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DoctorKnow® Application Paper

Title: An Introduction to Using the RF Smart Monitor System
Source/Author: Daniel J. Linehan
Product: RF Smart Sensor
Technology: Motor, STATUS Online Continuous Monitoring, Vibration

An Introduction to Using the RF Smart Monitor System

Daniel J. Linehan, PE
Computational Systems, Inc.
Abstract
The purpose of this paper is to discuss the operation of the RF Smart Monitor. In addition to
data collection, physical installation of the RF Smart Monitor System and the use of
RBMware will be discussed. At the conclusion of this paper, the reader will have a basic
understanding of how to operate the system and be able to identify possible applications for
this technology.

What Is It and How Does It Work

The RF Smart Monitor System, shown in Fig. 1, is designed to allow the user to remotely
collect machine vibration and temperature data without the need for cabling. This system,
which is designed to monitor a wide variety of machine components, consists of:
1. Battery-powered RF SmartSensors, which are placed on machine components
and collect/process vibration and temperature data,
2. One or more RF Transceivers, each of which is able to remotely communicate
with up to 64 RF SmartSensors via radio,
3. RBMware 4.20 or later to create the database and analyze the SmartSensor
data and,
4. A CSI Model 2120 or Handheld Personal Computer (HPC) to communicate
with RBMware and the RF Transceiver.

Figure 1. System Diagram of the RF Smart Monitor System

This system is designed to smoothly integrate with RBMware 4.20 or later. Databases and
routes are created in RBMware and downloaded to the 2120 or HPC. Four measurement
points (vibration, PeakVueTM, temperature, and battery life) are generated with each RF
SmartSensor created in RBMware. Once a route has been created, the user downloads this
information into a 2120 or HPC. The user then connects the 2120 or HPC to the RF
Transceiver and requests data from the remotely located RF SmartSensors specified in the
route. The RF Transceiver then transmits a message to the selected RF SmartSensors
directing them to collect and process data based on analysis parameters established in
RBMware. When complete, each RF SmartSensor remotely transmits vibration, PeakVue,
temperature, and battery life data back to the 2120 or HPC via the RF Transceiver. The
collected data is then downloaded to RBMware for trending and analysis.

Benefits and Uses

One of the distinguishing features of the RF Smart Monitor System is its wireless remote
access capability. This is accomplished via a robust form of radio communications known
as spread spectrum. This digital modulation technique has been widely used by the military
for many years due to its immunity to interference. Spread spectrum systems are also very
unlikely to cause interference with other radio systems, even other spread spectrum
devices. Interference issues are minimized with this technique because the signal of
interest is encoded with a lengthy digital pattern that approximates white noise.
Consequently, the resulting signal looks like low-energy, band-limited white noise that can
only be interpreted by a receiver that uses the same digital pattern to decode the signal.
While the signal is relatively low power, long range communication is attainable due to the
frequency of operation (2.4 GHz). The typical range achievable between an RF
SmartSensor and an RF Transceiver is approximately 300 feet. In addition, this form of
communication does not require line-of-sight between RF SmartSensors and RF
Transceivers. This allows the RF SmartSensors to be placed at the most ideal locations on
the machine to maximize sensitivity to vibration and temperature signals. Another
advantage of this modulation scheme is that no site license is required. The Federal
Communications Commission (FCC) grants licenses to the manufacturer for devices
operating in the Industrial, Scientific, and Medical (ISM) band, as long as they adhere to the
specified power-levels, bandwidth, etc. The RF Smart Monitor System has been granted an
FCC license since it uses a compliant radio that operates in the ISM band.

During the Beta test phase of this product, RF Smart Monitoring Systems were evaluated at
several industrial facilities on a variety of machines. One prime application of this
technology highlighted during the testing phase is the use of this technology on machines
that are either hard or dangerous to access. Machines in elevated locations (i.e., cooling
towers), where the analyst was required to climb a ladder to reach the site, or machines
located in hazardous locations (i.e., Class I, Div. II areas) are examples of such a scenario.
Another use of this technology is on machines that have a range of motion (i.e., robots,
accumulators, machine tools, cranes, etc.), where gaining access is difficult and routing
cables is nearly impossible. Machines that fall in this category often are not analyzed for
extended periods of time since they must typically be taken out of service prior to being
surveyed. As this technology becomes widely used, other unique applications will
undoubtedly be uncovered. In fact, the Beta program highlighted new concepts that are
now under consideration. A few of these concepts will be discussed later in this paper.

