Your machinery is on the line
1 Jun 2008
Remote Condition Monitoring (RCM) is becoming of increasing interest to a diverse cross- section of industries. However, rather like the dot.com boom/bust of the nineties, when wireless technology was first available, the initial growth predictions were vastly over-optimistic.
Underlying demand for such technology remains strong, however. Market analysis firm Venture Development Corp forecasts worldwide shipments of wireless (RF/microwave) products for industrial monitoring and control applications, alone, will increase nearly 20% per year from $629.1 million in 2007 to reach $1,504.3 million in 2012.
RCM encompasses three major technology areas, starting with fixed wire, such as ADSL and optical fibre, where access to the Internet via a fixed cable connection enables data to be transferred. This is most commonly used for high volumes of data.
Secondly, there is wireless, which includes GPRS/3G, based on cell phone technology. This is most suited to relatively low data traffic volumes (up to 5MB per device per month), where there is no fixed line capability, and where the distances for transmission exceed 1km.
Another wireless option, and the third RCM option, is radio transmission. This has the advantage of no data transmission charges, but is limited from 50m to over 1km, depending on equipment, line of sight conditions, etc.
Whilst there are many companies offering data SIM cards, the majority have dynamic IP addresses, according to Ross Kennedy, managing director of QHi Group Ltd of Harpenden, Herts.
"These are the type of cards commonly used to provide wireless internet access for laptops, where the IP address is allocated on connection," explains Kennedy. "But for monitoring assets, a static IP address is normally essential in order to provide continuous communication; the static IP address refers to the address only, what is being monitored can move anywhere."
Theses technologies enable RCM to be used in conjunction with wireless telemetry and machine-to-machine communication (M2M). Packages can also provide a virtual PLC with binary inputs/outputs, analogue inputs, I/O logic, internal data loggers, alarms, an integrated GPRS/GSM modem, and SIM card, all in a DIN rail-mountable case.
According to Kennedy, RCM devices are now being programmed to carry out I/O logic tasks, and can receive instructions. For example, in the event of alarm on a main pump, an instruction can be sent to switch it off and switch on an auxiliary pump.
Manufacturers are also applying GPRS/3G connection technology to communicate with capital plant or equipment so it can now send and receive data. This enables "always on" connection, as opposed to dial-up modems, and means there are no distance, weather, or terrain limitations.
Likewise, Lisa Wilkinson of t-mac Technologies Ltd highlights how the newer ranges of monitoring devices give users a clearer picture of the condition of machinery by logging data on a number of variables, from vibration levels to energy consumption. Users can then spot any inefficiencies, rectify problems, minimise waste and ensure equipment is working at its maximum efficiency and capacity.
There is, she added, growing demand for devices that monitor multiple pieces of equipment or sites from a single portal, 24 hours a day, seven days a week.
"These devices can also send SMS or email alerts to a user when pre-set conditions are altered, enabling them to act quickly to rectify problems either manually on-site or remotely via a dedicated web portal, accessible from any internet-enabled PC," said Wilkinson.
The enhanced capabilities of RCM technology can help manufacturing or maintenance managers to justify any expenditure on condition monitoring to their finance directors or MDs, notes Kate Hartigan, managing director of bearings manufacturer Schaeffler (UK) Ltd.
Hartigan cited how the company installed an online condition monitoring system to monitor 128 vibration sensors on rolls in the wet and dryer sections of a paper manufacturing plant. Additional signals such as speed are provided via an OPC server to further monitor the machine.
Alarms are sent to maintenance via an alarm log. When new alarms are triggered, reports are sent to the central control station via a second data acquisition card; these reports are also displayed to the paper makers.
After installing the on-line system, a sensor at one of the large roll bearings triggered an alarm that there was outer ring damage. The early detection and replacement meant the customer saved at least Euro230,000: 18 hours x €10,000 per hour = €180,000 production loss + €50,000 roll neck damage.
Underlying demand for such technology remains strong, however. Market analysis firm Venture Development Corp forecasts worldwide shipments of wireless (RF/microwave) products for industrial monitoring and control applications, alone, will increase nearly 20% per year from $629.1 million in 2007 to reach $1,504.3 million in 2012.
RCM encompasses three major technology areas, starting with fixed wire, such as ADSL and optical fibre, where access to the Internet via a fixed cable connection enables data to be transferred. This is most commonly used for high volumes of data.
Secondly, there is wireless, which includes GPRS/3G, based on cell phone technology. This is most suited to relatively low data traffic volumes (up to 5MB per device per month), where there is no fixed line capability, and where the distances for transmission exceed 1km.
Another wireless option, and the third RCM option, is radio transmission. This has the advantage of no data transmission charges, but is limited from 50m to over 1km, depending on equipment, line of sight conditions, etc.
Whilst there are many companies offering data SIM cards, the majority have dynamic IP addresses, according to Ross Kennedy, managing director of QHi Group Ltd of Harpenden, Herts.
"These are the type of cards commonly used to provide wireless internet access for laptops, where the IP address is allocated on connection," explains Kennedy. "But for monitoring assets, a static IP address is normally essential in order to provide continuous communication; the static IP address refers to the address only, what is being monitored can move anywhere."
Theses technologies enable RCM to be used in conjunction with wireless telemetry and machine-to-machine communication (M2M). Packages can also provide a virtual PLC with binary inputs/outputs, analogue inputs, I/O logic, internal data loggers, alarms, an integrated GPRS/GSM modem, and SIM card, all in a DIN rail-mountable case.
According to Kennedy, RCM devices are now being programmed to carry out I/O logic tasks, and can receive instructions. For example, in the event of alarm on a main pump, an instruction can be sent to switch it off and switch on an auxiliary pump.
Manufacturers are also applying GPRS/3G connection technology to communicate with capital plant or equipment so it can now send and receive data. This enables "always on" connection, as opposed to dial-up modems, and means there are no distance, weather, or terrain limitations.
Likewise, Lisa Wilkinson of t-mac Technologies Ltd highlights how the newer ranges of monitoring devices give users a clearer picture of the condition of machinery by logging data on a number of variables, from vibration levels to energy consumption. Users can then spot any inefficiencies, rectify problems, minimise waste and ensure equipment is working at its maximum efficiency and capacity.
There is, she added, growing demand for devices that monitor multiple pieces of equipment or sites from a single portal, 24 hours a day, seven days a week.
"These devices can also send SMS or email alerts to a user when pre-set conditions are altered, enabling them to act quickly to rectify problems either manually on-site or remotely via a dedicated web portal, accessible from any internet-enabled PC," said Wilkinson.
The enhanced capabilities of RCM technology can help manufacturing or maintenance managers to justify any expenditure on condition monitoring to their finance directors or MDs, notes Kate Hartigan, managing director of bearings manufacturer Schaeffler (UK) Ltd.
Hartigan cited how the company installed an online condition monitoring system to monitor 128 vibration sensors on rolls in the wet and dryer sections of a paper manufacturing plant. Additional signals such as speed are provided via an OPC server to further monitor the machine.
Alarms are sent to maintenance via an alarm log. When new alarms are triggered, reports are sent to the central control station via a second data acquisition card; these reports are also displayed to the paper makers.
After installing the on-line system, a sensor at one of the large roll bearings triggered an alarm that there was outer ring damage. The early detection and replacement meant the customer saved at least Euro230,000: 18 hours x €10,000 per hour = €180,000 production loss + €50,000 roll neck damage.
