New Sensor Technology for Broad Distribution of … Sensor Technology for Broad Distribution of Vibration Data ... piezo circuitry has the following ... The vibration sensor allows

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New Sensor Technology for Broad New Sensor Technology for Broad Distribution of Vibration Data Distribution of Vibration Data

CollectionCollection


IntroductionIntroduction

In this overview presentation, we will look at some In this overview presentation, we will look at some of the issues in distributing the effort to collect of the issues in distributing the effort to collect vibration data, and how some new sensor vibration data, and how some new sensor technology may help in overcoming those issues.technology may help in overcoming those issues.

Requirement for Broad Distribution of Data CollectionRequirement for Broad Distribution of Data CollectionEffortEffort

Obstacles to Achieving Broad Distribution Obstacles to Achieving Broad Distribution

Portable Vibration Data Collection Tools Portable Vibration Data Collection Tools -- Benefits and Benefits and Drawbacks for Broadly Distributed Data Collection.Drawbacks for Broadly Distributed Data Collection.

Digital Accelerometers Digital Accelerometers –– A Recent DevelopmentA Recent Development


Broad Distribution of Data CollectionBroad Distribution of Data Collection

One of the main difficulties in any vibration program One of the main difficulties in any vibration program is to access the resources needed to collect and is to access the resources needed to collect and analyze the appropriate data.analyze the appropriate data.

Vibration specialists can spend their time either collecting Vibration specialists can spend their time either collecting data or analyzing data.data or analyzing data.

It is widely recognized that having the vibration specialist It is widely recognized that having the vibration specialist collect the data that he/she analyzes is ideal.collect the data that he/she analyzes is ideal.

Having the specialist collect and analyze vibration data Having the specialist collect and analyze vibration data often leads to missed plant equipment or longer than often leads to missed plant equipment or longer than optimal intervals between readings.optimal intervals between readings.



One of the main difficulties in any vibration program One of the main difficulties in any vibration program is to access the resources needed to collect and is to access the resources needed to collect and analyze the appropriate data.analyze the appropriate data.

To expand a data collection and analysis program, To expand a data collection and analysis program, plants have several options.plants have several options.

TechnologyTechnology--Driven OptionsDriven OptionsHumanHuman--Driven OptionsDriven Options



Expansion of a data collection and analysis program Expansion of a data collection and analysis program can be undertaken in several ways:can be undertaken in several ways:

Use diagnostic tools such as condition assessment Use diagnostic tools such as condition assessment software to decrease analysis time for spectral data.software to decrease analysis time for spectral data.

Install equipment to facilitate data collection Install equipment to facilitate data collection ––permanently mounted sensors, switchboxes, etc.permanently mounted sensors, switchboxes, etc.

Install online data acquisition systems to collect data Install online data acquisition systems to collect data from permanently mounted sensors.from permanently mounted sensors.

TechnologyTechnology--DrivenDriven



Expansion of a data collection and analysis program Expansion of a data collection and analysis program can be undertaken in several ways:can be undertaken in several ways:

Use other plant personnel to collect vibration Use other plant personnel to collect vibration data, and have existing vibration specialists data, and have existing vibration specialists analyze that data.analyze that data.

Hire and/or train more vibration specialists.Hire and/or train more vibration specialists.

Outsource all or part of the data collection / analysis Outsource all or part of the data collection / analysis function.function.

HumanHuman--DrivenDriven


All of the methods listed to expand data collection All of the methods listed to expand data collection coverage merit consideration, and any combination coverage merit consideration, and any combination of these strategies can be used effectively.of these strategies can be used effectively.


For the rest of this presentation, we will focus our For the rest of this presentation, we will focus our attention on the last of the options attention on the last of the options –– using plant using plant personnel other than reliability staff to collect personnel other than reliability staff to collect vibration data. What is needed to even attempt to vibration data. What is needed to even attempt to make such a program effective? make such a program effective?


What is needed to even attempt to use nonWhat is needed to even attempt to use non--reliability reliability personnel to collect effective vibration data?personnel to collect effective vibration data?

Data collection tools that can and will be used by nonData collection tools that can and will be used by non--vibration specialists to collect vibration data.vibration specialists to collect vibration data.

Cooperation and participation from nonCooperation and participation from non--reliability staff reliability staff ––operations, lubrication and maintenance.operations, lubrication and maintenance.

