Machine Condition Monitoring Systems

Transcription

1 Machine Condition Monitoring Systems Targeting Industrial Applications Chris Fronda Product Manager Sound & Vibration

2 Agenda Sensors Sound and Vibration Signal Conditioning & A/Ds Analysis & Signal Processing Systems: Architecture & Case Studies Summary

3 Sound and Vibration Measurement System Components Sensors Input Signals Data Acquisition Analysis V Output Signals V Signal Conditioning A/D

4 Sound and Vibration Measurement System Components Sensors Input Signals Data Acquisition Analysis V Output Signals V Signal Conditioning A/D

5 Transducers used in Machine Condition Monitoring Applications Sensor Accelerometer Microphone Proximity Probe Tachometer Physical Phenomena Acceleration Sound Pressure Displacement Rotating Speed

6 Accelerometers Measure Acceleration Velocity and displacement (via integration versus time) Result is expressed units of gor m/s 2 1 g = acceleration at the surface of Earth 1 g = 9.81 m/s 2 Single axis or triaxial configurations Calibration is performed with a vibration shaker

7 IEPE Accelerometers Advantages Simple and easy to use Built-in microelectronics Simple constant current signal conditioner (18-30 VDC ; 2 ma) Limitations Temperature range: max 250 F (some 325 F) Fixed sensitivity Direct Connection

8 Charge Mode Accelerometers Advantages Temperature up to 1000 F Variable sensitivity Limitations External conditioning required Need low-noise cabling Sensitive to environmental influences External Conditioning Drawing credit PCB,

9 Transducers: Accelerometer Accel Y Accelero meter Bearing Mount Bearing Accelerometer Accel X Accelerometers Measure Acceleration Velocity and displacement (via integration versus time)

10 Demo: Accelerometer Measurement Demo 2

11 Displacement and Velocity Probes Non-contact displacement probes High-frequency oscillator generating eddy currents whose energy is a function of displacement Used when low level of acceleration is generated (for example, turbomachines) Velocity transducers Moving coil in permanent magnetic field Replaced by accelerometers, offering the same functionality through a wider frequency range

12 Transducers: Proximity Probes Measure: Distance or displacement Output:An AC signal proportional to the distance from the tip of the probe to a metallic surface Excitation:-15 to -24 V power source The AC signal is transmitted on this DC offset

13 Transducers: Tachometers Uses a wheel with N teeth (N pulses/rev) Or a notch in shaft (1 pulse/rev) Measure Angular position Angular speed (rpm) Used for Order analysis Order tracking Angular averaging Sensor Types Slow rpm Proximity Probe, Magnetic Sensor, Optical / Laser Diode time Fast

14 Dynamic Pressure Uses Compressor Gas Turbine Characteristics High Speed Pressure Pulsations at Machine Speed Piezoelectric types are best for higher frequency pulsations Piezoelectric Pressure Transducer Capacitance Pressure Transducer

15 Current Transducer Used in electric motor machinery applications Motor condition Rotor bar and winding faults The magnetic flux created by the primary current IP is balanced by a complementary flux produced by driving a current through the secondary windings. A hall device and associated electronic circuit are used to generate the secondary (compensating) current that is an exact representation of the primary current.

16 Temperature and Process RTDs Thermocouples Infrared Sensors (non-contact) 4-20ma process variables Voltage outputs from process sensors Standard NI Thermocouple / RTD / voltage / 0-20 ma input modules C series, cfp, Industrial DAQ boards

17 Sound and Vibration Measurement System Components Sensors Input Signals Data Acquisition Analysis V Output Signals V Signal Conditioning A/D

18 Why Use Signal Conditioning? Signal Conditioning Noisy, Low-Level Signal Filtered, Amplified Signal Improve signals for better measurement quality Power or excite sensors Read sensor information TEDS

