13,000 Vehicles currently in service
Operations & Support (O&S) costs account for 60% – 80% of the total lifetime cost for military platforms.
Sensors Expo 2013 Evigia Systems
CBM Case Study: Army TACOM
Condition Based Maintenance Plus, Return on Investment Analysis Ken Fischer (01/12/11) US Army RDECOM-TARDEC
• Sensor data acquisition system for engine, transmission, tires and batteries – $15k estimated per vehicle for “enabling technologies” of sensors, data acquisition/processing
and infrastructure
This initial TACOM CBM study identified $26M in potential cost savings (direct and avoided costs) for an analysis of 1045 vehicles
• DoD is looking for COTS solutions for Wireless Diagnostic Sensors (WDS) to support this activity
• Lowering the costs of the enabling sensor technologies will have a significant ROI impact when implementing a CBM initiative over a large number of vehicle systems
Sensors Expo 2013 Evigia Systems
CBM Case Study: Army AMCOM
AMCOM Condition Based Maintenance, AMC CBM Summit 7/18/08 US Army AMCOM, Gary Nenninger
• CBM Digital Source Collection (DSC) system for rotor aircraft, monitors 50+ sensor inputs – UH-60, AH-64, CH-47 Aircraft outfitted with DSC sensors and communications
– Monitoring rotor characteristics, engine health, drive train health, structural health and exceedance (over-temp, over-torque, etc.) conditions
• Sensor weight, connectivity, and robustness are major concerns in implementation – Current CH-47 DSC sensor infrastructure is > 45 pounds
Sensors Expo 2013 Evigia Systems
CBM Case Study: Army AMCOM
AMCOM Condition Based Maintenance, AMC CBM Summit 7/18/08 US Army AMCOM, Gary Nenninger
• Results of AMCOM one-year CBM implementation (350 aircraft deploying DSC system):
– Significant savings of >11,000 maintenance (MMF) and ~1,300 test flight (MTF) hours
– Extended component life and improved confidence in reliability
– An estimated $101M in one-year direct and indirect cost savings
– Improved mission readiness and hours flown, adding more available aircraft to operations
5% increase in Fully Mission Capable (FMC) status is
equivalent of 1.5 more aircraft. 1,431 increased Hours
Flown is equivalent of 2 additional aircraft at OPTEMPO
MMH: Ma in tenanc e Man-Hou rs MTF : Ma in tenanc e Tes t F l i gh t
AMCOM One-Year CBM Implementation
~ $101M in savings from CBM trial
Impact of equipping aircraft with DSCs
Sensors Expo 2013 Evigia Systems
CBM Case Study: Army AMCOM
AMCOM Condition Based Maintenance, AMC CBM Summit 7/18/08 US Army AMCOM, Gary Nenninger
• True benefits: avoidance of catastrophic component failure leading to loss of life and aircraft – Impending failure of specific AH-64 rotor bearing identified via CBM data, confirmed on teardown
2 Pilots saved $16M aircraft saved
Sensors Expo 2013 Evigia Systems
Prognostics Case Study: Caterpillar
Multi-sensor Equipment Health Diagnosis And Prognosis European Journal of Operational Research, 2007
• Prognostics and Health Management (PHM) study, analyzing health-state probability to predict the useful remaining life of Caterpillar hydraulic pump components.
• Diagnostics is the assessment of the current and past health of a system based on observed symptoms, and prognostics is a predictive assessment of the future health
• Uses novel multi-sensor fusion approach to adjust the weight or importance assigned to any sensor in the PHM analysis, yielding multi-dimensional model for PHM predictions
– Temperature, vibration, oil particle count sensors
Advances in networked multi- sensor technology enable corresponding advances in applications of diagnostics and prognostic health management
• Multiple sensors may have cooperative, complimentary or competitive predictive qualities, PHM studies can take advantage of multi-sensor characteristics
• Weighted multi-sensor fusion approach shows accuracy of PHM predictions was increased by 18.5% over single-dimensional model for Caterpillar 9J5082
Multiple hydraulic pumps and drive engine on test stand
Sensors Expo 2013 Evigia Systems
Case Study: Nuclear Material Storage • Hazardous material transport and storage presents a significant maintenance challenge
– Nuclear and radioactive materials, hazardous waste products, corrosive or toxic chemicals, volatile bulk process ingredients
• CBM enabled by custom container-mounted multi-sensors to monitor transit/storage location, seal breakage, package impact, temperature, humidity, radiation levels, and presence of gases and certain biological elements
Annual inspection and monitoring direct cost savings of over $2,000 per container
• CBM system lowers life-cycle management costs, reduces the requirements for manned surveillance and inspection, minimizes the potential hazardous exposure for plant personnel, and extends maintenance cycles of storage and transport vessels
Sensors Expo 2013 Evigia Systems
About Evigia Systems
Contact: Dr. Navid Yazdi CEO, Evigia Systems, Inc. [email protected] www.evigia.com Twitter: @EvigiaRFID
3810 Varsity Drive Ann Arbor, MI 48108
(734) 302-1140
• Evigia Systems (Ann Arbor, MI) develops wireless sensing, identification and tracking products and integrated solutions for military, security, and commercial applications
• Expertise in MEMS-based sensor development, integrated multi-sensors, robust wireless communication, ASIC design, and Active RFID systems
• Focus on delivering sensing technology with smaller form factors, higher energy efficiency, increased functionality, and lower production costs