Industrial WSN AnalysisIndustrial WSN Analysis

Cost and Functionality ComparisonCost and Functionality ComparisonReal World Deployment EvaluationReal World Deployment Evaluation

Mick FlaniganMick FlaniganSuhaime HassimSuhaime HassimIntel CorporationIntel Corporation

IntroductionIntroductionMick FlaniganIntel Corporation, Oregon, 11 years

8 years as Vibration Engineer

Deployment Engineer for Intel MoteTechnologies in Factories, Ships, etc

Developed Intel’s first centralized machine modeling and alarm system based on PDM

Currently work in Intel Research on Body Area Sensor network and other Health applications

Suhaime HassimIntel Corporation, 7 years

7 years as Vibration Engineer

Lead Deployment Engineer for JFS1 Project

Lead Engineer for Global PDM team: Asia, EU, US, Central America, Middle East

Currently based in Oregon on assignment as TD Engineer for Wireless Vibration systems evaluation

Problem StatementProblem Statement

Market available models of data Market available models of data collection for PDM applications separate collection for PDM applications separate into two classes: into two classes:

Online Surveillance and Protection systemsOnline Surveillance and Protection systemsHandheld Collection systemHandheld Collection system

Problem Statement (cont.)Problem Statement (cont.)

These systems do not address the growing need These systems do not address the growing need to monitor low cost critical system at higher to monitor low cost critical system at higher frequency than monthlyfrequency than monthlyOnline systems are very expensive: practical for Online systems are very expensive: practical for million dollar+ equipment or submillion dollar+ equipment or sub--hourly hourly collection needscollection needsHandheld capture is only practical on a Handheld capture is only practical on a >monthly basis, as labor to support rises quickly>monthly basis, as labor to support rises quickly

Handheld System: MagneticHandheld System: Magnetic

AdvantagesAdvantagesLow initial costLow initial costGood for small plantsGood for small plantsGreat for Infrequent Great for Infrequent CollectionCollectionExcellent diagnostic Excellent diagnostic tooltool

DisadvantagesDisadvantagesUser errorsUser errorsUnUn--correlated datacorrelated dataHigh labor costs as High labor costs as machine counts scalemachine counts scaleDifficult to support Difficult to support high collection high collection frequencyfrequency

Handheld System: WiredHandheld System: Wired

AdvantagesAdvantagesEasy to scaleEasy to scaleGood for low Good for low collection frequenciescollection frequenciesModerate Moderate implementation costsimplementation costsExcellent Excellent measurement measurement repeatabilityrepeatability

DisadvantagesDisadvantagesUser errorsUser errorsCosts similar to Costs similar to wireless systemwireless systemHigh labor costs as High labor costs as machine count scalesmachine count scalesDifficult to support Difficult to support high collection high collection frequencyfrequency

Online Ethernet SystemOnline Ethernet System

AdvantagesAdvantagesLarge machine Large machine population supportpopulation supportReliable and frequent Reliable and frequent data collectiondata collectionExcellent for machine Excellent for machine protectionprotection

DisadvantagesDisadvantagesHigh installation costHigh installation costCostly to scaleCostly to scaleLock into proprietary Lock into proprietary system, costly to system, costly to changechange

Wireless SystemsWireless Systems

AdvantagesAdvantagesLarge machine Large machine population supportpopulation supportReliable and frequent Reliable and frequent data collectiondata collectionLow costLow costEasy to ScaleEasy to Scale

DisadvantagesDisadvantagesUnable to capture sub Unable to capture sub minute intervals in minute intervals in our modelour modelSubject to RF Subject to RF InterferenceInterferenceSecurity is a concernSecurity is a concern

High Level ArchitectureHigh Level Architecture

Intranet

Backbone Stargate Cluster HeadStore query configurationControl SN sleep/wake cycleAcquire data from SNStore results when disconnected

Sensor NodeForm mesh topologyAccept queries, sense, and respondEdge processing (FFT, gSE)

Data ServerUser definition of queries via GUIPush query config to sensor netFetch sensed dataConvert and import into Enshare