19 Accelerometer Signal Conditioning Powering Piezoelectric Sensors 27 VDC 24 VDC 21 VDC AC Signal (Acceleration) DC Offset due to IEPE 0 VDC IEPE (Integrated Electronic Piezoelectric): Accelerometer power for internal amplifier at 2-20 ma constant current; V DC

20 Signal Conditioning AC / DC DC and AC Coupling AC Coupling = AC DC Coupling = AC+DC IEPE = Integrated Circuit Piezoelectric built-in charge amplifier or voltage amplifier 5 volts 0 volts DC Coupling = AC+DC AC AC Coupling = NO DC DC

21 Demo: 16-bit vs. 24-bit ADCs 16 bits 24 bits 12 bits Demo 3

22 Effect of ADC Resolution High resolution ADCs allow you to detect both strong and weak signal components at the same time. 24-bit 16-bit Measurement 90 db Detect Low-Level Signals 140 db

23 Aliasing Shannon sampling theorem The maximum frequency (Nyquist frequency: f N ) that can be analyzed is given by f N = f s /2 f s : sampling frequency Improperly sampled Properly sampled

24 Anti-Aliasing Filter in ADCs Removes frequency components higher than Nyquist frequency Needs to be performed before signal is digitized Mix of Analog and DSA Digital Filter vs. 8th Order Analog Bessel Digital filters 20 Bessel, Fc=15 khz Bessel, Fc=22.5 khz Characteristics of 0 Bessel, Fc=30kHz good filters: Flat in-band -40 frequency response -60 Good high frequency -80 alias rejection -100 Fast roll-off in the -120 transition band -140 Filter Response(dB) -20 Analog Bessel Filter attenuates signals in band of interest Signal Bandwidth DSA Digital Filter F Nyquist NI 4472 at ks/sec F Nyquist 150 ks/sec Frequency (Hz)

25 Sound and Vibration Measurement System Components Sensors Input Signals Data Acquisition Analysis V Output Signals V Signal Conditioning A/D

26 Frequency Analysis The Fast Fourier Transform (FFT) converts the time-domain signal into the frequency domain FFT Time-Domain Signal Spectrum

27 Typical Spectrum Showing Basic Faults Velocity (ips) unbalance misalignment bearing frequencies gear mesh frequencies Frequency (Hz) Courtesy of

28 Demo Frequency Analysis

29 What is Order Analysis? Many noise and vibration signal components are directly related to running speed: Imbalance, misalignment, gear mesh, bearing defects, loose coupling Order analysis normalizes the measurements to the rotating speed to better dissect these signal components

30 Using Order Analysis on Machinery Hz 3,300 RPM = 55 RPS 55

31 Relationship of Orders and Faults We can diagnose machine faults by knowing the order: Imbalance Misalignment Loose Coupling Valve Noise Bearing Defects / Wear Blade Pass Frequency Gear Mesh Low Order High Order

32 Understanding Order Analysis Time Domain sec FFT Frequency Domain Hz Resampling Angular Domain deg FFT Order Domain order

33 Resampling for Changing Machine Speed Data is converted to angular domain from time domain with the use of a tachometer (speed) signal Machine speed is increasing

34 Power Spectrum Rotating Speed: 60 Hz (3600 RPM) Rotating Speed: 50 Hz (3000 RPM) Frequency components shift with speed change

35 Order Spectrum Rotating Speed: 60 Hz (3600 RPM) Rotating Speed: 50 Hz (3000 RPM) Order components remain fixed with speed change

36 Demo Order Analysis

37 Shaft Measurement Plots Plots include: Orbit Plot Timebase Plot Shaft Centerline Plot Measured by two orthogonally placed, DC coupled proximity probes. Need to use 10dB attenuation cable with 447x rtical Clearance Ver CCW Rotation

38 Shaft Centerline Plot Compute gap reference first Bearing clearance start point Bottom Center Top

39 Demo: Order Analysis

40 Putting it all together Sensors Input Signals Data Acquisition Analysis V Output Signals V Signal Conditioning A/D Architectures Case Studies

