Condition Monitoring
Solutions that Deliver
Actionable Insights
1
©2020 Analog Devices, Inc. All rights reserved.
Industrial CbM
Enabling asset monitoring solutions that deliver actionable insights
2
©2020 Analog Devices, Inc. All rights reserved.
What Is CbM And
Why Is It
Important?
3
Extends Equipment Lifetime Through Advanced
Vibration Sensing
4
©2020 Analog Devices, Inc. All rights reserved.
Definitions: What do we mean when we say…
CbM – Condition
based Monitoring
5
PdM – Predictive
Maintenance
CbM / PdM
Unplanned downtime costs industrial
manufacturers an estimated $50B annually
6
Why is CbM Important?
Safety
< Catastrophic
Failures
Asset
Longevity
> Lifetime
7
Predictive
Maintenance
<Downtime
Quality
Control
> Product
Quality
End-to-End Solutions for CbM
8
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Example of a
motor fault bearing
issue
9
Bearings Play a Vital Role in a Wide Variety of Industrial
Machines & Equipment
% Occurances of Motor Faults
10%
41%
>90% of rotating machinery in
Industrial & Commercial
applications use rolling-element
bearings*
* Graney, Starry, “Rolling Element Bearing Analysis”
27%
12%
Rotor Related Fault
Other Stator Faults
Bearing Fault
10%
Stator Insulation Faults
Other Faults
P. Konar, “Bearing Fault Detection of Induction Motor using Wavelet and Neural
Networks.,” in Proceedings of the 4th Indian International Conference on Artificial
Intelligence, IICAI 2009, Tumkur, Karnataka, India, , Karnataka, 2009.
10
Detecting Emerging Faults in Bearings
Lowest Fault Freq
Highest Magnitude
Bearing
Fault
FFT
CbM MEMS
Accelerometer
Performance
High
Medium
Vibration (g)
Low
Medium Fault Freq
Medium Magnitude
1kHz
5kHz
Frequency
11
Highest Fault Freq
Lowest Magnitude
10kHz
Degree of Difficulty in Detecting Bearing Faults as
a Function of Machine Class
Class of Machine
Degree of Difficulty for
Bearing Fault Detection
Machine Type
CbM MEMS
Sensor
Performance
Low
Medium
Easiest
1
Fans, Electric Motors,
Generators
Slightly Complicated
2
Compressors, Pumps
Complicated
4
Industrial Gearboxes
Difficult
5
Turbines, Gas Turbine Engines
More Difficult
7
Helicopter Transmissions
Most Difficult
10
Specialized Equipment in
Extreme Noise Environments
https://apps.dtic.mil/dtic/tr/fulltext/u2/a291123.pdf
12
High
Motor Faults
13
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Machine Health vs. Time
14
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Relative Comparison Costs of Corrective,
Preventative and Predictive Maintenance
15
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Levels of
Performance
16
What Level Is Required In Your System?
Return on Investment
Prevent
Recommended
Scheduled
Maintenance
Of Asset
Detect
Monitoring
Asset
Diagnose
Predict
Real-Time
Determine Asset Optimization;
Remaining
Extending RUL
Identify & Isolate Useful Life (RUL)
Asset Health
Issues
Highest Performance Sensors
Required to Detect Faults at
Earliest Point in Time
Domain Expertise – Solution Integration
17
Prescribe
Analog Devices CbM Technologies
18 4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Condition Based Monitoring Sensing Modalities
19 4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
End-to-End Solutions for Condition Monitoring
20
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Vibration Analysis:
Most Commonly
Used PdM Technique
21
Popular Sensors used for Condition Based Monitoring
22
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Accelerometers
► Detects
faults while motors running
► Vibrations
are highly dependent upon the
measurement location, the mounting and the machine
frame
► Detects
mostly mechanical faults but some electrical
too
► Proven
to Diagnose & Predict Majority of Key Faults
EARLY!
► Least
reliant on other sensors for PdM applications
► Considered
23
the best technique for fault identification.
Vibration Analysis
24
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Machine Fault and Vibration Sensor Considerations
25
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Vibration Sensors
For Early Fault
Detection
26
CbM Sensor Performance Specifications
27
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
CbM Sensor Mechanical Specifications
28
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
MEMS Sensors
29
MEMS Sensing Technology
30
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
MEMS Enabling New & Improved CbM Capabilities
31
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
MEMS Accelerometer Product Offering for CbM
32
©2020 Analog Devices, Inc. All rights reserved.
