MCM & MCMSoC. Concept & Practice. The MCM & MCMSoC

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1 The MCM & MCMSoC MCM & MCMSoC Concept & Practice A new technology to be an industry standard for condition monitoring of motor based systems and beyond

2 Artesis Products MCM Motor Condition Monitor MQM Motor Quality Monitor MCMSoC Predictive Fault Sensor

3 The Artesis Company Arcelik Arcelik Koc KocGroup Largest firm in Turkey and the flagship company of the Koc Group Major European manufacturer of domestic appliances Provides research facilities within its R&D department Artesis Artesis A subsidiary of Arçelik R&D oriented company, develops fault detection and early failure prediction technologies for electric motors and motor driven systems. Largest group in Turkey. In Fortune Top-500 Companie with: - Automotive and automotive components - Consumer durables and goods - Energy - Construction and mining - Tourism and services - Finance

4 MCMSoC (MCM System On a Card) MCM (Motor Condition Monitor) is one of Artesis award-winning products, 40 Best products of 2000, Control Engineering Magazine, USA. MCMSoC (a predictive fault sensor) provides embedded condition monitoring solutions to assure early warning of faults and prevent unexpected breakdowns in OEM (Original Equipment Manufacturer) products and systems.

5 MCMSoC (Predictive Fault Sensor) What is MCMSoC (predictive fault sensor)? MCMSoc is a coprocessor/add-on unit for mounting in the control/monitoring system of an OEM product MCMSoC is customized to the requirements of each user MCMSoC is intended for volume applications and as such will have considerable cost advantages MCM is used for preventative maintenance by end users MCMSoC is for OEM producers interested in applying condition monitoring to their own equipment

6 MCM: Key Advantages Benefits of MCM and MCMSoC Increases Efficiency Reduces Expenses Increases Plant Value Increases productivity and decreases the cost of repair by early warning of pending breakdowns. Decreases the cost of energy and production losses by process optimization. Increases the efficiency and quality of production by remote monitoring machines and related equipment. Increases the life of machine and related equipment and the plant value by finding out the root causes of failure. Increases the effectiveness of maintenance staff.

7 Technology & Patent Previous applications include the space shuttle main engine, helicopter and jet engines (research funded by NASA, U.S. Army, Pratt and Whitney, and the State of Florida) Proprietary technology, US, EU, TC and other patents are owned by Artesis Patent Numbers: US TR1998/02541B

8 Principles of Model BasedB Fault Detection (1) Machine Profile Change in Profile Fault Warning Diagnosis u System (realized) Model Model Θ (estimated) y s y m Σ Σ e = y s -y m MCM determines the model and profile (parameters) of electr motor-based systems under normal operating conditions. These parameters are then used to estimate the system outp If the system outputs do not fit with the estimated values, then gives warning. The faults are identified by examining the differences in the system profile.

9 Principles of Model BasedB Fault Detection (2) MCM must handle conditions of variable input voltage, frequency and load, represented here as a surface in a multi-dimensional space. MCM learns the shape of this surface prior to starting system monitoring properly and finds the model parameter values at each point on a grid over the surface. During monitoring MCM will update this information if it finds a new position on the surface. Fault severity is determined by the difference between the measured parameters and those previously learned.

10 How MCM Finds Mechanical Faults by Using Only Currents and Voltages The relationship between input voltage and output current (characterised by the parameters) is very sensitive to air gap variations Any influence that causes the air gap to change can, (in principle) be detected by the effect it has on the parameters

11 MCM (Motor Condition Monitor) MCM monitors electric-motor based machines continuously measuring currents and voltages only. The measurements and results are stored in a database on a remote PC for remote monitoring and trend analysis. Early Fault Detection Diagnostics Energy Quality and Consumption Effectiveness of Maintenance Equipment Availability STOP PERFORM MAINTENANCE WATCH LOAD WATCH LINE OK MCM can be installed on motor control panels. MCM is easy to install

12 Benefits of MCM and MCMSoC In a Nutshell In a single, cost-effective unit that is simple to install and run, MCM / MCMSoC can provide: - Continuous and automatic monitoring of electrical and mechanical fault conditions with operator action required only as a fault develops - Maintenance scheduling by monitoring the severity of a fault as indicated by the rate of deterioration - Energy monitoring and harmonic analysis MCM / MCMSoC can be extended to other applications such as power transformers, rotating systems, gas turbines, wind turbines, generators, etc.

