Machine Condition Monitoring Systems

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

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

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

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

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

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

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

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, www.pcb.com

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

Demo: Accelerometer Measurement Demo 2

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

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

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

Dynamic Pressure Uses Compressor Gas Turbine Characteristics High Speed Pressure Pulsations at Machine Speed Piezoelectric types are best for higher frequency pulsations www.pcb.com www.kistler.com Piezoelectric Pressure Transducer Capacitance Pressure Transducer

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. www.lem.com

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

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

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

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; 18-30 V DC

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

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

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

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

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 102.4 ks/sec F Nyquist 150 ks/sec 0 10000 20000 30000 40000 50000 60000 70000 80000 Frequency (Hz)

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

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

Typical Spectrum Showing Basic Faults Velocity (ips) 0.0001 0.001 0.01 unbalance misalignment bearing frequencies gear mesh frequencies 100 1000 10000 100000 Frequency (Hz) Courtesy of

Demo Frequency Analysis

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

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

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

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

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

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

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

Demo Order Analysis

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

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

Demo: Order Analysis

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

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

The Monitoring Process Data Acquisition Data Analysis Diagnose & Actions

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

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

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

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

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

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

Sound and Vibration Case Studies and Architectures

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

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.

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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.

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

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

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

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

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.

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

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

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 9203 4-20ma Process Serial Port Modbus Speed and Vibration Buffered Output

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

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

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

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

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

Single-Board RIO Products (Q3 2008 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

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

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

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

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

Data Navigation and Reporting

Questions and Discussion