MEMS Accelerometer Requirements for PdM
Matching the Right Sensor to Fault Type
Spec
ADXL337
No. Axes
Fault Type 3
g-range
±3g
ADXL356
BW
[kHz]
ADXL359
Noise
3 Density 3
ADXL317
Dynamic
Range3
±40g[µg/ 𝐻𝑧 ] ±40g
[g]±16g
ADXL1002
PdM MEMS
Accelerometer
Performance
ADcmXL
3021
Resolution
1
1/3
[bits]
±50g
High
±50g
Medium
Bandwidth
1.6kHz
Resonance
5.5kHz
Imbalance
Misalignment
1
2 - 3kHz
1.5kHz
100 -1000
5.5kHz
1-5
5.5kHz
<100 1000
4kHz
11kHz
10kHz
5.1kHz
3.1kHz
21kHz
21kHz
>20
>20
14 - 16
14 - 16
175µg
55µg /√Hz
Noise
/√Hz
80µg
Bearings
>5
<100
20
16/√Hz
- 20
80µg /√Hz 5 - 120µg
25µg
Density
300µg
/√Hz
/√Hz
/√Hz
Gears
>>5
<100
<5
16 - 20
Cross-axis1%
1%
1%
1%
1%
sensitivity
D. O. &. P. S, “How Sensor Performance Enables Condition-Based Monitoring Solutions,” Analog
Dialogue, vol. 53, 2019.
Temperature
-40°C Range
85°C
33
−40°C to
+125°C
−40°C to
+125°C
−40°C to
+125°C
−40°C to
+125°C
26µg
/√Hz
2%
−40°C to
+105°C
Low
►
Noise < 100µg/ 𝐻𝑧
►
BW from 5kHz - 10kHz+
►
Noise >100µg/ 𝐻𝑧 & < 1000µg/ 𝐻𝑧
►
BW from 1kHz – 5kHz
►
Noise > 1000µg/ 𝐻𝑧
►
BW <1kHz
ADI Accelerometers for Condition Based Monitoring
34
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Precision Converters
35
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
ADXL1002 Accelerometer Sensor With IEPE Interface
CN0532 IEPE
CN0533 4-20mA
EVAL-XLMOUNT1 Mounting Cube
foundation
36
structure
Wired and Wireless
Solutions
37
Wired / Wireless CbM Connectivity Options
Wired solutions up to 100Mb data
rate with optional power capability
Wired
•
SPI
•
IEPE
•
4-20mA
•
RS-485 + Power
•
Isolated RS-485 + Power
•
Ethernet
CbM Connectivity Solutions
High-reliability wireless,
low-power, mesh network
topology
38
©2020 Analog Devices, Inc. All rights reserved.
Wireless
•
•
100BASE-TX (100Mb + Power/PoE)
•
10BASE-T1L (10Mb + Power/PoDL)
SmartMesh IP (< 250kbps)
Industrial Wireless Technology
39
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
SmartMesh IP
40
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Industrial Ethernet
41
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Wireless CbM Reference Designs
ADuCM4050
+ SmartMesh
AD7685+
ADuCM4050
+ SmartMesh
ADXL1002
ADXL356
EV-CBM-VOYAGER3-1Z
42
Analog Devices Confidential Information. ©2020 Analog Devices, Inc. All rights reserved.
EV-CBM-VOYAGER3-2Z
PdM Development
Platforms and
Solutions
43
CbM Development Platforms Ecosystem
44
4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Evaluation & Development Platforms
Wireless Dev
Platform
45
SemiAutonomous
PdM Module
MEMS-Piezo
Conversion
RS-485 Ref
Design
Machine
Learning
Enablement
Kit
ADI CbM Reference Designs and Platforms
46 4 April 2022
Analog Devices Information. ©2020 Analog Devices, Inc. All rights reserved.