41 What is Machine Monitoring? Predict maintenance requirements and protect machines Collecting machine electrical and mechanical signatures to analyze maintenance requirements in a predictive nature Machine and Process Performance Collecting process information to provide insight to process optimization opportunities Other names Machine Condition Monitoring (MCM), Vibration Monitoring Machine Test A $300 to $500 million dollar market

42 The Monitoring Process Data Acquisition Data Analysis Diagnose & Actions

43 MCM is Increasing Availability Machine Health Preventative Maintenance Predictive Maintenance Acceptable Operating Zone Run to-failure Time

44 Lead Time of Options Vibrations Machine condition Conditions start to change Noise Heat Smoke Emergency stop 10 min Time 3 month 2 weeks 2 days

45 Vibration Sources Loose Mechanical Mechanical Looseness Components Slot Frequency / EM related Bent Shaft Alignment Gears Unbalance Blade Pass / Fluid Related Sam Shearman National Instruments Motor Mechanical Resonances Couplings Journal (Fluid Film) Bearings Rolling Element Bearings

46 Bearings are Used Everywhere Vibration monitoring and test of bearings Reduce maintenance costs Avoid unplanned machinery shutdown Increase plant Availability Mining Equipment Steel and Paper Rolling Equipment Pumps and Compressors in Chemical Railway and Automotive Power Generation such as wind

47 Motivation of Condition Monitoring Bearing with problems Bearing with problems not detected

48 Signal Conditioning Accelerometer Accel Y Accelero meter Bearing Mount Accelerometer Accel X Bearing

49 Sound and Vibration Case Studies and Architectures

50 Compact/Portable Architectures Small and Lightweight 25 x 9 x 6 cm < 1 kg Easy to Setup USB plug-and-play Built-in IEPE power for microphone and accelerometers Conveniently Powered USB bus powered or DC-powered for in-vehicle use Full Featured Measurement 24-bit simultaneous ADCs 102 db dynamic range 50 ks/s/ch sample rate Anti-aliasing filters

51 Eaton Driveline Vibration Analyzer Challenge:Low Cost, Easy to use, Automatic data analysis NI Tools Used:USB DAQ, LabVIEW, S&V, OAT Results:Successful implementation in a flexible environment allowing specific truck driveline vibration analysis.

52 Das Bildelement mit der Beziehungs-ID rid7 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid11 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid9 wurde in der Datei nicht gefunden. vibdaq Solution 20 Lbs. Virtual Instruments PC based solution Run-Up Cascade Plot Waterfall Plot Polar Plot Orbit Plot Tabular List

53 Das Bildelement mit der Beziehungs-ID rid4 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid5 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid3 wurde in der Datei nicht gefunden. Hydro Generator Diagnostic Dynamic analysis of rotating machine Behavior monitoring Fault identification Root cause association based on computational intelligence Maintenance Web based Portal

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55 Das Bildelement mit der Beziehungs-ID rid3 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid5 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid4 wurde in der Datei nicht gefunden. Nexjen Reactor Pump Vibration Monitor Challenge Provide a combined system for 32 vibration channels in four machinery locations NI Tools PXI-DSA, LabVIEW, S&V Measurement Suite Results Real-Time Monitoring Historical Data Transient Data Alarming Expands to Process Variables

56 Das Bildelement mit der Beziehungs-ID rid4 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid3 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid5 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid6 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid7 wurde in der Datei nicht gefunden. Instituto de Investigations Electricas SICAD for PEMEX and CFE Challenge: Develop a cost effective and advanced machine monitoring and diagnostic tool for Oil Platforms and Power Generation Flexible, Cost Effective, Advanced Process and Vibration Monitoring NI Tools PXI, DSA, Counter Timer LabVIEW, S&V, OAT, RT Results 12 systems deployed Pemex asking for more Adapted for portable solution

