Sensors & maintenance managementmobile application

Sensor and multi-service co-operation

Industrial Internet

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• Current practises in maintenance & service

• Motivation

• Technology and applications available

• Metso application

• Questions & discussion

Presentation topics

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Dr. Mika KarailaResearch Manager

Metso Automation

Research & Technology, Tampere

mika.karaila@metso.com

+358 40761 2563

Contact info

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• Computerized Maintenance Management Systems (CMMS):

- Part of asset management / ERP system

• Scheduled maintenance:- Walkaround

- Measurement and data archiving

• Hardwired measurements:- Continuous, online, immediate

warning & alarm

- Critical devices

Traditional maintenance

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More work and less people require effective

communication and device

”knowledge”

• Less people working at the factories

• Outsourcing:- Device vendors taking care of devices

- Special service companies doing maintenance

• Large plants:- Devices are spread in wide area

New demands and practices in maintenance

© Metso© Metso6 Source: Cisco & Morgan Stanley, picture: CNN

Read more:

• Cisco- More things are connecting to the

Internet than people - over 12.5 billion devices in 2010 alone.

- Cisco’s Internet Business Solutions Group (IBSG) predicts some 25 billion devices will be connected by 2015, and 50 billion by 2020.

• Morgan Stanley- By 2020 75 billion devices will be

connected to the Internet of Things.

• Estimates for Nordic area- By 2020 1 billion devices will be

connected

Click icon to add picture

MotivationNumbers behind research: Internet of Things

http://www.businessinsider.com/75-billion-devices-will-be-connected-to-the-internet-by-2020-2013-10#ixzz2pbe7K22s

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Connect the world’s machines, facilities, fleets and networks with advanced sensors, controls and software applications

Industrial Internet, term by General ElectricDefinition according Tim O´Reilly

Source: Tim o´Reilly

Intelligent machines

Combines the power of physics-based analytics, predictive algorithms, automation and deep domain expertise

Advanced analytics

Connecting people at work or on the move at any time to support more intelligent design, operations, maintenance and higher service quality and safety

People at work

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Scalability: from some devices to thousands / site -> Billions

• More devices, sensors & information

• Connectivity & interoperability on devices & applications

• Knowledge sharing & intelligence needed

• Usability: easy & fast

Information explosionIndustrial Internet

Intelligent Reliability

Metso experience: Intelligent maintenance

New technologies – challenges and opportunities

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Technology fusionMulti-sensor Industrial Internet

• Devices & sensors: - Bluetooth low energy & mems technology

• TI sensortag as a proto-type platform

• Rapid testing: small HW changes, modified SW examples

• Interoperability & Connectivity:- Smart phones (many existing applications), iOS & Android

- Internet access through gateway (Linux)

• Measurements:- Acceleromation, temperature, audio (plus humidity & gyroscope from TI sensortag)

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Sensortag

Internet

ERP systems

CMMSsystems

Condition monitoring system overviewKey components: utilizing existing HW, customizing SW

Wifi / 2G/3G

Desktop application

BeagleBone Black

Mobile applications

M-BoardRaspberry Pi + Full HD camera

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• Vibration:- Based on accelerometer X,Y,Z

(correction by gyroscope)

- RMS classification / clustering

- NOT for high sample rates (limited resources)

• Temperature:- IR & ambient

• Audio: - Based on MEMS microphone (VTT)

- Leak detector for on/off valves (e.q. safety valve)

• Battery level:- Based on capacity & average power

consumption (Bluetooth LE, Profile 4.1)

• Camera based (separate platform):

- Rope damage detection, IR photos

Metso Automation case: sensor usageCondition monitoring measurements

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Multi-sensor Industrial Internet

• Interoperability: smart phones (iOS / Android)

• Usability: Bring Your Own Device (BYOD), - Applications like others

- Indoor navigation (based on magnetic field)

• Low cost sensors, reuses existing infra structure

• Interoperability: bluetooth & internet providing standards

• Autonomy / adaptation: few parameters, self configuration

• Integrated services:- Indoor location

- Cloud storage for sensor measurement data and for tasks / events

Facts / requirements that are fulfilled

New ideas forservice & maintenance

Changing the way we work

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• Personal login for authentication & customer ID

• Key points for connectivity:- Android 4.3 or iOS with Bluetooth LE

- Wifi / 3G

• Usability:- Fast sensor access NFC or QR-code

- Indoor navigation

Use your own deviceMetso mobile service application

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Task list shared

• New way of working:Gamefication

=> Who executes most of the tasks?

• Different points, dependson task hardness orneeded working time

Metso service application

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Navigate: Find device even in an unknown plantMetso service application

• Indoor Atlas navigation- 1m accuracy

• Useful in cases:- Wide area

- Multiple devices

- New customer

- Relocated device

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• Select task from the list

• Look sensor data, trends and photo

• Can be accepted as done

=> CMMS integration

Execute maintenance taskMetso service application

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• Touch NFC tag OR Scan QR-code (attached on device) => Application shows sensor data

Fast access to sensor data by NFC / QR-codeMetso service application

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Share information & knowledgeMetso service application

• Priority

• Location

• Photo in small icon in the middle

• Add other information to task like:Service|Calibration|Broken

• Description: database etc.

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• Drag & drop tasks to maintenance date

Reschedule sensor tasks & check eventsSensor management

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Place sensors on correct location on floor planSensor data management

• Create sensor, add tag, name etc.

• Location / relocation

• Measurement trends

• Printout QR-codes

• Write NFC tags

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• Before map can be used

• Walk once to get data

• Walk same route backto validate data

• Fast to create map

• No extra devices needed

Easy & fast map creationMap Creator

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InteroperabilityVTT Vibration data clustering tool

• Android application

• Analysis acceleration measurement data

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InteroperabilityRaw data in iOS

• Graphs from the same sensors

Technology & benefits

Summary

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• Bluetooth smart & NFC tags => => Connectivity & easy access

• Small sensors & Smart phones

=> Mobility => Indoor navigation

• Internet & Cloud integration

=> Intelligence

Industrial Internet: keywords

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Benefits

More effective working, less time

wasted, people can work faster

Thousands of points can be checked

instead of hundreds

More regular measurements

mean less unscheduled breakdowns

Cost effective solution that

scales up

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Metso Mobile Service Application helps you to find the field device which needs service!

• Sensors: battery life | distance | security

• Signal handling: local | gateway | cloud

• Gateway: functionality

• Cloud: intelligence

• Integration: 3rd party systems | ERP

• Mobile application & Smart glasses

Discussion topics

http://www.youtube.com/watch?v=S6xyKf_QVIk

http://www.youtube.com/watch?v=jHFCork_R1Q

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