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FMI Capabilities inFMI Capabilities inRobotics, Diagnostics, andRobotics, Diagnostics, and

Multi-Phase Flow MonitoringMulti-Phase Flow Monitoring

Dr. Wayne S. HillDr. Wayne S. Hill

whill@foster-miller.comwhill@foster-miller.com

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Shipboard Weapons LoadingShipboard Weapons LoadingThe Problem !The Problem !

The Navy Wants Double the Rate and Half the People The Navy Wants Double the Rate and Half the People

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.

LAB PROTOTYPE SWL

• 3000 lb Payload Capacity

• Nine Degrees of Motion Freedom

• Can Handle All Shipboard Weapons

• Human Force Amplification With Gravity Compensation and Ship Motion-Induced Dynamic Error Compensation

• Built-In Equipment Diagnostics

Shipboard Weapons LoaderShipboard Weapons LoaderThe SolutionThe Solution

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AutoGalley:

• Integration of Modular Robotic Food Service System into Existing DDG-51 Galley

• Adaptable to any ship platform

• Automation concepts adaptable to a wide range of shipboard material handling needs

Smart Galley

• Allows full oversight and supervision of galley functions for both new and legacy ships

• Meal planning, consumption monitoring, inventory control, food safety (HAACP) monitoring

• Equipment diagnostics & prognostics

Auto-Galley and Smart GalleyAuto-Galley and Smart Galley

Networked Galley

Database

Monitored Data

PrognosticsAlgorithms

Diagnostics

Archived Data

Results/Reports

ERP

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Performance Mapping for Performance Mapping for Dishwasher OperationDishwasher Operation

0

0.5

1

1.5

2

2.5

0 0.2 0.4 0.6 0.8 1 1.2

Power Factor

Po

we

r (k

W)

Idle or Solenoid Valve

Pump Only

Heater Only

Pump & Heater

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Industrial Robotics for Plant AutomationIndustrial Robotics for Plant Automation

BoxHandler• Mobile Robot for Refrigerated Material

Storage• Designed to eliminate hazardous, high

injury jobs• Totally electric design (food storage,

hydraulic fluids not permitted• Inventory tracking key part of system• Distributed control system with

autonomous robotic operationsRoboPacker / AutoBoxer• Box Packing automation system

• Manipulate a wide range of different size, weight, and shape products

• Reduce packing personnel

• Improve speed and quality of packing

• Designed for use in difficult food plant cleaning environment (high pressure hot water)

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Robotics for Inspection, Repair Robotics for Inspection, Repair and Hazardous Dutyand Hazardous Duty

• TOMCAT: remotely operated robot arm

• High voltage insulation maintenance tool

• Tactile feedback loop

• Keep personnel out of hazardous environment

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Pipe MousePipe MouseAttributes

•Semi-autonomous operation in a live gas main

•Fault tolerant distributed control system

•Multi-car design permits different sensors and tool payloads to be added depending on specific task at handPerformance

•Range – 2000 ft.

•Negotiate all elbows, tees, valves and pipe orientation

•Operate in operating pipe environment – gas or liquid

•8-hr per battery charge

•Travel speed 5 to 10-ft/min

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•Operational Concept•System Software•Operator Control Stations•Modeling & Simulation

•Electromagnetic Design•Motor Control•Health Monitoring•Prognostics

EMALSEMALS

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•Operational Concept•System Software•Operator Control Stations•Modeling & Simulation

•Electromagnetic Design •Motor Control•Health Monitoring•Prognostics

Advanced Arresting Gear (AAG)Advanced Arresting Gear (AAG)

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FMI Skill Areas forFMI Skill Areas forCondition-Based MaintenanceCondition-Based Maintenance

Sensors

User Interfaceand

Data Storage

Sensor DeliverySystems

Signal andSignatureAnalysis

DataCommunication

HardwareFailure Modes

CBM andPrognostics

Systems

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FMI’s Dynamical Instruments TechnologyFMI’s Dynamical Instruments Technology

Concept: Nonlinear portion of signalsConcept: Nonlinear portion of signals

can be a more sensitive indicator of acan be a more sensitive indicator of a

problem than the harmonic or linearproblem than the harmonic or linear

portion.portion.

