A DIGITAL "STETHOSCOPE" FOR MACHINE MONITORING

An intelligent diagnostic system from Siemens can monitor the condition of mechanical equipment just by analyzing the noises it makes. The system s sensors listen to machine noises in the same way that a doctor listens to a patient s heart and lungs. The system learns to tell the difference between normal and faulty operation by analyzing noises and vibrations. The sensors it requires are simple, and the system can be used on many different kinds of machines and equipment. Three prototypes of STEVE (Siemens Tremor EValuation Equipment) — as the Siemens researchers have dubbed their system — are currently undergoing testing in power plants in Morocco and the U.S., as well as at Siemens gas turbine test center in Berlin. Many technical facilities, such as power plants, are so complex that it isn t possible to continuously check all of the running machines without leaving a few gaps in the process. If there is a breakdown, the replacement of critical components such as turbines, generators, transformers, and important support systems is very complicated and can cost hundreds of thousands of euros. Power companies contract Siemens Energy to operate around 25 power plants worldwide, with a combined capacity of more than 15 gigawatts. It is important for Siemens to be able to guarantee the highest possible operational availability of these facilities. As a result, experts from Siemens Energy cooperated with the global research department Corporate Technology (CT) in Princeton to develop the mobile monitoring system. STEVE registers malfunctions before they can cause an interruption in operations, thus reducing down time. It is equipped with coin-sized sensors that can be affixed at various places on just about every machine. When STEVE identifies an abnormality, specialists from Siemens can assist operators at the plant with their analysis by cell phone. The system detects noises, or rather structure-borne sounds, at a rate of almost one million measurements per second - that s 25 times faster than the human ear. Additionally, STEVE is programmed to "learn" which machine noises and vibrations are characteristic of different operational states. After a data collection phase of about one week, STEVE can tell the difference between noises and vibrations that are normal and those that indicate a malfunction. The system is mobile, weatherproof, and easily transferable from one component to another, so it can periodically take measurements on many technical devices. Because of STEVE s ability to learn, it can be installed on practically any machine that emits vibrations.

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MULTIHOP ETHERNET DATA RADIO

The MultiHop Ethernet Data Radio system provides extremely reliable communication in large plants, over long distances, or through difficult terrain. A network can easily cover many square miles and has a raw bit rate of 300Kbps. Master, Repeater, and Slave Radios All radios can be configured as a master, repeater, or slave radio. Master Radio: Every network has only one master radio and all data is routed to or from the master. Because of this, the network will have better throughput if the master radio is connected to the PLC or HMI that generates the most data traffic.

Repeater Radio: Repeater radios are slaves that also repeat. Although it is possible to use many repeaters in a network, it is usually better to carefully define only a few devices as repeaters to help the network form faster and result in fewer repeated messages. Repeating a message many times unnecessarily slows down the network. Repeater radios should be stationary and always on; a moving or powered off repeater causes a slight delay in communications while the network reforms through other repeaters.

REPLACING THE ETHERNET CABLES WITH THE MULTIHOP ETHERNET RADIOS
1. Remove the Ethernet cables from the switch and plug the cables into two MultiHop Ethernet Data Radios placed at least 6 feet apart. Do not change the IP address of the radios. They will relay all Ethernet traffic by default. Think of them as simple cable replacements.


Flexibility
» Each model can be selected to be a Master, Slave or a Repeater
» 10 to 30 V dc or a low power 5 V dc mode for Solar Power applications
Ease of Use
» No software or IP addressing required for deployment
» Built in LCD interface to display radio signal strength results
Applications
» Ethernet Wire Extension and Replacement
» Remote I/O
» Message Display Signs
» SCADA (PLCs, Modbus, Ethernet IP)
» AGV Integration
» Electric, Oil, and Gas Utilities/Metering

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Solar Charge Controller

Since the brighter the sunlight, the more voltage the solar cells produce, the excessive voltage could damage the batteries. A charge controller is used to maintain the proper charging voltage on the batteries. As the input voltage from the solar array rises, the charge controller regulates the charge to the batteries preventing any over charging.