57 Das Bildelement mit der Beziehungs-ID rid4 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid6 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid3 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid5 wurde in der Datei nicht gefunden. Control/Monitoring Architectures On-board Data Processing 400 MHz PowerPC Processor 2 GB internal memory (external USB hard-drive support) Easy Data Sharing Standard Ethernet connectivity Built-in web browser Harsh Environment-Ready Certified: Class I, Div 2; ATEX -40 to 70 C temperature range 50 g shock rating Full Featured Measurements 24-bit simultaneous ADCs 102 db dynamic range 50 ks/s/ch sample rate Anti-aliasing filters

58 Das Bildelement mit der Beziehungs-ID rid7 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid10 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid5 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid4 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid3 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid6 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid8 wurde in der Datei nicht gefunden. Das Bildelement mit der Beziehungs-ID rid9 wurde in der Datei nicht gefunden. Hydro Plant: Overall architecture Signal Conditioning Dynamic Measurements Signal Processing n Process Variables Static Measurements SCADA - Process Monitoring and Local Operation (Data Management ) SCADA - Enterprise Network

59 Condition Monitoring in Open-Pit Mining Electromechanical Shovels CompactRIO measures vibration and compares to alarm limits Analysis software is fully built in LabVIEW. Mining electromechanical shovels can load 100 ton of ore per pass. Combined rated power is about 3MW. Hardware must survive in a harsh environment.

60 NI CompactRIO and PXI for Turbine Speed Controller Simulation and Testing Application: Upgrade the existing turbine speed controller test equipment and software. Challenge:Design a portable system that could simulate the external components, the state of the turbines, the state of the power grid, and the power demand. Products: PXI, CompactRIO, and LabVIEW Key Benefit:Replaced more than 50,000 lines of C++ code with LabVIEWcode, which gave users a more realistic view of the industrial process. Improving the software by using the National Instruments LabVIEW graphical interface and upgrading the hardware to an easy-to-transport single device, which enabled instant visualization, greatly reduced development and installation time. NI CompactRIO and PXI for Turbine Speed Controller Simulation and Testing in Power Plants

61 NI CompactRIO Reconfigurable Embedded System Real-Time Processor Reconfigurable (RIO) FPGA I/O I/O I/O I/O Real-Time Controller I/O I/O I/O I/O I/O Modules DC power with redundant supply inputs 50 G shock -40 to 70 C temperature Connectivity Signal Conditioning ADC

62 NI CompactRIO Embedded System Architecture Real-Time Processor Reconfigurable FPGA Real-Time Controller I/O I/O I/O I/O I/O I/O I/O I/O Industrial I/O Modules Connectivity Signal Conditioning Industrial I/O Modules with built-in signal conditioning for direct connection to industrial sensors/actuators Reconfigurable FPGA for high-speed and custom I/O timing, triggering, processing, control Real-Time Processor for deterministic, stand-alone operation and advanced analysis New! Integrated Controller/Chassis ideal for high-volume applications ADC

63 LabVIEW Programming & CompactRIO User Interface Real-Time Processor Reconfigurable FPGA LabVIEW LabVIEW Real-Time LabVIEW FPGA

64 Field Programmable Gate Array (FPGA) PROGRAMMABLE INTERCONNECT I/O BLOCK Source: Xilinx CONFIGURABLE LOGIC BLOCK (CLB) Field Programmable Gate Array (FPGA) devices feature a reconfigurable digital circuit architecture with a matrix of Configurable Logic Blocks (CLBs) surrounded by a periphery of I/O Blocks. Signals can be routed within the FPGA matrix in any arbitrary manner by Programmable Interconnect switches and wire routes.

