Accelerating the realization of industrial manufac

  • Detail

Under the new infrastructure, we will accelerate the upgrading of safety monitoring of industrial manufacturing based on CBM

the concept of new infrastructure is first written in the government work report of the two sessions just concluded to strengthen the construction of new infrastructure, with the goal of stimulating new consumer demand and helping Industrial upgrading. Under the new infrastructure, how can industrial manufacturing, as the core driving force of China's economy, usher in the opportunity of self upgrading? With the acceleration of AI and the maturity of wired and wireless technology solutions, the predictive maintenance of manufacturing equipment based on condition based monitoring (CBM) may be a key link

especially with the development of industry, industrial robots and rotating machines such as turbines, fans, pumps and motors are more and more widely used in factories, and with the trend of automation, a complete set of embedded assembly lines have been formed. In the best case, once the assembly line is formed, it can operate all the time, but the machine will always suffer mechanical losses. Once problems occur, this precise production line will stop working, causing great losses to the enterprise. Therefore, if we can monitor and predict the industrial state and carry out targeted predictive maintenance at the early stage of the machine life cycle, we can reduce the risk of production downtime, so as to improve reliability, significantly save costs and improve the productivity of the factory

to ensure the accuracy of prediction, reliable data acquisition sensor module is indispensable

to implement condition based monitoring of industrial machines, a series of sensor data can be used, such as electrical measurement, vibration, temperature, oil quality, acoustics and process measurement (such as flow and pressure). However, vibration measurement is the most common at present, because it can most reliably indicate mechanical problems, such as imbalance and bearing failure

as the ADI company that is best at signal conditioning and acquisition in the global semiconductor field, it has long had a complete technical layout in this regard. They use the optimized micro electro mechanical system (MEMS) acceleration. The public does not have enough time to prepare for the new policy. The meter, low-power microcontroller and wired icoupler isolation interface signal chain can extract and adjust the machine health data from remote CBM slaves, And reliably transmit it back to the main controller for analysis. Over time, machine health data can be used to create software based models to determine changes in machine behavior and actively maintain machine health

the first step in industrial condition detection is to obtain accurate mechanical data, so it is very critical to select a reliable MEMS vibration sensor. Generally speaking, the selection of MEMS vibration sensors will be considered from many aspects, such as the number of shafts, fault types, performance requirements and so on

the number of axles monitored is usually a function of the type of fault and the installation arrangement of the sensor. If it can be clearly seen that the fault involves a leading axis, and there is a clear transmission path on the axis, then using a single axis sensor is sufficient. Triaxial sensing is useful for faults containing energy in multiple axes or faults with unclear fault energy transmission path

if water cooling is adopted, regularly inspect whether the cooling steel pipe has cracks and water leakage.

the monitored fault type has an important impact on the selection of sensors. The noise density and bandwidth of the sensor are important indicators in this regard, because they determine the vibration level and frequency range that can be reliably extracted. For example, for imbalance and misalignment faults of low speed machines, a low noise density sensor may be required, but the bandwidth requirement is quite low, while gear fault detection requires both low noise density and high bandwidth

in addition to the fault type, it is also important to understand the performance requirements of CBM. Among the measurable physical quantities, vibration spectrum measurement can provide the most information about the root causes of problems in rotating machines (engines, generators, etc.). Abnormal vibration may be ball bearing failure, shaft deviation, imbalance, excessive looseness and other problems. Each vibration measurement can be carried out using an accelerometer placed near the monitored element. This kind of sensor can be piezoelectric or MEMS type. The latter has more advantages. Adcmxl3021 MEMS accelerometer module is a representative solution

this accelerometer has ultra-low noise density. In fact, it does not mean that the impact testing machine is very cold to humidity of any size (25 g/Hz), supports excellent resolution, and can meet the needs of different solutions. Adcmxl3021 also has a wide bandwidth (from DC to 10 kHz, 5% flatness) and can track key vibration characteristics on many machine platforms. Adcmxl3021 provides customers with a mechanically optimized aluminum package that provides stable coupling with integrated MEMS sensors over a wide frequency range. This ensures that the vibration characteristics obtained from the tested equipment can be reliably extracted and conditioned. Adcmxl3021 can provide SPI output, which can be directly connected with rs-485/rs-422 devices, or connected with rs-485/rs-422 devices through microprocessor and/or icoupler signal and power isolation. In order to monitor the vibration characteristics of industrial equipment in real time, adcmxl3021 provides real-time transmission mode, and its working rate is about 12 Mbps SPI

after acquiring the sensor data, the next step is to process and transmit it into information that the operator can easily read. This transmission means that the sensor data from the sensing node is sent to the master controller or the cloud highly dependent application. In many applications, some local data will be processed at the terminal node, and the summarized data will then be sent to the server

to achieve reliable, highly integrated, wired MEMS accelerometer, the option of the solution based on condition monitoring

wired and wireless optional, industrial condition monitoring at will

after obtaining the vibration data, the next thing to do is to transmit and process. When transmitting in long cables, the communication network may be affected by hazards, such as large common mode noise, ground potential differences, and high voltage transients. Using ADI icoupler chip level transformer isolation technology can improve the anti-interference ability of these noise sources

in wired communication networks, exposed connectors and cables may also suffer from many severe high-voltage transients. System level IEC standards related to EMC immunity requirements for variable speed electric drive systems require a minimum of 4 kV (contact)/8 kV (air) IEC ESD protection. ADI new generation RS-485 transceiver provides IEC ESD protection higher than 8 kV (contact)/8 kV (air)

all kinds of wires for status monitoring and all kinds of wires for the machine itself will occupy a lot of space. In some application scenarios, wired monitoring cannot meet the requirements. At this time, a more lightweight wireless status monitoring solution is needed. After the data is processed locally, it is sent to the network gateway wirelessly, or directly to the cloud or analysis server through the cellular link when the detected data and functional requirements are not many and the digital display can meet. ADI provides a complete set of CBM wireless condition monitoring scheme based on smartmesh technology, which adopts high-performance, broadband and wide sensor technology, ultra-low power processor and powerful wireless industrial network to realize vibration monitoring of industrial equipment

CBM wireless status monitoring scheme based on smartmesh wireless network

smartmesh network is the core technology of the transmission part of this monitoring scheme. It is equipped with chip of shape network software and pre certified PCB module, so that the sensor can communicate in the harsh industrial IOT environment, so as to simplify the manufacturing operation. The installation will not interfere with normal industrial production, especially for the industrial environment with compact space constraints and inconvenient line layout, and provides real-time data, thus reducing downtime and helping with future capacity planning. At the same time, smartmesh IP embedded wireless network can achieve 99.999% data reliability and ultra-low power consumption in harsh industrial environments

GUI user interface


the CBM status monitoring solution launched by Adi can help industrial technicians quickly understand the operating status of industrial equipment, so as to deal with it quickly in advance. It also provides wired and wireless connection methods, and adopts wired transmission when you want more original data; When you want a lighter layout, wireless transmission is used to meet the needs of users in different dimensions and accelerate the development of industrial automation

Copyright © 2011 JIN SHI