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TRANSCRIPT
Wireless Asset Health Monitoring
Made Easy
Company
mgt.team
iQunet = Tech start-up (Belgium, °2015)
iQunet Vision : “Wireless Asset Health Monitoring Made Easy”
Founders iQunet• CEO, Dirk Van den Branden, Ing, MBA• CTO, Wim Vereecken, Dr. Ir.
Vast knowledge of• Electronic (chip) design• RF-technology• Product development
100% in house R&D and production with focus on• Innovative• battery operated• wireless• small sensors • for industrial applications
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Wireless Online Vibration Monitoring
Product Overview 2019 (details see online shop)
Basic Network Components
OptionalNetwork components
Sensors
iQunet server
Base station
Repeater
Actuator
Vibration + temp. (acceleration)
Inclination + temp. (accelaration)
Proximity + temp. (hall effect)
Proximity switch + temp. (reed)
CO2 + VOC + RH + T° (not available yet)
PIR motion + temp. (not available yet)
Temperature logger (temperature)
Why Condition Based Maintenance (CBM)?
Start Vibration Analysis & Fault Detection
IncreasePlant Asset Availability
89% of failures are random in nature !
Potential Failure Functional Failure
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A complete system of - Wireless Sensors- Base station - Small Din Rail Server
… that measures vibration of rotating equipment
… and makes the data available from anywhere via standardized OPC UA communication
… stores the data on the local iQunet Unix Server
Vibration Monitoring (predictive)APIs
Web-dashboard
From any browser(*)
(*) WebRTC ready browser e.g. Chrome
With 2-way communication• Configure sensors• Analyse data
With easy access to sensors• Via Internet• Via company network
Full control from any device
Communication
Vibration data locally stored on iQunet server is open (no lock-in)
OPC UA ensures seamless flow of information
Sensor Network
OPC UAServer
iQunet offering
Technology
Sensor sleep current is extremely low (<1µA)• Touching the batteries reduces the battery life
time with approx. 50% due to induced leakage current being higher than sensor consumption
Wireless transmission is ultra fast with low consumption• Lean but effective wireless iQunet protocol
increases payload/overhead ratio
Digitalisation of the sensor makes it very low power• Inside accelerometer made of MEMS Integrated
Circuits makes it possible to run the electronics on 2 standard CR2032 coin cells
Features
Range of the sensors• 10-50m depending on (*)
• sensor mounting• Machine density in the plant• Construction of the plant
• Can be extended 1x with Repeater node(s) (**)
Number of sensors in the range• Unlimited
Life time of the batteries in the wireless sensors• ±5 years (@1 complete 3-ax measurement/day + 100 x T°/day)
(*) Note1: 50m in ideal setting / 15 to 25m in average in industrial settings(**) Note2: with inherent reduced data bandwidth (slower wireless transfer rates)
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• Advantages MEMS wireless battery operated sensors• Semi-continuous measurement – largely available (trend) data• Compressive sensing techniques
• Full spectrum (not only RMS)• Characteristic harmonic detection• Operating point clustering
• Lower TCO, smaller physical footprint, cheaper • Largely available cheap measurement points
• Faster installation• Low power / on batteries / no cables
• Disadvantages MEMS wireless battery operated sensors • Trade off between power, accuracy and number of datapoints• Less accurate (but many datapoints = Machine Learning ready)
--> available for many assets !
