Machine Condition Monitoring Market

Machine health monitoring is a process of supervising the machinery to identify considerable changes that indicates a fault. The use of machine health monitoring system allows timing for maintenance to be scheduled in a manner that prevents the failure of system and thus avoid its consequences. Machine health monitoring system benefits machinery by identifying the fault before it develops into a major failure. The growing importance of asset management and manufacturer’s drive to optimize productivity and increase efficiency of plant is driving the demand for machine health monitoring equipment market.

Additionally, increasing emphasis on asset utilization and the rising need for elimination of possible machine breakdowns which may lead to redundant maintenance costs has led to an increased adoption of this technology. This technique is generally used on rotating equipments and other machinery such as electric motors, pumps, presses and internal combustion engines. Manufacturing processes, such as breweries and oil refineries, employ monitoring systems, to measure critical parameters. This system makes use of sensors for the purpose of monitoring the machines. SCADA (Supervisory Control and Data Acquisition), is used to analyze information and provide data.

This system is used to monitor current and historical performance of equipments. Machine health monitoring facilitates prediction of machine failure which minimizes production losses, by planning corrective activities beforehand. This technique is primarily aimed towards reducing cot and repair time and is considered to be an efficient strategy in the manufacturing industry. Machine health monitoring involves strategic tools which help in decision making processes.

Various products of machine health monitoring systems are corrosion monitoring equipments, thermograph equipments, lubricating oil examination equipments, ultrasound emission equipments and vibration monitoring equipments. These products make use of various components such as spectrometer, corrosion probes, spectrum analyzer, ultrasonic detector, thermal camera and vibration sensor. The rising need for a system to decrease the risk of unforeseen machine failures and implementation of planned preventative maintenance techniques has increased the demand for machine health monitoring system Obtaining a return on investment from the installment of machine health monitoring system, and irregular maintenance cycles which may require certain modifications in existing machinery to fit the new systems are some of the factors that are constraining the growth of the market. Smart sensors development, vibration sensor machinery and development of Internet of Things (IoT) for machine health monitoring are some the current trends in this industry that are likely to drive the market during the forecast period.

Currently, North America accounts for the largest market share. The growth is mainly driven by the technological advancements in the industrial processing which in-turn have increased the adoption of machine health monitoring systems in this region. However, with growing manufacturing bases of the major market players in automotive, semi-conductor and consumer electronics sectors, Asia-Pacific is expected to be the key contributor for the market growth among all the geographic regions in near future

Where the often quoted ISO 10861-21 falls short for CMS

There is dire need for the system certification of condition monitoring, mostly because current CMS vendors offer at least nine different approaches for basic sensor selection and placement. This confusion originally prompted the call for a certification for owners to assist in the selection of a viable CMS for wind.

After speaking at recently NREL and UVIG events, I was asked if there was a certification for CMS systems in the wind industry. The answer is yes…and no. To investigate further, we will go through the available standards for CMS in wind to find what is helpful.

The standard for vibration in wind turbines is listed as ISO 10816-21. This ISO standard states it “does not apply to diagnostics or fault detection.” It also states that the vibration “evaluation zone boundary values are not intended for use as acceptance values. These must be agreed upon between the manufacturer and user.” So how does the standard help?

To be clear, if you adhere to ISO 10816-21, there is no guarantee you will have a successful CMS program. Also note that the standard applies to a rather wide range of wind turbines, from 200 kw up to 3-MW ratings.

So, what does the standard suggest regarding monitoring? It suggests the use of piezoelectric accelerometers and separates equipment into rotating and non-rotating components.

For rotating components, the standard suggests:

Sensor placement – For rotating components (drive train is a given), it advises the use of sensors in three axis across the drive train. This is not standard for many reasons. Using accelerometers in three axes is not beneficial in determining a failure component. A single sensor can work except when determining some defects. However, as this standard states, its purpose is not intended to measure specific defects.

The main bearing – Three-axis measurements are recommended but not demodulated readings for detecting early bearing defects, nor time waveform measurements. The standard makes no suggestion for the number of lines-of-resolution in the spectrum, averaging, or overlap.

Gearbox – Three-axis measurements again but no demodulated reading for early bearing defect detection nor time waveform measurements. No suggestion for lines-of-resolution in the spectrum, averaging or overlap.

