Wireless Asset Health Monitoring Made Easy
Company iQunet = Tech start-up (Belgium, °2015) iQunet Vision : “Wireless Asset Health Monitoring Made Easy” Founders iQunet • CEO, Dirk Van den Branden, Ing, MBA • CTO, Wim Vereecken, Dr. Ir. Vast knowledge of • Electronic (chip) design • RF-technology • Product development 100% in house R&D and production with focus on • Innovative • mgt.team battery operated • wireless • small sensors • for industrial applications
Wireless Online Vibration Monitoring 3
Product Overview 2019 (details see online shop) Sensors Basic Vibration + temp. (acceleration) Network Components iQunet server Inclination + temp. (accelaration) Base station Proximity + temp. (hall effect) Proximity switch + temp. (reed) Temperature logger (temperature) Optional Network components Repeater CO 2 + VOC + RH + T° (not available yet) Actuator PIR motion + temp. (not available yet)
Why Condition Based Maintenance (CBM)? P otential Failure F unctional Failure 89% of failures are random in nature ! Start Vibration Analysis & Fault Detection Increase Plant Asset Availability
Vibration Monitoring (predictive) APIs A complete system of - Wireless Sensors - Base station - Small Din Rail Server … that measures vibration of rotating equipment … stores the data on the local iQunet Unix Server … and makes the data available from anywhere via standardized OPC UA communication 6
Web-dashboard Full control from any device From any browser (*) (*) WebRTC ready browser e.g. Chrome With 2-way communication • Configure sensors • Analyse data With easy access to sensors • Via Internet • Via company network
Communication Vibration data locally stored on iQunet server is open (no lock-in) OPC UA ensures seamless flow of OPC UA information Server Sensor Network iQunet offering
Technology Sensor sleep current is extremely low (<1µA) • Touching the batteries reduces the battery life time with approx. 50% due to induced leakage current being higher than sensor consumption Wireless transmission is ultra fast with low consumption • Lean but effective wireless iQunet protocol increases payload/overhead ratio Digitalisation of the sensor makes it very low power • Inside accelerometer made of MEMS Integrated Circuits makes it possible to run the electronics on 2 standard CR2032 coin cells
Features Range of the sensors • 10-50m depending on (*) • sensor mounting • Machine density in the plant • Construction of the plant • Can be extended 1x with Repeater node(s) (**) Number of sensors in the range • Unlimited Life time of the batteries in the wireless sensors • ±5 years (@1 complete 3-ax measurement/day + 100 x T°/day) (*) Note1: 50m in ideal setting / 15 to 25m in average in industrial settings (**) Note2: with inherent reduced data bandwidth (slower wireless transfer rates)
“MEMS”-vibration monitoring The classic way • Advantages MEMS wireless battery operated sensors • Advantages Piezo-electric sensors • Semi-continuous measurement – largely available (trend) data • Larger measuring range, more • Compressive sensing techniques information in one measure • Full spectrum (not only RMS) • Proven analytical technique (experts) • Characteristic harmonic detection • Operating point clustering • Lower TCO, smaller physical footprint, cheaper • Largely available cheap measurement points • Faster installation • Low power / on batteries / no cables • Disadvantage Piezo-electric sensor • Disadvantages MEMS wireless battery operated sensors • Trade off between power, accuracy and number of datapoints • Labour-intensive • Less accurate (but many datapoints = Machine Learning ready) • Snapshot (portable equipment) • Very expensive online wired/wireless equipment --> available for many assets ! -->used with highly critical assets 11
“MEMS”-vibration monitoring • With the same available power less accurate , but more datapoints • Interesting mechanical features of MEMS: Less sensitive ( up to 10.000g) 3-axial • Small: combination with other features (T°, Wireless, Memory, …) • Inexpensive electronics part: use of more MEMS sensors in one device • Inexpensive computing power correlation via Machine learning possible 12
VS. Comparison (performed by Siemens) between High-end piezo-electric sensor and iQunet wireless sensor Contact : Dirk Van den Branden CEO / co-owner +32 478 44 66 20 Winner BEMAS Digital Innovation Award 2017 dvdb@iqunet.com
Case Bio Mass Central please note differences in graph scales
• iQunet sensor detects also the bearing errors (all “frequency peaks” related to bearing errors are available – yet with less resolution) • iQunet resolution in lower frequencies could be increased by sampling at lower rates with high number of samples (setting in dashboard) • The iQunet sensor is a perfect low cost fit for anomaly detection with machine learning techniques
Setup & Installation Contact : Dirk Van den Branden CEO / co-owner +32 478 44 66 20 Winner BEMAS Digital Innovation Award 2017 dvdb@iqunet.com
Setup: “plug&play”
Mounting: “plug&play”
Mounting instructions Antenna top must be free from metal obstructions for best range (8 cm around the top in all directions) Use epoxy adhesive for permanent mount Equipment base (e.g. rotating equipment) Hex Socket Cap Stainless Steel Plain Socket Screw, M3 x 16mm Drill Ø4mm and insert M3 wire bus
Mounting instructions
Mounting instructions
Mounting instructions
Mounting instructions
CASES Contact : Dirk Van den Branden CEO / co-owner +32 478 44 66 20 Winner BEMAS Digital Innovation Award 2017 dvdb@iqunet.com
Case Paper Mill – M&M Germany
Karton Machine – Selection PoC High approx. 13 meter Length approx. 130 meter 28
Case Paper Mill – M&M Germany
Case Paper Mill – M&M Germany
Case Bio Mass Central
Live demo: Case Bio Mass Central
Case Hot Mill (Arcelor Mittal Gent)
Live Demo – Hot Mill plant Run out table hot mill – cooled down with water
Live Demo – Hot Mill plant Sensors Drive Side
Live Demo – Hot Mill plant Sensors Operator side
CASES Contact : Dirk Van den Branden CEO / co-owner +32 478 44 66 20 Winner BEMAS Digital Innovation Award 2017 dvdb@iqunet.com
iQunet wireless battery-powered vibration sensors detect pump damage. With automatic measurements every hour, the increasing deviation compared to a recent pump was detected and followed up. Due to the iQunet sensors it was possible to replace the bad pump within planned downtime. Use Case: Monitoring end of life of motor-pump combination
Keep antenna top free from obstacles UseEpoxy (8 cm around) for permanent mount Mount sensor with M3 bolt and wire bus
Conclusion Contact : Dirk Van den Branden CEO / co-owner +32 478 44 66 20 Winner BEMAS Digital Innovation Award 2017 dvdb@iqunet.com
Conclusion : IIoT in predictive maintenance and asset monitoring with MEMS sensors Secured iQunet server and save wireless communciation API with 200+ commands for maximum integration Clear pricing of the products, plug&play setup Excellent technical iQunet support Performant standardized OPC UA communication Many available ways to export or address data Partnering with Siemens Easy to expand system Products according to CE standards Computing in the edge solution minimilizes network usage Data remains local , no iQunet lock-in
Asset Health Monitoring Made Easy Please contact us for a live demo (via online meeting) www.iQunet.com Contact : Dirk Van den Branden CEO / co-owner +32 478 44 66 20 Winner BEMAS Digital Innovation Award 2017 dvdb@iqunet.com
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