Data collection tools that have the ability to collect data Data collection tools that have the ability to collect data at a level of detail sufficient for vibration specialist’s at a level of detail sufficient for vibration specialist’s analysis time to be used effectively.analysis time to be used effectively.

Cooperation and participation from the vibration Cooperation and participation from the vibration specialists themselves.specialists themselves.



Getting CooperationGetting Cooperation

It can be difficult to get nonIt can be difficult to get non--reliability staff reliability staff (operators, lubrication techs, PM mechanics) to (operators, lubrication techs, PM mechanics) to cooperate with a vibration data collection routine. cooperate with a vibration data collection routine. How Do You Do It?How Do You Do It?

Keep It Light Keep It Light –– the amount of additional work should be the amount of additional work should be kept to a reasonable amount (< 1 hour per week, if kept to a reasonable amount (< 1 hour per week, if possible) possible)

What's In It For Me? What's In It For Me? –– operators and lube techs operators and lube techs have their own data collection / inspection duties have their own data collection / inspection duties –– can can you offer them a solution that will improve their situation you offer them a solution that will improve their situation while facilitating collection of vibration data?while facilitating collection of vibration data?

Keep It Simple Keep It Simple –– any data collection tool you ask any data collection tool you ask operators to use must be usable with minimal training.operators to use must be usable with minimal training.


Getting Cooperation(2)Getting Cooperation(2)

It can also be difficult to get vibration specialists to It can also be difficult to get vibration specialists to be enthused about nonbe enthused about non--reliability staff reliability staff –– and they and they have some valid reasons to object. How to deal with have some valid reasons to object. How to deal with their objections? their objections?

Ensure Data Richness Ensure Data Richness –– vibration specialists need vibration specialists need enough data richness to be able to make a frontenough data richness to be able to make a front--line line evaluation of the machine.evaluation of the machine.

What's In It For Me? What's In It For Me? –– vibration specialists prefer to vibration specialists prefer to analyze data they’ve collected themselves, but even the analyze data they’ve collected themselves, but even the most diligent find it difficult to cover all “balancemost diligent find it difficult to cover all “balance--ofof--plant” equipment.plant” equipment.

Help Ensure Positional Accuracy Help Ensure Positional Accuracy –– data collection tools for data collection tools for operators should use tools such as bar codes or RFID to operators should use tools such as bar codes or RFID to make sure they are recording data at the right sport. make sure they are recording data at the right sport.


Tools/TechnologyTools/Technology

Assuming that we have convinced operators or lube Assuming that we have convinced operators or lube techs to contribute to an overall asset care program techs to contribute to an overall asset care program by collecting vibration data, what tools do we give to by collecting vibration data, what tools do we give to these nonthese non--vibration specialists to collect this data? vibration specialists to collect this data?

Overall Vibration MetersOverall Vibration Meters

One, two or four channel multiOne, two or four channel multi--purpose data purpose data collector / analyzers.collector / analyzers.

Overall Vibration Meters connected to PDAOverall Vibration Meters connected to PDA--based based devices.devices.

or ???or ???



Overall vibration meters can be used to collect Overall vibration meters can be used to collect acceleration, velocity and/or displacement overall acceleration, velocity and/or displacement overall values. Many can also collect bearing condition values. Many can also collect bearing condition using shock pulse or some other highusing shock pulse or some other high--pass filtered pass filtered signal.signal.



The main benefits of using overall meters are cost The main benefits of using overall meters are cost and simplicity.and simplicity.

It is relatively easy to teach an operator to use an overall It is relatively easy to teach an operator to use an overall meter meter –– if the operator is interested and involved.if the operator is interested and involved.

Operators can be equipped with overall meters for Operators can be equipped with overall meters for a low cost relative to more sophisticated tools.a low cost relative to more sophisticated tools.



The main drawback to using overall meters centers The main drawback to using overall meters centers on resistance from the nonon resistance from the non--reliability staff. reliability staff.

Asking operators to collect and write down vibration Asking operators to collect and write down vibration levels onto a clipboard is unlikely to create an levels onto a clipboard is unlikely to create an enthusiastic response.enthusiastic response.You can expect a fairly high number of errors in your You can expect a fairly high number of errors in your data, based on readings taken incorrectly or simple data, based on readings taken incorrectly or simple transcription errors.transcription errors.

ClipboardClipboard--collected data is difficult to use for decision collected data is difficult to use for decision support until it is entered into a spreadsheet or database. support until it is entered into a spreadsheet or database. Many manual inspection programs fail at this Many manual inspection programs fail at this critical point.critical point.