• Advantages Piezo-electric sensors• Larger measuring range, more
information in one measure• Proven analytical technique (experts)
• Disadvantage Piezo-electric sensor• Labour-intensive• Snapshot (portable equipment)• Very expensive online wired/wireless
equipment -->used with highly critical assets
“MEMS”-vibration monitoringThe classic way
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• With the same available power less accurate , but more datapoints
• Interesting mechanical features of MEMS: Less sensitive ( up to 10.000g) 3-axial
• Small: combination with other features (T°, Wireless, Memory, …)
• Inexpensive electronics part: use of more MEMS sensors in one device
• Inexpensive computing power correlation via Machine learning possible
“MEMS”-vibration monitoring
Anomaly Monitoring Service
Firewall (customer)
ML
DATA
*
MO
DEL
*
iQunet Machine Learning Computer
Local sensor network at SubGHz frquency(Free ISM band at 868Mhz or 915Mhz center frequency – country dependent)
Ethernet network or WiFi network at 2,4GHz or 5GHz free frequency
(*) One time data transfer of historical data setML Model transferred and stored back in iQunet local server for continuous local Anomaly Monitoring(subscription based)
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Anomaly Monitor: iQunet Machine Learning Service
All in same dashboard
Automated data compression and transfer toiQunet Machine Learning Servers
Model returned and storedon the local iQunet server
Anomaly trend graphs(MSE) with alarm levels
MSE: Mean Squared Error. Indicates thedifference from new samples (measurements) compared to the model
Contact :Dirk Van den BrandenCEO / co-owner+32 478 44 66 [email protected] Winner BEMAS Digital Innovation Award 2017
Comparison (performed by Siemens) between
High-end piezo-electric sensor and
iQunet wireless sensor
VS.
Case Bio Mass Centralplease note differences in graph scales
• iQunet sensor detects also the bearing errors (all “frequency peaks” related to bearing errors are available – yet with less resolution)
• iQunet resolution in lower frequencies could be increased by sampling at lower rates with high number of samples (setting in dashboard)
• The iQunet sensor is a perfect low cost fit for anomaly detection with machine learning techniques
Mount sensor withM3 bolt and
wire bus
Use Epoxy for
permanent mount
Keep antenna top free from obstacles
(8 cm around)
Setup & Installation
Contact :Dirk Van den BrandenCEO / co-owner+32 478 44 66 [email protected] Winner BEMAS Digital Innovation Award 2017
Sensor mounting: “plug&play”
Sensor mounting instructions
Equipment base (e.g. rotating equipment)
Drill Ø4mm and insert M3 wire bus
Hex Socket Cap Stainless Steel Plain Socket Screw, M3 x 16mm
Use epoxy adhesive for permanent mount (*)
Antenna top must be free from metal obstructions for best range (8 cm around the top in ALL directions)
(*) see install guide or online shop for recommended epoxy type
Mounting instructions
Mounting instructions
Mounting instructions
Mounting instructions
Contact :Dirk Van den BrandenCEO / co-owner+32 478 44 66 [email protected] Winner BEMAS Digital Innovation Award 2017
CASES
Case Paper Mill – M&M Germany
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Karton Machine – Selection PoC
Length approx. 130 meter
Hig
h ap
prox
. 13
met
er
Case Paper Mill – M&M Germany
Case Paper Mill – M&M Germany
Case Bio Mass Central
Live demo: Case Bio Mass Central
Case Hot Mill (Arcelor Mittal Gent)
Live Demo – Hot Mill plant
Run out table hot mill – cooled down with water
Live Demo – Hot Mill plant
Sensors Drive Side
Live Demo – Hot Mill plant
Sensors Operator side
Contact :Dirk Van den BrandenCEO / co-owner+32 478 44 66 [email protected] Winner BEMAS Digital Innovation Award 2017
CASES
iQunet wireless battery-powered vibration sensors detect pump damage. With automatic measurements every hour, the increasing deviation compared to a recent pump was detected and followed up. Due to the iQunet sensors it was possible to replace the bad pump within planned downtime.
Use Case:Monitoring end of life of motor-pump combination
Contact :Dirk Van den BrandenCEO / co-owner+32 478 44 66 [email protected] Winner BEMAS Digital Innovation Award 2017
Conclusion
Secured iQunet server and save wireless communciation API with 200+ commands for maximum integration Clear pricing of the products, plug&play setup Excellent technical iQunet support Performant standardized OPC UA communication Many available ways to export or address data Partnering with Siemens Easy to expand system Products according to CE standards Computing in the edge solution minimilizes network usage Data remains local, no iQunet lock-in
Conclusion : IIoT in predictive maintenance and asset monitoring with MEMS sensors
Asset Health Monitoring Made Easy
Contact :Dirk Van den BrandenCEO / co-owner+32 478 44 66 [email protected] Winner BEMAS Digital Innovation Award 2017
www.iQunet.com
Please contact us for a live demo (via online meeting)