SensorClusters

SNAPSSNAPS

Navigation Tree

Menu & Toolbar

FMAX

Lines

Averages

Window

Filter

Warm upTime

SignalDetection

TachState

SensorType

BaseUnits

Calibration

UnitsDataType

Example:Data Type: SpectrumSensor Type: AccelerometerEngineering units: G’sCalibration Value: 100mV/e.u.Sensor Zero: 0 G’sFmax: 90000Lines: 3200Averages: 4Window: HanningFilter: NoneWarm up time: 10 deci-secondsSignal Detection: PeakTach present: No

If no, RPM: 1785Output Units Desired: IPS

FFT Data Acquisition Single Value Data Acquisition

FMAX

Lines

Averages

Window

Filter

Warm upTime

SignalDetection

TachState

SensorType

BaseUnits

Calibration

Units

SensorZero

Slope

DataType

Example:Data Type: NumericSensor Type: TemperatureEngineering units: deg.KCalibration Value: 10mV/e.u.Sensor Zero: 240 deg.KFmax: 1500Lines: 25Averages: 1Window: NoneFilter: NoneWarm up time: 10 deci-secondsSignal Detection: PeakTach present: No

If no, RPM: 0Output Units Desired: deg.F

SensorZero

Slope

System Configuration ParametersSystem Configuration Parameters

Not user configurable

Intel Mote 2 Intel Mote 2 Picture and FeaturesPicture and Features

MDA440 Sensor BoardMDA440 Sensor BoardSensor inputsSensor inputs

6 AC6 AC--coupled accelerometer inputscoupled accelerometer inputsProvides 6 channels of temperature integrated vibration sensorsProvides 6 channels of temperature integrated vibration sensorsSurface temperature readings in Deg F, Deg C or Deg KSurface temperature readings in Deg F, Deg C or Deg K

3 DC3 DC--coupled 0coupled 0--5V inputs (current transducers + MISC)5V inputs (current transducers + MISC)Tachometer input (for RPM and triggering purposes)Tachometer input (for RPM and triggering purposes)

To

pB

otto

m

Imote2

Supported Sensor TypesSupported Sensor TypesAccelerometers:Accelerometers:

10, 50, 100, 500 mV/G calibration values10, 50, 100, 500 mV/G calibration valuesSupports integrated temperatureSupports integrated temperatureSupports 18Supports 18--30VDC ICP styles only 30VDC ICP styles only

Voltage Inputs:Voltage Inputs:00--5VDC channels 5VDC channels Example: Current transducers, pressure, temperature, flow, etcExample: Current transducers, pressure, temperature, flow, etc

Tachometer Input:Tachometer Input:Supports magnetic proximity type sensors: channel will support Supports magnetic proximity type sensors: channel will support up to 5V up to 5V pkpk--pkpk..

Triggered MeasurementsTriggered Measurements

Utilizing a channel as a trigger allows for three Utilizing a channel as a trigger allows for three distinct benefits:distinct benefits:

Users link to vibration channel to act as an Users link to vibration channel to act as an operational gate:operational gate:

User sets a minimum value assigned to the trigger channelUser sets a minimum value assigned to the trigger channelIf the minimum value is not met, the acquisition of further If the minimum value is not met, the acquisition of further data from the specified node can be cancelled, preventing data from the specified node can be cancelled, preventing zero data entering the databasezero data entering the database

Added benefit: Node does not collect unwanted data, Added benefit: Node does not collect unwanted data, extending battery lifeextending battery life

Various Types of Vibration MonitoringVarious Types of Vibration Monitoring

Convert raw data into usable data as defined by Convert raw data into usable data as defined by end users:end users:

Raw Waveform data is rarely used in industrial Raw Waveform data is rarely used in industrial applicationsapplicationsFast Fourier Transform (FFTFast Fourier Transform (FFT’’s) are most useful in s) are most useful in analysis of machine defect frequenciesanalysis of machine defect frequenciesOverall magnitude representations provide good Overall magnitude representations provide good alarming pointsalarming points

Why do Signal Processing on Mote?Why do Signal Processing on Mote?Problem: Machines typically have vastly different Problem: Machines typically have vastly different sampling rate requirementssampling rate requirements