Applications:Applications:

• Aircraft flight control actuators

• Electromechanical system diagnostics and prognostics

• Helicopter vibration reduction

• Mechanical equipment fault identification

• Multi-phase flow sensing

• Oil/water/gas

• Gas-solid (coal/air)

• Container security

7.3 7.35 7.4 7.45 7.5 7.55 7.6 7.65

x 104

-0.8

-0.6

-0.4

-0.2

0

0.2

0.4

0.6

0.8

Reading Number (time)

Am

plit

ud

e

Raw Helicopter Vibration Raw Helicopter Vibration SignalSignal

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Prognostics for HydraulicPrognostics for HydraulicAircraft Flight Control ActuatorAircraft Flight Control Actuator

act1gcanard.PDW

-4.60

-4.40

-4.20

-4.00

-3.80

-3.60

-3.40P

osit

ion

-5.00 -4.50 -4.00 -3.50 -3.00

CommandLegend

Left Canard

Right Canard

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Prognostics for Electric Aircraft ActuatorsPrognostics for Electric Aircraft Actuators

Flight controller signals analyzed to determine

EHV health

Fault level (remaining life) of EHV DeterminedFault level (remaining life) of EHV Determined

Clustering and Associated Command Window for Sine-Wave Command.Frequency: 1/6 Hz Amplitude: 0.25”

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Background

• The Westland-Augusta EH-101 is the first production helicopter to use active vibration reduction.

• Active Control of Structural Response (ACSR) is a quasi-linear vibration isolation system.

• ACSR can only address the “average vibration” from previous rotor rotations, and cannot handle the chaotic variation of vibration.

Phase II SBIR Program

• Investigate improved vibration control techniques based on Chaotic Control (nonlinear dynamics of structure)

• Demonstrate control improvements on helicopter structural test stand using flight vibration data as input to structure

Helicopter Active Vibration ReductionHelicopter Active Vibration Reduction

EH-101 has been licensed by Lockheed Martin to be the new Presidential helicopter.

Results: 80% reduction in vibration amplitude, close to the limit of controllability for the test aircraft. ACSR reduced vibration by 56%.

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Sensitive Diagnostics for Mechanical EquipmentSensitive Diagnostics for Mechanical Equipment

Cases Used to Train NetworkCases Used to Test Network

Saline Shutoff

0

4

8

12

16

20

Pre

dic

ted

Tim

e A

fter

Sal

ine

Sh

uto

ff 24

2 4 6 8 10 12 14 16 18 20 22 24

Minutes After Saline Shutoff

Ac

cel

era

tio

n, g

500 1000 1500 2000 2500 30000

0.025

0.05Tim

e (s

pectra

eve

ry 2

min

)

Frequency, Hz

10

18

Ac

cel

era

tio

n, g

500 1000 1500 2000 2500 30000

0.025

0.05Tim

e (s

pectra

eve

ry 2

min

)

Frequency, Hz

10

18

Spectral

Analysis

Dynamical Instrument Analysis Fluid Film BearingVentricular Assist Device

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Multi-Phase Flow MeasurementMulti-Phase Flow Measurement

0.00

0.10

0.20

0.30

Thi

ckne

ss M

easu

rem

ent

(in)

7.00 7.20 7.40 7.60 7.80 8.00

Time (sec)

0.0 2.0 4.0 6.0 8.0 10.0

Actual Liquid Flow (gpm)

12.0

0.0

2.0

4.0

6.0

8.0

10.0

Pred

icte

d L

iqui

d Fl

ow (

gpm

)

12.0

0 20 40 60 80 100

Actual Gas Flow (slpm)

0

20

40

60

80

100

Pred

icte

d G

as F

low

(sl

pm)

0.000 0.005 0.010 0.015 0.020 0.025 0.030

Actual Quality

0.000

0.005

0.010

0.015

0.020

0.025

0.030

Pre

dict

ed Q

ualit

y

Liquid Flow

Gas Flow

Quality

RawData

Example: UltrasonicExample: UltrasonicThickness MeasurementThickness Measurement

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Water Cut in Oil/Water FlowsWater Cut in Oil/Water Flows

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

Actual Water Cut

Pre

dict

ed W

ater

Cut

Data Collected inLaboratory TestingWith Mineral Oil And Water Using Swept-FrequencyAcoustic Interferometry and Dynamic Pressure