Generator – Three-axis measurements yet no demodulated reading for early bearing defect detection nor time waveform measurements. No suggestion for lines-of-resolution in the spectrum, averaging or overlap.

Number of sensors

It is not practical to use the suggested 17 sensors across the drive train. Typically, most commercial CMS systems use 7 to 8 sensors. Seventeen of them are cost prohibitive. They will also generate too much data. Consider that 7 to 8 sensors installed on 100 towers will produce an annual data volume is in excess of two-million measurements based upon once-a-day intervals.

Using three sensors on a generator bearing to find a bad bearing within is simply not practical. Installation costs go up, data volume increases, hardware costs double, and network load increases as well to get the data out. So this portion of the specification is simply not practical.

On Non-rotating equipment:

Sensor placement – The standard suggests three axes in two locations to monitor the bedplate of the tower for structural purposes. This is more for a process and controls purpose than a condition-monitoring function. Most bedplate monitoring I have been involved with is at a prototype level, certainly not at a fleet level.

Number of sensors – The standard specifies installing eight low-frequency sensors. Again, as with 17 sensors on the drive train, adding eight expensive low frequency sensors is not a good suggestion. It is doubtful that any owner would install eight sensors per tower to understand the vibration of the structure.

Measurement parameters – The standard suggest performing evaluations in 10-minute periods. This really requires specialized equipment. It is certainly not something that is fleet advisable. At 10 minutes per tower, the data volume would be significant, and the data storage and analysis substantial.

Vibration levels – The standard suggests measuring only acceleration and velocity. The accompanying chart (above) shows overall vibration levels in velocity measurement units.

Other standards

ISO 10816-21 standard does not give the end user guidance for acceptable vibration levels, diagnostics, or fault detection. So what can it offer the owner? It does advise as to structural vibration measurements and parameters as well as sensor types and placement. To be clear, not one CMS system commercially available today, marketed and installed, meets this standard.

However, portions of two other suggested standards might be helpful to owners. They are:

• VDI 3832, for rolling element bearing noise and vibration. This also has a wide range of application in wind turbine size. And,

• ISO 13373-2, techniques for bearing and gearbox defects analysis.

So between rotating and non-rotating components, the suggested 25 sensors per tower is literally three times the amount normally installed. Owners show pause at the current eight-accelerometer pricing per tower. Twenty-five is likely not realistic.

Here is what’s missing and crucial to a successful CMS program:

Quality of the sensors – There are at least 10 to 12 sensor factors that are not covered. Cables are not even discussed.

Ability of the software – There are no specifications on measurement parameters, measurement types, resolution, averaging, and a dozen other measurement factors.

Ability of the analyst – There currently are three companies that certify vibration analysts. It certainly makes sense to have an analyst who is certified but this is no guarantee that the person is a good analyst. Ironically, the certifying bodies that teach the theory and background of vibration analysis measurements, teach very little on actual vibration analysis.

We will discuss these important factors in a following article. We will also look at what makes sense for a standard for CMS installs to benefit the owners, ISPs, and manufacturers. 

Source: http://www.windpowerengineering.com/featured/often-quoted-iso-10861-21-falls-short-cms/ 

Vibration sensor market projected to hold automotive industry as the fastest growing segment till 2020 according to market forecasts

According to the report “Vibration Sensor Market Analysis: By Technology (Capacitance, Piezo-resistive, Strain Gauge) By Material (Ceramics, Quartz, Silicon) By Industry (Automotive, Nuclear, Consumer Electronics, Machine & Structural Monitoring, Mining) Forecast - (2015 - 2020)”, published by IndustryARC, the Vibration Sensor Market in automotive industry to reach $881.3 million by 2020

The Vibration Sensor Market has witnessed significant deployment rate in the past few years majorly in automotive and aerospace industry. The vibration sensors in automobiles perform real time monitoring of the automobile mechanical systems in order to prevent breakdown and intimate the drivers beforehand.

The vibration sensor market in automotive industry is projected to attain market worth of $881.3m by 2020 as per the IndustryARC analysis. The recent advancements in the automobile systems such as driver assistance systems, commercial telematics solutions have embraced the sensor technology at an extensive level and have perforated high ends market of the automotive industry. OEMs are constantly making efforts to make these technologies accessible to a larger customer base rather than serving the niche segment.