Capabilities of the RF SmartSensor

The RF SmartSensor, whose construction is shown in Fig. 2, consists of:
1. A high quality 10 mV/g accelerometer and temperature sensor,
2. Analog circuitry to condition the vibration signal as well as generate
 a PeakVue signal,
3. Digital circuitry to process the vibration and temperature signals,
4. An energy and power dense lithium C-cell battery for long life, and
5. A 2.4 GHz spread spectrum radio transmitter/receiver with antenna.

Fig. 2. Construction of the RF SmartSensor

RF SmartSensor battery life under normal conditions is expected to be one year or greater
even with a full set of data being collected once per day. In addition, this device is
mechanically designed to withstand the harsh conditions encountered in typical plant
environments. The NEMA 4x rating has already been achieved and a Class I Division II
version is in progress and should be available late 1999. Even with all the functionality built
into the RF SmartSensor, it is only approx. 4" tall and 2.5" in diameter.

In terms of measurement point setup, the RF SmartSensor is capable of the following:

1. Vibration data displayed in acceleration, velocity, or displacement,
2. Pre-set sensor power on/off, measurement point sensitivity, and auto-
ranging,
3. Single analog integration and double digital integration, and
4. Pre-set analog overall mode override.
All other measurement point setup options in RBMware are supported in the usual manner.

In terms of analysis parameter setup, the RF SmartSensor has the following capabilities:
1. A series of pre-set Fmax values ranging from approx. 39 Hz to 9375 Hz
(RBMware and the 2120 plotting functions will select the nearest Fmax which
exceeds that of the RF SmartSensor),
2. Up to 1600 lines of resolution, ten averages, and twelve analysis
parameters (Hz INT, Order INT, HFD, Hz vHFD, MP Wave, P-P Wave, and
 Crest), and
3. Analog preprocessing with a fixed highpass filter setting of 2500 Hz.

Note that the RF SmartSensor Fmax values in Hz are: 39.06, 58.59, 78.13, 117.19, 195.31,
191.97, 390.63, 585.94, 781.25, 1171.9, 1562.5, 2343.8, 4687.5, 6250.0, 9375.0. Also note
that spectral weighting, 1/3 octave analysis, SST, special time waveform collection, and
demodulation in the envelope demodulator are not supported. All other analysis parameter
options in RBMware are supported in the usual manner.

Finally, supported alarm limit set unit codes are VELOC, DISPL, ACCEL, HFD, TEMP
(overall only), W-ACC, and W-VEL. Additionally, only the four absolute alarms are
supported for the alarm type. All other alarm limit setup options are supported in the usual
manner.

Physical Installation

The first step in the installation process should be a site survey. Typically, the PdM program
determines the locations of the RF SmartSensors. The location of the RF Transceiver,
however, is dependent on the plant environment (i.e., building layout) as well as the
location of RF SmartSensors assigned to that particular RF Transceiver. The site survey,
then, aids in determining the number and approximate location of the RF Transceivers
required. Note that while line-of-sight between RF SmartSensors and RF Transceivers is
not required, large obstructions between the two devices (i.e., metal walls) will result in
weak communications. Conversely, with line-of-sight, high quality communications can be
achieved at distances greater than the typical 300-foot range.

Once the survey is complete and the system components have been received (and their
batteries installed and connected), RBMware is used to create a database that includes the
assignment of RF SmartSensors to machines and RF Transceivers. A template of this
information can be printed from RBMwizard to aid in physical installation. While not
recommended, the user can physically install the system first and then setup RBMware if
desired.

The RF SmartSensors are then ready to be mounted on the desired machine, with the
recommended method calling for ¼" x 28 TPI stud mounting. Once the RF SmartSensors
are installed, placement of the RF Transceivers are determined. Using the results of the site
survey, the RF Transceiver is temporarily positioned in its predetermined location. A 2120
or HPC running the appropriate software is connected to the RF Transceiver and a Quick
Scan function performed. The purpose of the Quick Scan is to determine whether the RF
Transceiver is able to communicate with the desired RF SmartSensors. The process of
determining the best location for the RF Transceiver may require the user to perform a
series of Quick Scans, relocating the RF Transceiver after each attempt, before a suitable
location is found.

The next step is to ensure that signal quality is acceptable. A high quality signal path
between RF SmartSensors and RF Transceivers is important in order to maximize battery
life. This is accomplished by performing a Thorough Scan using the same hardware
configuration required for a Quick Scan. This process, which may also be iterative, will
determine the permanent location of the RF Transceiver. When the Thorough Scan step is
complete, the RF Transceiver memory will store a list RF SmartSensor ID's assigned to it.
The RF Transceiver can be mounted in a variety of ways using the included universal
bracket or used in a mobile fashion, where the operator collects data at predetermined
locations. The advantage of the mobile approach is that the same RF Transceiver can be
used to collect data from RF SmartSensors that would otherwise be out of range.