Modern multi-stage charge controllers
Most quality charge controller units have what is known as a 3 stage charge cycle that goes like this :
  
1) BULK  During the Bulk phase of the charge cycle, the voltage gradually rises to the Bulk level (usually 14.4 to 14.6 volts) while the batteries draw maximum current. When Bulk level voltage is reached the absorption stage begins.
  
2)ABSORPTION  During this phase the voltage is maintained at Bulk voltage level for a specified time (usually an hour) while the current gradually tapers off as the batteries charge up.
  
3)FLOAT After the absorption time passes the voltage is lowered to float level (usually 13.4 to 13.7 volts) and the batteries draw a small maintenance current until the next cycle.

MPPT Maximum Power Point Tracking
Most multi-stage charge controllers are Pulse Width Modulation (PWM) types. The newer Maximum Power Point Tracking (MPPT) controllers are even better. They match the output of the solar panels to the battery voltage to insure maximum charge (amps). For example: even though your solar panel is rated at 100 watts, you wont get the full 100 watts unless the battery is at optimum voltage. The Power/Watts is always equal to Volts times Amps or P=E*I .With a regular charge controller, if your batteries are low at say 12.4 volts, then your 100 watt solar panel rated at 6 amps at 16.5 volts (6 amps times 16.5 volts = 100 watts) will only charge at 6 amps times 12.4 volts or just 75 watts. You just lost 25% of your capacity! The MPPT controller compensates for the lower battery voltage by delivering closer to 8 amps into the 12.4 volt battery maintaining the full power of the 100 watt solar panel! 100 watts = 12.4 volts times 8 amps = 100 (P=E*I).
  
The Charge Controller is installed between the Solar Panel array and the Batteries where it automatically maintains the charge on the batteries using the 3 stage charge cycle just decribed. The Power Inverter can also charge the batteries if it is connected to the AC utility grid or in the case of a stand alone system, your own AC Generator.

  

If you are using four 75 to 80 Watt solar panels, your charge controller should be rated up to 40 amps. Even though the solar panels dont normally produce that much current, there is an edge of cloud effect. Due to this phenomenon I have seen my four 6 amp panels (4*6=24) pump out over 32 amps. This is well over their rated 24 amps maximum. A good 3 stage 40 amp Charge Controller will run about $140 to $225 depending on features like LCD displays. For eight 75 to 80 watt solar panels you would need two 40 amp Charge Controllers to handle the power or you could increase your system voltage to 24 volts and still use just one 40 amp Charge Controller.

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Differential Pressure Level Transmitters

The importance of level measurement cannot be overstated. Incorrect or inappropriate measurements can cause levels in vessels to be excessively higher or lower than their measured values. Vessels operating at incorrect intermediate levels can result in poor operating conditions and affect the accounting of material.

The level of a liquid in a vessel can be measured directly or inferentially. Examples of direct level measurement include float, magnetostrictive, retracting, capacitance, radar, ultrasonic and laser level measurement technologies. Weight and differential pressure technology measure level inferentially. All have problems that can potentially affect the level measurement. Differential pressure level measurement technology infers liquid level by measuring the pressure generated by the liquid in the vessel.

For example, a water level that is 1000 millimeters above the centerline of a differential pressure transmitter diaphragm will generate a pressure of 1000 millimeters of water column (1000 mmWC) at the diaphragm. Similarly, a level of 500 millimeters will generate 500 mmWC. Calibrating this differential pressure transmitter for 0 to 1000 mmWC will allow it to measure water levels of 0 to 1000 millimeters. Using the available information properly is another potential problem. Some years ago, distributed control system inputs were incorrectly configured to correspond to the maximum transmitter spans. Aside from using incorrect values, the levels should have been expressed in percent. Using absolute level measurement units such as inches, feet, millimeters or meters increases the potential for error because operators must remember the height of each vessel to put the level measurement in context with the vessel. This can easily become overwhelming and cause operator errors because plants often have hundreds of vessels.