The awareness among the end users has remarkably increased and is acknowledging the offered technology. Europe and North America are the dominant regions in the vibration sensors market owing to the presence of leading end user industries in nations such as The U.S.A, Canada, Germany, and the U.K.

Maintenance and Safety of the equipment has always been the prime objective of the manufacturing industry. A number of solutions has been developed integrating electronics into the mechanical components to improve the operational efficiency and minimize the complexity of the process.

Vibration sensors help to analyze the frequency and intensity of vibrations in order to take decisions regarding performance, production and quality of the object in various industries. These sensors are extensively used to determine the specific cause and location of machinery problems.

Vibration sensors are capable of measuring and analyzing displacement, linear velocity, and acceleration. These sensors primarily facilitate measurements of vibration displacement, velocity and acceleration.

With the development of computer technology, electronic technology and manufacturing process, a variety of vibration sensors have drawn attention and importance in various industry verticals. With the shift towards intelligent or automatic monitoring of machinery in manufacturing plants, vibration sensors market is estimated to benefit hugely and grow significantly in coming years.

Apart from automotive, vibration sensor has revealed promising applications for equipment maintenance in non-destructive testing, nuclear, oil & gas industry. Nuclear power plants majorly depend upon vibration monitoring systems for ensuring continuous power generation and safety of personnel and equipment.

Nuclear reactor outage costs are very high and thus unexpected downtime may lead to enormous losses to the company. Thus approximately 90% of the operation cost is utilized for the monitoring of machinery health using equipment such as vibration sensors.

In Oil & Gas industry, the vibration sensor market is speculated to register double digit CAGR by 2020. Vibration monitoring systems are highly effective in determining machinery health, planning maintenance intervals, reducing downtime and avoiding catastrophic loss.

Sensors offering hazardous area approvals are widely used on gas and oil well heads, supply lines, natural gas power engines, multi-stage gas compressors and other machinery operating in hazardous environments.

Source: http://industryarc.com/Report/165/Vibration-Sensors-Market-Forecast.html 

Vibration sensor helps analyze sense of touch

Type an email on your computer. Raise a glass to your lips. Feel for the light switch in a dark room. Simple, everyday tasks can demand subtle interactions between our hands and our surroundings, but, surprisingly, much remains unknown about the mechanics of the sense of touch.

"Most people don't have a very clear picture of how touch sensation actually arises," said UC Santa Barbara faculty member Yon Visell, an assistant professor in the Department of Electrical and Computer Engineering and in the campus's Media Arts and Technology graduate program. While people are familiar with touch as consisting of the interaction between two surfaces -- the skin and whatever it is in contact with -- they are less aware of the subtle ways that touch sensing helps us to identify and navigate our surroundings, he said.

For instance, if your fingers are numb, you may still be able to move them, but be hesitant to pick up an object or send a text message, because of the lack of sensation -- think of what happens when your foot or arm falls asleep. According to a study co-authored by Visell that appears in the Proceedings in the National Academy of Sciences, our hands in particular have access to rich tactile information that travels far beyond the tips of our fingers. This may help to explain some remarkable capabilities of the sense of touch -- why, for example, people whose fingers have been anesthetized are still able to feel fine surface detail, as has been demonstrated in prior research.

"The way they seem to be able to do this is by using mechanical signals, or vibrations, that travel beyond the fingers, farther up the arm," said Visell. "The hand has specialized sensory end organs distributed widely in it that can capture such mechanical vibrations at a distance."

Their study used a specialized array of tiny accelerometers, or vibration sensors, worn on the sides and backs of the fingers and hands. With this device, the researchers were able, for the first time, to capture, catalog and analyze patterns of vibration in the skin of the whole hand that were produced during active touch. Actions such as tapping and sliding one or several fingers over different types of material, as well grasping, gripping and indirect tapping (using an object to tap on a surface) all gave rise to distinctive vibration signatures. "We can liken this to the different ways that a bell will sound if it is struck by a metal hammer or a rubber mallet," said Visell.

