Development of a Smart Condition Monitoring Sensor System for Variable Speed Machinery

The objective of this project was is to design and develop a wireless 'smart' condition monitoring sensor system for variable speed machinery.   This system includes four parts, A Smart Sensor, A Transceiver, PC and A Communication Module. The smart Sensor automatically detects the machine condition using comprehensive alarm “Mask” methodology. The machine condition data is remotely transferred regularly to a transceiver without the need for cabling. To save, analyse and review data on a PC, the condition monitoring analysis, diagnosis and evaluation of machine fault severity software will be used. Network or other devices, such as WAP enabled cellular phones, will distribute the machine fault messages.

The subject of this project is to carry out the prototype version of the wireless Smart Condition Monitoring System development, including a Transceiver, a Control Centre with a PC and a Communication Module.

This project consists of four elements:

• The smart sensor is a completely self-contained wireless machinery analyser that can carry signal processing and detect a machine conditions using comprehensive alarm “Mask” methodology. If necessary, the pre-processed measurements from the Smart Sensor can be transmitted regularly to a transceiver without cabling. Transmitting interval is dependent on your machine process.
• The multi-channel Transceiver supports up to 50 smart sensors within a 50m radius and provides instruction and communication with the Smart Sensors. The Transceiver will be AC-powered for permanent mounting.
• The analysis results, such as alarms, spectra and 'sensor status', will be downloaded to a control centre with a PC from the transceiver. The control centre will hold the machine database with a special condition monitoring system. The system uses advanced state-of-the-art software, which will be required for accurate fault diagnosis and prognosis of machine faults. When the Alarm parameters are exceeded, then the fault classification and fault severity ranking will be conducted in the centre. In addition, the control centre will be used to manage a comprehensive database incorporating details of all the equipment being monitored, update the measured data, graph and trend data, and readjust the sensor set up, etc..
• The subsequent dissemination of the fault message is through the Control Centre by modem to the Internet, for access via network or Mobile technologies. The annunciated fault “message” will include a fault identifier/description, the fault severity, and the machine identifier (or IP address).

An e-newsletter has also been published for this project, highlighting its significance for the industry.