RBMware Use
In general, all RBMware tools can be used with the RF Smart Monitor System. Note that
RBMwizard must be used for initial system configuration. RBMwizard employs an
intelligence engine to automatically generate representative measurement points, analysis
parameters, and alarm limits based on a series of detailed questions asked of the user. RF
SmartSensors and RF Transceivers are created in RBMwizard during database setup via
an RF SmartSensor button displayed in the technology menu. If selected, the user is
prompted to complete those fields necessary to define an RF Smart Monitor System in
RBMware. Once all the relevant information is input, the user can print a form containing
this data as an aide during physical installation.

Four measurement points (vibration, PeakVue, battery life, and temperature) are
automatically generated in RBMwizard for each RF SmartSensor created. Individual
measurement points can be edited by any of the RBMware tools. However, only in
RBMwizard can the entire RF SmartSensor or RF Transceiver be edited. In addition, only
one instance of the same RF SmartSensor measurement point can exist on any given
machine. Both of these rules were created to prevent data or database corruption.

Once the database has been created, the user can generate and download a route as
normal to either a 2120 or HPC. As with other technologies, RF SmartSensor points can be
included in any route. Once RF SmartSensor data has been collected, the route is
uploaded to RBMware as usual. Analysis and trending of RF SmartSensor data uses the
standard RBMware tools.

Data Collection and Analysis

RF SmartSensor data collection and analysis is similar to that of any route-based
technology. The user downloads a route to either a 2120 or an HPC, collects the data,
dumps it to RBMware, and performs analysis. However, instead of collecting data at the
machine, the user collects the data from the RF Transceiver. In addition, because each RF
SmartSensor contains up to four measurement points and because data is collected from
the RF SmartSensors via the RF Transceiver, the user is offered a variety of collection
options. These include collection of a measurement point, an entire RF SmartSensor, a
machine, or an entire RF Transceiver. The validity of these options depends on the
database and route setup. If the RF Transceiver is used in a mobile fashion, these same
collection options are available. However, collecting data from an entire RF Transceiver
may not apply since some of the RF SmartSensors are likely to be out of range.

RF SmartSensor data can be analyzed via RBMware or in the field. Analysis capability of
the HPC is limited to displaying a vibration spectrum. However, full featured plotting
capability as well as analyze mode functionality are implemented in the 2120. With either
device, once data has been downloaded to RBMware, trending and analysis are performed
using any of the standard tools (PLOTDATA, PLOTREND, NSPECTR, etc.)

What's Next
New applications will be discovered as users become familiar with the RF Smart Monitor
System. To date, several product evolution ideas are being evaluated. First, a variety of
user interface improvements are being explored. With any new product, these types of
improvements occur as a result of customer feedback. Second, a means of automating the
collection process is being explored. This would allow the user to monitor machinery more
frequently without increasing manpower requirements. Finally, a means of alerting the user
when an alarm condition occurs is under evaluation. When combined with automated
collection, this feature would provide the user with a simplified form of on-line operation.
These and other concepts identified by customers are still under evaluation. As a result, the
timing of future product releases is not yet known.

Summary
The RF Smart Monitor System is designed to allow the user to remotely collect vibration
and temperature data on a wide variety of machine components without the need for
cabling. This is accomplished via a robust form of radio technology that dramatically
reduces the likelihood of interference, does not require line-of-sight, and is capable of long
range communications. Data collection and analysis is similar to any route-based
technology, where either an HPC or a fully featured 2120 is used for collection and field
analysis. RBMware is used for database setup and detailed analysis. Each RF
SmartSensor, which includes four measurement points (vibration, PeakVue, temperature,
and battery life), is designed to withstand harsh industrial environments. Prime applications
of the RF Smart Monitor System to date include hard or dangerous to access machines and
equipment that has a range of motion. Some concepts under evaluation for future
development include automated data collection and remote alarm annunciation. However,
customer feedback will ultimately determine the evolution of this technology.

About the Author

Daniel J. Linehan is an R&D manager in the Engineering Division at CSI. Prior to joining
CSI, he worked as a Program Manager at the Oak Ridge National Laboratory. He holds
Bachelors and Masters degrees in Electrical Engineering from the University of Tennessee,
Knoxville and is a licensed Professional Engineer.

© Copyright 1999, Computational Systems Incorporated. All rights reserved

All contents copyright © 1998, Computational Systems, Inc.

All Rights Reserved.