What’s in it for me?What’s in it for me? –– well, for the operators collecting well, for the operators collecting data, there is nothing except extra work. data, there is nothing except extra work.


Overall Vibration Meters + PDAsOverall Vibration Meters + PDAs

Some overall vibration meters can be connected to a Some overall vibration meters can be connected to a PDA, or using their own internal memory.PDA, or using their own internal memory.

An overall vibration level meter that can connect to a PDA.

Vibration data can be collected by Vibration data can be collected by operations personnel during operations personnel during inspection rounds.inspection rounds.


Overall Vibration Meters Overall Vibration Meters -- PDAsPDAs

The main benefit of using overall meters connected The main benefit of using overall meters connected to data capture devices is to data capture devices is

It is relatively easy to teach an operator to use an overall It is relatively easy to teach an operator to use an overall meter meter –– if the operator is interested and involved.if the operator is interested and involved.

Operators can be equipped with serial output overall Operators can be equipped with serial output overall meters for a lower cost relative to more sophisticated meters for a lower cost relative to more sophisticated tools tools -- but more expensive that simple overall meters.but more expensive that simple overall meters.

What’s in it for me?What’s in it for me? –– Operators / lube techs can use the Operators / lube techs can use the PDAs to manage their own data collection rounds. They PDAs to manage their own data collection rounds. They can be convinced to use the PDA device to collect can be convinced to use the PDA device to collect vibration data in addition to their own inspections vibration data in addition to their own inspections ––however, they are generally opposed to collecting however, they are generally opposed to collecting vibration data alone.vibration data alone.


The main drawback to using overall meters with The main drawback to using overall meters with PDAs in an asset care program centers on PDAs in an asset care program centers on resistance from the vibration specialists. resistance from the vibration specialists.

It is impossible to know if a high overall reading is a It is impossible to know if a high overall reading is a problem bearing or a poorly taken reading. problem bearing or a poorly taken reading.

Doubt over the status of the machine causes vibration Doubt over the status of the machine causes vibration specialists to make more trips to verify machine specialists to make more trips to verify machine condition using their standard data collector/analyzer.condition using their standard data collector/analyzer.

It is difficult to know if a very low overall reading is a It is difficult to know if a very low overall reading is a wellwell--running machine or a faulty meter/sensor or a poorly running machine or a faulty meter/sensor or a poorly taken reading. taken reading.

What’s in it for me?What’s in it for me? –– vibration specialists do not see any vibration specialists do not see any real reduction in their workload.real reduction in their workload.

Overall Vibration Meters Overall Vibration Meters -- PDAsPDAs


Data Collector / AnalyzersData Collector / Analyzers

MultiMulti--purpose, multipurpose, multi--channel data collector / channel data collector / analyzers can be used to collect a wide variety of analyzers can be used to collect a wide variety of both static and dynamic data.both static and dynamic data.


Data Collector / AnalyzersData Collector / Analyzers

Why donWhy don’’t we equip operators with data collector / t we equip operators with data collector / analyzers? Operators could gather rich (FFT/TWF) analyzers? Operators could gather rich (FFT/TWF) data. There are three reasons why we dondata. There are three reasons why we don’’t t (typically) do this.(typically) do this.

It is too expensive. The cost to equip operators with It is too expensive. The cost to equip operators with these tools is prohibitive.these tools is prohibitive.

These devices have limited ability to collect inspection These devices have limited ability to collect inspection data, or have difficult interfaces, so it would be tough to data, or have difficult interfaces, so it would be tough to convince operators to use them to carry out inspections.convince operators to use them to carry out inspections.

The multiThe multi--purpose nature of these devices purpose nature of these devices –– they can be they can be used for data collection, balancing, bump tests etc., make used for data collection, balancing, bump tests etc., make them complex to learn to use, even for simple operations.them complex to learn to use, even for simple operations.


What Would Be A Solution Of Choice? What Would Be A Solution Of Choice?

A solution of choice would be to equip operations A solution of choice would be to equip operations and lubrication staff withand lubrication staff with

a device capable of collecting inspection data (thus a device capable of collecting inspection data (thus fulfilling an operations staff need);fulfilling an operations staff need);

that is relatively easy to use, and rugged enough to that is relatively easy to use, and rugged enough to withstand operators’ mistreatment;withstand operators’ mistreatment;

with the data acquisition capability to collect dynamic with the data acquisition capability to collect dynamic data of sufficient quality for vibration specialists to do a data of sufficient quality for vibration specialists to do a complete “firstcomplete “first--pass” analysis;pass” analysis;

and is priced so that it can be widely deployed.and is priced so that it can be widely deployed.