Possible solutions:Possible solutions:Complex hardware that can dynamically adjust sampling rate Complex hardware that can dynamically adjust sampling rate combined with simple software driver: combined with simple software driver: Expensive, custom per Expensive, custom per appapp

Simple Hardware with one sampling rate and simple software Simple Hardware with one sampling rate and simple software driver: driver: Not flexible, does not cover all machine typesNot flexible, does not cover all machine types

Simple Hardware with one sampling rate, software driver that Simple Hardware with one sampling rate, software driver that dynamically adjusts sampling rate: dynamically adjusts sampling rate: Need the CPU power, Need the CPU power, Memory for realMemory for real--timetime

Edge Processing using Intel Mote2Edge Processing using Intel Mote2

Frame processingReal time processing

A/D samples at 100 kHz Power-of-2

decimation

DC removal FFT

Averaging over N frames

Ready for transmission

Fine-tune sampling rate Hanning window Magnitude

gSE

Achieving Long Battery LifeAchieving Long Battery Life

Contributing factors to battery lifetimeContributing factors to battery lifetimePower consumptions in different modesPower consumptions in different modes

Sensing (sensor + board power consumption)Sensing (sensor + board power consumption)Data transfer (mote + radio)Data transfer (mote + radio)Sleep (mote in sleep mode)Sleep (mote in sleep mode)

Sensor types and quantitySensor types and quantityCollection frequencyCollection frequencyMeasurement types and set pointsMeasurement types and set pointsNumber of nodes in a clusterNumber of nodes in a clusterUse trigger to stop collection on nonUse trigger to stop collection on non--running machinesrunning machines

Improving the Battery Lifetime:Improving the Battery Lifetime: Implemented ImprovementsImplemented Improvements

Edge processingEdge processingPerform downPerform down--sampling, FFT at the Imote2 saves powersampling, FFT at the Imote2 saves power

Supporting trigger based collectionsSupporting trigger based collectionsAvoid collecting and transmitting data when machines are offAvoid collecting and transmitting data when machines are off

Software optimizationsSoftware optimizationsReduced awake time from 90 to 29 Reduced awake time from 90 to 29 minsmins per hour (10 Node)per hour (10 Node)Improved discovery, routing, warmImproved discovery, routing, warm--up time, averaging, up time, averaging, cachingcaching

Advantage of Edge ProcessingAdvantage of Edge ProcessingLocal processing advantage

0

40

80

120

160

Raw datatransfer

Local real-time downsampling

Localspectralanalysis

Tim

e (s

econ

ds)

RF time (s)assuming 50 kbpsProcessing Time (s)

Capture Time (s)

272

Current draw in different modes

0

50

100

150

200

250

Collecting data Processing data Transfering data

Mote Mode

Cur

rent

Con

sum

ed (m

A)

Downsampling performance using WMMX

0

50

100

150

200

250

300

2 4 8 16 32 64 128 256

Downsampling factor

Filte

ring

time

for 4

K b

lock

s (m

s)

" C code"

WMMXoptimized code

Sampling rate(real-time constraint)

Overview of Intel JFS1Overview of Intel JFS1

Located in Hillsboro Located in Hillsboro OregonOregonBuilt in Nov 2005Built in Nov 2005Humidity and Humidity and temperature control temperature control environmentenvironmentHouse critical House critical computing for Intel computing for Intel manufacturingmanufacturing

Deployment AreaDeployment Area

HighTemperature

Room

CoolingTowers

LowTemperatureRoom

Roof

Cluster Cluster IDID

IP AddressIP Address TO #TO # LocationLocation MotesMotes PIDPID ConfigConfig

Cluster BCluster B 10.7.244.20310.7.244.203 JFS1SCC1JFS1SCC1-- CSC29CSC29--AA-- 1515

JFS1 JFS1 CTsCTs 88 0x780x78 15.4 15.4 EthEth

Cluster CCluster C 10.7.244.20210.7.244.202 JFS1SCC1JFS1SCC1-- CSC29CSC29--AA-- 1616