Differential pressure measurement is a workhorse of industrial level measurement that is been used for decades and will continue to be used for decades to come.

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SENSOR COMBINATIONS AND MINIATURIZATION

New sensor combinations are emerging in the sensor market as combining those cuts the overall costs of the sensors. Putting several sensors on a package, such as accelerators and gyroscopes is becoming more commonplace. Miniaturization is an interesting trend. Miniaturization of sensors is enabling some of the innovative sensor packaging and devices. Innovations in gaming, such as in the X-Box Connect, which brought in multiple types of sensors to deliver rich fidelity, are moving into mobile devices as well. Traditional fitness is seeing the same thing as key vital signs and biometrics are becoming visible. Miniaturization of sensors combined with enhanced fidelity of devices allows product manufacturers and service providers to experiment with devices and offer compelling and fulfill compelling and specific needs. Bosch MEMS sensor: Bosch has rolled out a MEMS sensor that combines pressure, humidity, and temperature measurement in a single component. The BME280 is aimed at handsets and wearables where it is to be used for greater control as well as sports and fitness use cases. Its humidity sensor measures relative humidity from 0 to 100 percent and from -40°C to +85°C with less than 1 second of response time. The humidity measurement accuracy is plus or minus 3 percent, with a hysteresis of 2 percent or more, and a temperature reading accuracy within half a percent Celsius. The device’s pressure is intended to offer floor-level tracking for indoor navigation. The relative accuracy of pressure readings is plus or minus 0.12 hPA, which equates to plus or minus 1 meter of altitude difference at a resolution of 1.5 cm. The device comes with I2C and SPI serial digital outputs. Its packaging measures 2.5mm by 2.5mm with a height of 0.93mm in an 8-pin LGA package. More

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Texas Instruments launches industry first highly integrated NFC sensor transponder

Texas Instruments (TI) announced the industry first flexible high frequency 13.56 MHz sensor transponder family using NFC Technology. The highly integrated ultra-low-power RF430FRL15xH system-on-chip (SoC) family combines an ISO 15693-compliant Near Field Communication (NFC) interface with a programmable microcontroller (MCU), non-volatile FRAM, an analog-to-digital converter (ADC) and SPI or I2C interface. The dual-interface RF430FRL15xH NFC sensor transponder is optimized for use in fully passive (battery-less) or semi-active modes to achieve extended battery life in a wide range of consumer wearables, industrial Automations, medical, Sensors and asset tracking applications. Near field communication (NFC) is basically a short-range, high-frequency (13.56 MHz) RFID technology that allows for the exchange of information between two NFC-enabled devices. Non-volatile FRAM combines the speed, flexibility and endurance of SRAM with the stability and reliability of flash – while providing the industrys lowest power consumption and virtually unlimited write cycles. FRAM allows developers to create products that can quickly store sensor data and enables easy configuration of the transponder and sensors to meet any applications needs. Integrating NFC sensors into medical, industrial and asset-tracking applications. Developers can now design products that require an analog or digital interface, data-logging capabilities and data transfers to an NFC-enabled reader. The RF430FRL15xH transponder acts as a sensor node for these applications and generates an IoT-ready solution when an NFC-enabled device pushes the data to the cloud. In medical or health and fitness applications, the RF430FRL15xH can be used in disposable patches that sense temperature, hydration and more. This allows patients to monitor and share vital data securely with their health providers. The device monitors and logs data in local storage (FRAM) before transferring it to an NFC-enabled tablet or Smartphone. The RF430FRL15xH enables the design of maintenance-free and hermetically sealed galvanic isolated sensor systems in the industrial markets. These sensors are powered out of the RF field and communicate wirelessly through NFC to collect and log data. Logistics applications such as food tracking need constant temperature control, which can be monitored and logged with the RF430FRL15xH transponder. It allows the design of highly integrated, size-optimized and easy-to-use data loggers with several sensors that connect to NFC-enabled devices and readers throughout the distribution channel.

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