A solution of this nature would enable broad distribution of theA solution of this nature would enable broad distribution of thecollection of collection of ““balancebalance--ofof--plantplant”” vibration data, while allowing vibration data, while allowing the vibration specialists enough data to effectively carry out the vibration specialists enough data to effectively carry out analysis and focus their efforts on critical/troubled equipment.analysis and focus their efforts on critical/troubled equipment.


Recent developments in the world of digital sensing Recent developments in the world of digital sensing technology may make the technology may make the ““solution of choicesolution of choice””available in the immediate future.available in the immediate future.

There are at least two organizations working on USB There are at least two organizations working on USB (Universal Serial Bus) digital accelerometers.(Universal Serial Bus) digital accelerometers.

Dynamic Digital SensorsDynamic Digital Sensors

Other technologies being investigated/used include Other technologies being investigated/used include Bluetooth,Bluetooth, WiFiWiFi and Wireless USB. and Wireless USB.

Rugged PDA technology has progressed to where there Rugged PDA technology has progressed to where there are numerous brands to choose from for deployment of are numerous brands to choose from for deployment of handheld technology in industry.handheld technology in industry.


The two main development efforts for USB digital The two main development efforts for USB digital accelerometers are quite different from each other.accelerometers are quite different from each other.

MEMS Accelerometer MEMS Accelerometer -- one company has developed a one company has developed a maximum 20maximum 20 kSampleskSamples/sec device using a capacitive /sec device using a capacitive MEMS accelerometer, the first attempt to use this type of MEMS accelerometer, the first attempt to use this type of technology for industrial health monitoring. technology for industrial health monitoring.

USB Digital AccelerometersUSB Digital Accelerometers

ICP Accelerometer ICP Accelerometer –– a second company has developed a a second company has developed a maximum 65maximum 65 kSampleskSamples/sec device using a more /sec device using a more traditional ICP*traditional ICP*--type accelerometer coupled to an internal type accelerometer coupled to an internal A/D converter.A/D converter.

Both systems are powered directly by the USB cable, Both systems are powered directly by the USB cable, with no A/D cards or separate power supply required with no A/D cards or separate power supply required between computer and sensor.between computer and sensor.

*ICP is a registered trademark of PCB Piezotronics, Inc.


The accelerometer built on the more traditional ICPThe accelerometer built on the more traditional ICP™™(charge to voltage) (charge to voltage) piezopiezo circuitry has the following circuitry has the following capabilities.capabilities.

Sensor can be interfaced to any computer with a USB Sensor can be interfaced to any computer with a USB port, including PCs, Macs, Linux and Pocket PCs.port, including PCs, Macs, Linux and Pocket PCs.

USB Digital ICP AccelerometerUSB Digital ICP Accelerometer

Sensor has a builtSensor has a built--in 16in 16--bit A/D bit A/D converter.converter.

Sensor is capable of sampling Sensor is capable of sampling rates ranging from 125 Hz to rates ranging from 125 Hz to 65KHz.65KHz.

Sensor is capable of producing a Sensor is capable of producing a digitized time waveform up to 64 digitized time waveform up to 64 kSampleskSamples in size.in size.


Hermetically sealed Hermetically sealed –– resistant to hot/wet environments.resistant to hot/wet environments.


Communicates to host computer via USB 1.1 or USB 2.0 Communicates to host computer via USB 1.1 or USB 2.0 –– very fast transfer of digital data.very fast transfer of digital data.

Sensor has two builtSensor has two built--in analog band pass filters/rectifiers in analog band pass filters/rectifiers for amplitude demodulation/enveloping of signals.for amplitude demodulation/enveloping of signals.


The vibration sensor allows operators to collect full The vibration sensor allows operators to collect full waveform data with no more operational complexity waveform data with no more operational complexity than using an overall meter.than using an overall meter.


Digitized time waveform data is Digitized time waveform data is retrieved from the sensor. The retrieved from the sensor. The host computer (PDA) is host computer (PDA) is responsible forresponsible for

digital filtering of the signaldigital filtering of the signalgenerating generating FFTsFFTscalculating overallscalculating overallsstoring results to disk / memorystoring results to disk / memory


The vibration sensor allows operators to collect full The vibration sensor allows operators to collect full waveform data with no more operational complexity waveform data with no more operational complexity than using an overall meter.than using an overall meter.