JFS1 LT CHJFS1 LT CH 66 0x290x29 15.4 15.4 EthEth

Cluster DCluster D 10.7.244.20110.7.244.201 JFS1SCC1JFS1SCC1-- CSC29CSC29--AA-- SCC1SCC1-- 1/4011/401--D2D2

JFS1 HT CHJFS1 HT CH 1111 0x170x17 15.4 15.4 EthEth

Cluster ECluster E 10.7.244.20010.7.244.200 JFS121JFS121-- 3/4523/452--D2D2

JFS1 RoofJFS1 Roof 44 0x6E0x6E 15.4 15.4 EthEth

C

DBE

JFS1 Network TopologyJFS1 Network Topology

Monitoring DetailsMonitoring Details

EquipmentEquipment QtyQty SensorsSensorsPumpPump 88 4040ChillerChiller 55 2020Air CompressorAir Compressor 22 2020Cooling TowerCooling Tower 88 4040Air HandlerAir Handler 22 1212

DevicesDevicesWilcoxon 793T Wilcoxon 793T –– 10/100mV/G 10/100mV/G accelerometers with embedded temperature accelerometers with embedded temperature capability.capability.

FlexFlex--Core AC SplitCore AC Split--Core Current Core Current Transducer .Transducer .

Honeywell tachometer model Honeywell tachometer model 3015A3015A

DevicesDevices

Crossbow MDA 440: Series of Crossbow MDA 440: Series of sensor/data acquisition boards sensor/data acquisition boards designed to interface with Imote2.designed to interface with Imote2.

Stargate: HighStargate: High--performance performance processing platform designed for processing platform designed for sensor, signal processing, control sensor, signal processing, control and wireless sensors networking and wireless sensors networking applications.applications.

Data Types and FrequencyData Types and FrequencyData types:Data types:

RPMRPMAmperage (Current Transducer)Amperage (Current Transducer)Temperature (deg F)Temperature (deg F)Battery voltage (Vdc)Battery voltage (Vdc)Accelerometer bias voltage (Vdc)Accelerometer bias voltage (Vdc)Vibration IPS (magnitude and FFT spectrum)Vibration IPS (magnitude and FFT spectrum)

Data Collection Frequency:Data Collection Frequency:Once every 24 hoursOnce every 24 hours

ResultsResults

FFT (ips)

Waterfall FFT (ips) Battery voltage (Vdc)

Bias voltage (Vdc)

Based on 6 accels capturing FFT and MAG IPS and G’s, temperatureBOV, Battery voltage, RPM and one current transducer input

Battery LifetimeBattery Lifetime Effect of collection frequencyEffect of collection frequency

Assumes machinery always onAssumes machinery always onData based on model and chiller room profilingData based on model and chiller room profiling

Effect of Collection Frequency on Battery Life

0100200300400500600

1 3 6 9 12 24

Number of collections per day

Bat

tery

life

(day

s)

10 Node Cluster4 Node cluster

Key LearningKey Learning

Network Limited to 35 nodes as software Network Limited to 35 nodes as software is written todayis written today15.4 communications are robust indoors 15.4 communications are robust indoors and outdoorsand outdoorsStargate connectors can be susceptible to Stargate connectors can be susceptible to vibrationvibrationCollection cycles more than every 8 hours Collection cycles more than every 8 hours may dictate hard power to motesmay dictate hard power to motes

Key Development AreasKey Development Areas

Need board for 4Need board for 4--20mA sensors20mA sensorsCompartmentalize clusters and XML Compartmentalize clusters and XML programming to allow system scaling, ease of programming to allow system scaling, ease of managementmanagementHarden Stargate systems, or find a better Harden Stargate systems, or find a better solution with embedded 802.11, 15.4 solutionssolution with embedded 802.11, 15.4 solutionsIntegrate devices into CBM software platformIntegrate devices into CBM software platform

Cost Comparison:Cost Comparison: JFS1 JFS1 Project CostsProject Costs

COMPONENTSCOMPONENTS COSTSCOSTS

StargatesStargates $3,600$3,600

MDA440MDA440’’ss $23,925$23,925

SensorsSensors $6,120$6,120

CablesCables $25,160$25,160

TachometersTachometers $1,450$1,450

Current TransformersCurrent Transformers $1,700$1,700

ServerServer $3,800$3,800

LaborLabor $48,300$48,300

TOTALTOTAL $114,055$114,055

JFS1 Deployment Cost ComparisonJFS1 Deployment Cost ComparisonComponentsComponents WirelessWireless HandheldHandheld