Condition-Based Monitoring Development Platform
System Section
Part Numbers
Documentation Description
Available Links
Sensor HW
CN-0532
Using the ADXL1002 as an IEPE-compatible sensor, buy options
analog.com/cn0532
How to use and configure the CN-0532 hardware
wiki.analog.com/resources/eval/user-guides/circuits-from-the-lab/cn0532
Mounting Block HW
XLMOUNT1
Mechanical dimensions and compatible boards
analog.com/en/design-center/evaluation-hardware-and-software/evaluationboards-kits/eval-xlmount1.html
Data Acquisition
(DAQ) HW
CN-0540
Performance details on the DAQ system, buy options
analog.com/cn0540
How/where to connect cabling, configure options
wiki.analog.com/resources/eval/user-guides/circuits-from-the-lab/cn0540
How to use the CN-0540 with DE10-Nano FPGA and software
wiki.analog.com/resources/eval/user-guides/circuits-from-the-lab/cn0540/de10nano
How to use the CN-0540 with Cora Z7-07s FPGA and software
wiki.analog.com/resources/eval/user-guides/circuits-from-the-lab/cn0540/coraz7s
How to download/burn the SD card
wiki.analog.com/resources/tools-software/linuxsoftware/zynq_images/windows_hosts
CN-0540 HDL project files
wiki.analog.com/resources/eval/user-guides/circuits-from-the-lab/cn0540/hdl
AD7768-1 Linux driver
wiki.analog.com/resources/tools-software/linux-drivers/iio-adc/ad7768-1
FPGA SW
ADI Kuiper Linux®
LTC2606 Linux driver
Machine Learning
Enablement
Platform
Data Applications
47
CN-0549
IEPE application details and understanding
analog.com/cn0549
How to connect the CN-0549 and run the software
wiki.analog.com/resources/eval/user-guides/circuits-from-the-lab/cn0549
Creating a demo case for the CN-0549 to bring to customers
wiki.analog.com/resources/eval/user-guides/circuits-from-thelab/cn0549/pelican_kit
Download, install, and how to use the IIO Oscilloscope application
wiki.analog.com/resources/tools-software/linux-software/iio_oscilloscope
Download and install the IIO libraries (libIIO)
wiki.analog.com/resources/tools-software/linux-software/libiio
Python
How to interface the CN-0549 with Python tools and stream data, link
to example project
wiki.analog.com/resources/eval/user-guides/circuits-from-thelab/cn0549/python_example
MATLAB®
How to interface the CN-0549 with MATLAB and stream data, link to
example project
wiki.analog.com/resources/eval/user-guides/circuits-from-thelab/cn0549/matlab_example
IIO Oscilloscope
©2020 Analog Devices, Inc. All rights reserved.
To Learn More
• How Sensor Performance Enables Condition-Based Monitoring Solutions by Pete Sopcik and Dara O’Sullivan
• Choosing the Most Suitable MEMS Accelerometer for Your Application by Chris Murphy
• Choose the Right Accelerometer for Predictive Maintenance by Bertrand Campagnie
• Demands on Sensors for Future Servicing: Smart Sensors for Condition Monitoring by Thomas Brand
• Enabling Robust Wired Condition-Based Monitoring for Industry 4.0 by Richard Anslow and Dara O’Sullivan
• ICP General Signal Conditioning Guide –PCB Piezotronics
• MEMS Vibration Monitoring: From Acceleration to Velocity - Mark Looney
• Choosing the Most Suitable Predictive Maintenance Sensor – Chris Murphy
• An Engineer’s Guide to Aliasing –Naiqian Ren (Hyperion)
• ISO 20816 Mechanical vibration -- Measurement and evaluation of machine vibration
• ADI MEMS Accelerometer portfolio
• ADI ADC Driver portfolio
• ADI precision ADC portfolio
48
Summary
▪ 4 New Reference Designs (CftLs)
▪ IEPE Compatible Interface for ADXL100x Vibration Sensors – CN0532 - Released
▪ 4-20mA Compatible Interface for ADXL100x Vibration Sensors – CN0533 – Released
▪ DAQ Reference Design – CN0540 – Released
▪ Machine Learning Platform – CN0549 – Released
▪ Consists of CN0532, CN0540, Processor/Gateway and ALL required SW to start streaming vibration data to machine learning
environment
▪ Analog Devices are committed to enabling you to keep your customers factories running.
▪ Pioneering MEMS for CbM/PdM
▪ Addressing key customer pain points
▪ Breadth of CbM offering
▪ Visit Analog.com/CbM for more information
49
Condition Monitoring Solutions that Deliver Actionable Insights
50
©2020 Analog Devices, Inc. All rights reserved.