Overall Meter Settings Time Signal FFT



Data collected from the sensor is stored in the PDA. Data collected from the sensor is stored in the PDA. This data is then uploaded to the host computer for This data is then uploaded to the host computer for further analysis.further analysis.



Integrated Bar Code Integrated Bar Code Scanning support.Scanning support.

Pen and Keyboard Entry.Pen and Keyboard Entry.

RFID Tag readers.RFID Tag readers.

InspectCEInspectCE™ PDA firmware processes data from the ™ PDA firmware processes data from the USB accelerometer USB accelerometer -- firmware works on all brands firmware works on all brands of Windows Mobile™ handheld units.of Windows Mobile™ handheld units.

Wireless networking support.Wireless networking support.

AddAdd--on data acquisition tools on data acquisition tools i.e. portable thermometers.i.e. portable thermometers.

Windows Mobile™ Based Inspection SystemWindows Mobile™ Based Inspection System


InspectCEInspectCE™ firmware was primarily designed for ™ firmware was primarily designed for operators and lubrication techs to carry out inspections.operators and lubrication techs to carry out inspections.

TWF Filtering, TWF Integration, FFT/TWF Filtering, TWF Integration, FFT/iFFTiFFT, and a complete , and a complete signal processing library added to signal processing library added to InspectCEInspectCE™ firmware. ™ firmware.

Fortunately, the MAINTelligence™ desktop system was Fortunately, the MAINTelligence™ desktop system was already a capable vibration analysis software.already a capable vibration analysis software.

Operators can still take advantage of automating their PM Operators can still take advantage of automating their PM and TPM inspections, and vibration data can be collected and TPM inspections, and vibration data can be collected during those inspections using identical handheld during those inspections using identical handheld technology.technology.

Time waveform collection and storage capability has been Time waveform collection and storage capability has been added to added to InspectCEInspectCE™ firmware. ™ firmware.



Operator Area Housekeeping Check Sheets.Operator Area Housekeeping Check Sheets.

Scheduled Lubrication Rounds. Scheduled Lubrication Rounds.

Asset Condition Check Routes.Asset Condition Check Routes.

InspectCEInspectCE™ firmware designed to automate ™ firmware designed to automate operations, lubrication and preventive maintenance operations, lubrication and preventive maintenance routes. Typical types of data collected on these routes. Typical types of data collected on these routes include: routes include:

Safety / Health Protection Inspection Routes.Safety / Health Protection Inspection Routes.

Asset Basic Care

Operator Asset Production Check Sheets.Operator Asset Production Check Sheets.


design maintenance systems inc.Login Screen

MAINTelligence uses Windows Mobile™ handheld MAINTelligence uses Windows Mobile™ handheld units to automate the basic care data collection.units to automate the basic care data collection.

User Defined Form

Numeric / text data capture.Numeric / text data capture.




User Defined Form


User Defined Checklist

Single/multi selection pick Single/multi selection pick lists.lists.




User Defined Form




Capture Notes

Notes EntryNotes Entry




User Defined Form




Capture Notes


Data trendingData trending

Trend Graph




User Defined Form




Capture Notes


Data trendingData trending

Trend GraphImage / Sketch

Image DisplayImage Display



ConclusionConclusion

In this presentation, we have looked at some of the In this presentation, we have looked at some of the issues raised by expanding vibration data collection issues raised by expanding vibration data collection beyond the vibration specialist.beyond the vibration specialist.

There are several methods that can be used to expand There are several methods that can be used to expand data collection data collection –– all have merit and should be considered.all have merit and should be considered.

If considering using operations or lubrication staff to If considering using operations or lubrication staff to collect balancecollect balance--ofof--plant, all parties (including vibration plant, all parties (including vibration specialists) must feel that they are gaining (winspecialists) must feel that they are gaining (win--win) win)

Using overall meters (either connected to a PDA or not) Using overall meters (either connected to a PDA or not) have drawbacks to both the operations staff and vibration have drawbacks to both the operations staff and vibration specialists.specialists.

New technology (addNew technology (add--on digital accelerometers) resolve on digital accelerometers) resolve some of those drawbacks.some of those drawbacks.

Documents

New Sensor Technology for Broad Distribution of … Sensor Technology for Broad Distribution of Vibration Data ... piezo circuitry has the following ... The vibration sensor allows