13 MCMSoC Integrated Intelligent Products

14 Detective Multimeter The firts integration of MCMSoC The Motor Condition Monitor (MCM) technology, which is being developed, manufactured and marketed by Artesis Techonology Systems, is integrated with a microprocessor based panel multimeter as a result of the collaboration between Inter Electric-Electronic and Artesis. This new product, called Dedective Multimeter is based on a new, state-of-the-art technology and it will lead other next generation products.

15 Applications of MCM Technology MCM is being used to monitor: Pumping systems (circulation, lubrication, hydraulic, filtration, fuel, water, gas etc) Compressors (refrigeration, gas,nitrogen and air etc.) Control panel of Compressors, Fans, Pums, Gear Boxes, Presses.. Industrial Machines: Paper, Textile, Glass, Plastic... Industrial Equipment :Powermeters, Multimeters, Digital Voltmeters, Invertors, Electronic Over Current Relays, Electronic Motor Protection Relays, Softstarters, Meetering & Monitoring Equipment, Air Circuit Breakers, Molded Case Circuit Breakers, Contactors, Energy Analyzers, etc. Medium & High Voltage applications: Motor Protection Relays- Softarters, Industrial Motors, Monitoring Equipment, etc.

16 MCMSoC (Predictive Fault Sensor) MCM is used for preventative maintenance by end users. For OEM producers interested in applying condition monitoring to their own equipment, MCMSoC should be considered MCMSoC is a coprocessor/add-on unit for mounting in the control/monitoring system of an OEM product MCMSoC is customized to the requirements of each user MCMSoC is intended for volume applications and as such will have considerable cost advantages

17 MCMSoC Concept Serial Command/Data interface Power 3.3, 5VDC Reset Host processor MCMSoC 16 bit configurable port + handshaking Conditioned voltage and current signals

18 MCMSoC Component Placement View from top View from below

19 MCM Hardware Flash RAM DRAM Timers µc ADC Sensor Inputs Serial Interface Keypad Interface LCD Interface

20 MCM Networking MCM MCM DCOM LAN GUI DCOM SRL COMM MCM MCM MCM MCM DBASE MCM MCM LAN Server Inet User User User User User User GUI GUI GUI Modem Client Node MCM MCM MCM MCM

21 MCMSoC Specifications Number of pins Approximate dimensions Input voltage supply Power consumption On board clock frequency Reset signal Serial communication ports Parallel port 40 5x4 cm 5VDC, 3.3VDC 500mW max 33MHz Active low pulse of width > 1ms Asynchronous: max 153 kbaud Port 1: Tx, Rx, CLK, R/T Port 2: Tx, Rx, CLK + 2 mode pins Communications: 16 bits + 4 handshaking lines Other: Individually configurable as 20 I/O lines

22 Summary of Field Results Faults detected by MCM in the field: Isolation problems of stator windings, worn/damaged bearings, damaged couplings, broken oil seals, clogged pump filters, loose bearing housings, excessive line harmonics, incorrect servicing, load imbalance, shaft problem, contactor capacitor problems, misalignment, rotor-stator problems, leakages, valve and vane misadjustment and variety of other mechanical problems from motor and motor driven equipment. MCM can detect developing faults in both the motor and the driven system (fans, pumps, compressors, gear boxes, presses, conveyors, radars, etc.) Typical warning period is between days

23 Summary In a single, cost-effective unit that is simple to install and run, MCM / MCMSoC can provide: Continuous and automatic monitoring of electrical and mechanical fault conditions with operator action required only as a fault develops Maintenance scheduling by monitoring the severity of a fault as indicated by the rate of deterioration Energy monitoring and harmonic analysis MCM / MCMSoC can be extended to other applications such as power and distribution transformers, rotating systems, gas turbines, generators, wind turbines etc.