MagneticMagneticHandheldHandheld

WiredWiredOnline Ethernet Online Ethernet

BasedBased

Switch boxesSwitch boxes -- -- $17,250$17,250 --

Enwatch cabinetsEnwatch cabinets -- -- -- $174,000$174,000

HandheldHandheld -- $19,250$19,250 $19,250$19,250 --

StargatesStargates $3,600$3,600 -- -- --

MDA 440MDA 440’’ss $23,925$23,925 -- -- --

CablesCables $6,120$6,120 -- $6,120$6,120 $6,120$6,120

SensorsSensors $25,160$25,160 $1,200$1,200 $25,160$25,160 $25,160$25,160

TachometersTachometers $1,450$1,450 -- $1,450$1,450 $1,450$1,450

Current Current XformersXformers $1,700$1,700 -- $1,700$1,700 $1,700$1,700

ServerServer $3,800$3,800 $3,800$3,800 $3,800$3,800 $3,800$3,800

LaborLabor $48,300$48,300 $14,000$14,000 $43,100$43,100 $57,300$57,300

TOTALTOTAL $114,055$114,055 $38,250$38,250 $117,830$117,830 $269,530$269,530

Cost per PointCost per Point Equipment and Installation costs onlyEquipment and Installation costs only

* Does not include monitoring remote Cooling Tower and AHU points

$408

$171*

$447

$964

$0

$200

$400

$600

$800

$1,000

$1,200

Wireless Handheld Handheld Wired Ethernet

Cost vs. CaptureCost vs. Capture

HandheldMagnetic

EthernetCapture

$10 $100 $500 $1000

EthernetSurveillance, Protection

Weekly

Monthly

Daily

Hourly

Minutes

Seconds

Cost per Point

Colle

ctio

n Fr

eque

ncy

HandheldWired

Wi-Fi BasedCapture

Major WSN BenefitsMajor WSN Benefits

Less costly to deploy than EthernetLess costly to deploy than EthernetProvide more reliable, more frequent collection Provide more reliable, more frequent collection than handheld model at no added costthan handheld model at no added costJFS1 model excellent for moderate to infrequent JFS1 model excellent for moderate to infrequent data collection (>hourly)data collection (>hourly)Edge processing reduces data transmission sizeEdge processing reduces data transmission sizeLarge opportunities for edge network Large opportunities for edge network intelligence (rule sets, Statistics, Bayesian)intelligence (rule sets, Statistics, Bayesian)

PREPRE--WORK TO DEPLOY WSNWORK TO DEPLOY WSNUnderstand your application: Understand your application:

Data Type, Collection interval, CPU needs, securityData Type, Collection interval, CPU needs, securityNetwork Traffic, BandwidthNetwork Traffic, BandwidthEnvironmental Concerns: RF noise, Metal, PowerEnvironmental Concerns: RF noise, Metal, PowerDefine radio, infrastructure, cohabitation, legacy compatibilityDefine radio, infrastructure, cohabitation, legacy compatibilityEnsure RF testing has been completed and there are no issues Ensure RF testing has been completed and there are no issues with interference in production processeswith interference in production processes

These items will determine the needed CPU, These items will determine the needed CPU, memory, radio and security for your systemmemory, radio and security for your system

D1D R

onler A

cres

BP Phase 1

CUB3 Phas

e 1

CUB3 Phas

e 2

JF3 P

hase 1

BP Phase 2

JFS1

AT9 Viet

nam

Intel W

orldwide

2003 2004 2005 2006 2007 2008 2009+

2002 Conference Room Usage:

Mica2 Initial Trials

JF3 Mica2Trials

CUB3 Mica2 vs.

Imote1Trials

BP Imote2

Deployment

JF3 Imote2 Trials

JFS1 Imote2

Deployment

Future?

Future?

Future?

DecisionPoint

ROADMAPROADMAP

Q & AQ & A