Product category:
Asset Management and maintenance planning
News Release from: Perpetuum | Subject: Esholt trials
Edited by the Processingtalk Editorial
Team on 08 June 2007
Wireless, battery-free condition
monitoring at YWA
The Yorkshire Water Esholt Waste Water Treatment Works is conducting a trial of the world's first practical vibration energy-harvesting microgenerator, on a wireless condition monitoring sensor
The Perpetuum microgenerator - which powers wireless, battery-free devices capable of sending large amounts of critical data - will enable Yorkshire Water to increase plant efficiency by providing advanced, low cost condition monitoring It is also expected to considerably reduce machine repair costs by allowing improved pro-active maintenance whilst reducing the risk of compliance failures
This article was originally published on Processingtalk on 23 Jun 2008 at 8.00am (UK)
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The trial is part of a GBP120K research and development project undertaken by the water company to optimise its facilities and therefore provide a better service for its customers.
Integral to the project is increasing the reliability of its equipment.
Yorkshire Water had previously installed conventional hard-wired systems to send and record performance data, but these were difficult and expensive to install, and proved un-reliable.
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Following the success of its PMG7 microgenerator, Perpetuum has launched its next generation microgenerator, PMG17, which generates more power from low levels of vibration
Through the water company's close links with The University of Southampton in the UK, it became aware of Perpetuum, and its groundbreaking vibration energy-harvesting technology, developed from original research at the university.
The Perpetuum PMG7 microgenerator is the enabling technology that powers the S5NAP wireless sensor nodes, developed by RLW Inc of State College, Pennsylvania, USA.
RLW had originally selected an early prototype of the microgenerator for a project for the Office of Naval Research.
Its S5NAP records and then transmits over a wireless link the vibration and temperature data using only the existing vibration of industrial equipment to power itself: as a result it eliminates the need for a conventional source of power, such as a battery.
"We are very interested in how such new technologies can help us improve efficiency," says Martin Tillotson, Manager of Research and Development, Yorkshire Water: "We decided to conduct a trial, the first phase of which would be to ensure the microgenerator produces enough energy to power the sensor nodes and reliably transmit data.
We also needed to be confident that the device would transmit data back to a central hub without distortion or interruption".
In November 2005 six devices were installed on motors and blowers in the waste incineration plant.
This environment was chosen because it is especially harsh - there are many platforms and other steel work where there is potential for interference to the data signal.
Each piece of equipment has a unique vibration signature and the devices were installed to measure and transmit the readings of the vibration spectra.
Once the system is fully developed, should the vibration reading change (for example as a result of a bearing overheating) operators would be alerted immediately.
As a result equipment could be serviced before failure, preventing costly downtime, and could also be used to prevent any expensive, unnecessary routine maintenance.
"We are exceptionally pleased with the results so far," explains Peter Boruszenko, Research and Development Engineer, Yorkshire Water: "The microgenerators have generated enough electricity and data from day one.
They have also transmitted data reliably and without any interruption.
Tests to date show that vibration energy-harvesting is now a practical and feasible method of powering such wireless condition monitoring".
Having completed phase one and proven that the device is reliably sending data, Yorkshire Water has now embarked on phase two, and the PMG7 micro-generator has now been replaced by the next generation unit, the Perpetuum PMG17.
Yorkshire Water will now look at how best to interpret the data generated, linking it to appropriate software that will recognise trends and alert the operator when problems occur.
If this stage is successful, devices could be deployed throughout the facility and potentially at many other Yorkshire Water sites across the region.
It is hoped that in the future the device will be fitted on remote motors at isolated water sites and with further developments, the operators will be alerted to any problems directly by a text message to their mobile phone, or via the regional telemetry system.
Roy Freeland, CEO at Perpetuum explains how the technology works; "Vibration energy-harvesting uses the simple idea that vibration of a piece of plant or machinery could be turned into an electrical signal.
Using a magnet and coil arrangement, based on the Faraday Principle, we have found a way to successfully transform the kinetic energy of the vibration into a useful low-power electrical signal".
Designed to resonate at mains frequency (50 or 60Hz) with a bandwidth of +/-0.2Hz, giving excellent performance on any AC induction or synchronous motor-powered equipment, it can generate up to 5mW.
This is enough to power a wireless transmitter sending up to 6Kbytes of critical data every few minutes, or smaller amounts of data - such as a temperature reading - several times a second.
It is a practical, easy-to-install device that can operate in most industrial environments and at minimal vibration levels (25mg).
Freeland continues; "By using the device in continuous monitoring applications, valuable data about the performance and condition of equipment and machinery is given to the operators.
This data can then be used to optimise the operation and availability of plant, improve cost-efficiency of maintenance work, prevent accidents and make significant savings in energy costs".
In addition to the work with Yorkshire Water, Perpetuum has continued to develop its microgenerator product lines further, to increase the amount of useful electrical energy it can harvest.
Already the PMG17 next generation unit has installed for use with any further trials.
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