65 Machine Monitor and Protection Architecture Accelerometers, Proximity Probes, Tach DUT Temperature & Process Variables Analog Inputs Machine Monitoring System Processing - Vib Level (rms, peak) - Order Tracking (1x, 2x, etc) - Relay Logic & Alarms Buffered Analog Outputs 4-20 ma Outputs for level Relays BNC Connect for Diagnostics To control/dcs system For machine shutdown

66 NI CompactRIO Reconfigurable Embedded System Product Roadmaps C Series I/O Modules Real-Time Controllers RIO Backplanes Real-Time Controller LabVIEW RT CompactRIO Block Diagram Reconfigurable RIO Chassis LabVIEW FPGA Ethernet RS-232 I/O Module I/O Module I/O Module I/O Module I/O Module I/O Module I/O Module I/O Module Connectivity Signal Conditioning ADC

67 Ethernet CompactRIO Block Diagram Ethernet Real-Time Controller Reconfigurable RIO Chassis LabVIEW FPGA Command Based Arch Shared Variable Order Analysis Frequency Analysis Customer Specific Analysis Measurements DMA Speed Vibration RMS Vibration DC Temperature Process 9211 / 9217 Temperature 9234 Accelerometer 9229 Proximity Probe 9221 Tachometer 9263 Buffered Output 9263 Buffered Output 9263 Buffered Output ma Process Serial Port Modbus Speed and Vibration Buffered Output

68 Bearing Monitoring Custom analysis algorithm on FPGA Real-Time System for managing analysis and communication Host application For Control & asset management Digital Demodulation online 20KHz 20kHz / 50kS/s FPGA 20kHz / 50kS/s 20 Hz / 50 S/s f = 0,0122 Hz Sensor A D Z -n +90 x x + 20Hz 4k Samples FFT

69 Control/Monitoring Case Studies FIS: Bearing Monitoring On-board analysis: Digital demodulation Custom filtering High-speed signal acquisition at 50 ks/s simplified to easy-to-manage slow-speed data

70 Remote Service ISDNphone Satellite FIS Diagnosis-Center Mobile phone Internet Customer benefit: Automatic monitoring and early warning Recommendation for action by a trained analyst

71 Das Bildelement mit der Beziehungs-ID rid5 wurde in der Datei nicht gefunden. NI as a Machine Monitoring Supplier Sound and Vibration is a strategic business segment Specific hardware and software products Leveraging over 15 years in Sound and Vibration applications Leveraging over 20 years in instrumentation control software Leveraging over 30 years in computer based instrumentation Domain expertise employees and partners Run-Up Polar Plot Orbit Plot Tabular List Cascade Plot Waterfall Plot

72 The NI RIO Deployment Curve I/O I/O System Flexibility and Price PXI RIO PCI RIO CompactRIO Modular Processor CompactRIO Integrated FPGA Single-Board RIO I/O Custom I/O LabVIEW Number of Systems Deployed

73 Single-Board RIO Products (Q Launch) Embedded device and machine I/O, processing and control FPGA customization and performance Integrated RT Processor, FPGA and I/O Processor FPGA I/O I/O I/O Custom I/O Lowest cost RIO product for high volume machines and devices

74 Shipping FPGA Signal Processing IP Butterworth Filter DC and RMS Measurement Analog Period Measurement Tachometer Processing Notch Filter Additional Functionality Sine-Cosine Look-up Table Linear Interpolation Cascaded Integrator Comb Filter Single-rate MAC FIR Filter Single-rate MAC IIR Filter Multirate MAC FIR Filter Arbitrary Resampling Filter Discrete PID Express VIs make set up easy Shorten prototype development Use the FPGA as a high-performance DSP

75 Digital Filter Design Toolkit for CompactRIO Generate Graphical Code Interactively Design Filter Generate FPGA Code Target Generate C Code

76 Fixed Point Math Library for FPGA Core Math Functions Trigonometric functions Exponential functions

77 Das Bildelement mit der Beziehungs-ID rid5 wurde in der Datei nicht gefunden. Analysis Software: Order Tracking Order Analysis User-defined magnitude and phase 1x, 2x, 3x, 20x, etc. Subsynchronousorder tracking 0.3x, 0.67x, etc. Analog and digital tachometer processing Order-based spectrum analysis Waterfall, Cascade, Colormap, Bode, Orbit, Polar Shaft Centerline Plots

78 Data Navigation and Reporting

79 Questions and Discussion