"How do those signals reflect what it is that we're doing and what it is we're touching? Do parts of the hand nearer to the wrist receive significant information about the shape of the object that we're touching, what it's composed of, or how we're touching it? How are different parts of the hand involved in touch sensing?" Visell said of the fundamental questions that motivated his group to pursue this research. "It is possible that the hand, like the ear, is able to use vibrations produced through contact in order to infer what is being touched, and how the hand is touching it."

According to the study, the vibrations generated through touch, and the distribution of vibrations in the hand, depend very closely on the type of action and the object being manipulated. For instance, vibration patterns produced by tapping a single finger were stronger than those made by grasping, gripping or sliding, but were much more localized in the finger. The patterns of vibration throughout the skin of the hand also varied according to the number of fingers used, the object being manipulated and the action being performed. Tapping the index and middle finger alone was sufficient to elicit vibrations that covered most of the surface of the hand. Even the size of the object being grasped - for example, whether a glass was small or large -- influenced the vibrations that were felt by the hand.

The applications for the information gained in this study are many. They may contribute not only to the foundations of our understanding of touch, but also contribute to fields such as virtual reality by enabling wearable technologies that allow the user to feel if he or she is picking up a feather or a brick while visiting a virtual world. This work may also enable robots to touch and interact more effectively within changing and uncertain environments, and allow future generations of prosthetic hands to provide their wearers with more natural touch feedback, enabling a greater range of functionality to be restored.

Source: http://www.news-medical.net/news/20160329/Vibration-sensor-helps-analyze-sense-of-touch.aspx 

PIEZOELECTRIC SMART MATERIALS GLOBAL MARKET2016-2020

A new report has been added by wiseguyreports in its research database. This market research study segments the global piezoelectric smart materials market by type (ceramics, polymers, and composites), by application (motors, transducers, sensors, and building materials), and by end-users (transportation, healthcare, leisure and sports, construction and infrastructure, and agriculture and food). This report also segments the industry by geography (the Americas, APAC, and EMEA). The key vendors identified in the market are AAC Technologies, Advanced Cerametrics, Arkema, KYOCERA, and Solvay.

Outlook of the piezoelectric smart materials market

Smart materials are special building materials whose properties change when subjected to external stimuli such as stress, temperature, moisture, pH, or magnetic field.  Piezoelectric materials are a class of smart materials that produce a voltage when mechanical stress is applied. These materials are widely used in sensors and help in measuring fluid density, the force of impact, and fluid composition. Technavio’s market research analysts have estimated the global piezoelectric smart materials market to grow at an impressive CAGR of close to 13% over the forecast period. The increasing demand for piezoelectric smart materials from the military and aerospace sector is expected to drive the market for piezoelectric smart materials globally. These materials help in controlling the airflow across the wings of an aircraft and maintaining it during take-off and landing. Furthermore, these materials are also used to solve common problems with the aircraft, such as engine vibration, high cabin noise levels, ice formation on wings, flow separation due to turbulence, and control surfaces in cold climatic conditions. Also, piezoelectric materials find extensive applications in military and defense sector like smart sensors, smart nanorobotics, smart combat suits, and smart skins. Therefore, the numerous applications of piezoelectric smart materials in military and aerospace industry will spur the growth of this market until the end of 2020.

In this market research study, analysts have estimated factors like the increasing applications of piezoelectric materials in nanotechnology to impel the prospects for market growth until the end of the forecast period. For example, piezoelectric smart materials are used in the manufacture of smart nanofibers that are used in light-emitting transistors and advanced organic solar cells. The recent advancements in the nanotechnology sector will, in turn, bolster this market’s growth potential during the forecast period.

Segmentation by application and analysis of the piezoelectric smart materials market

• Motors
• Transducers
• Sensors
• Building materials

During 2015, the automobile motors industry dominated the piezoelectric smart materials market with a market share of more than 60%. Factors such as rapid growth in the automobile industry will translate into the demand for piezoelectric materials during the forecast period.

Geographical segmentation of the piezoelectric smart materials market

• Americas
• APAC
• EMEA

In this market study report, the analysts have estimated the Americas to be the largest market for piezoelectric smart materials during the forecast period. The increasing demand for MEMS sensors, used in airbags and anti-lock braking systems, will translate into the demand for piezoelectric smart materials in the Americas. The market for piezoelectric smart materials will account for a market share of more than 47% until the end of 2020.

Complete report in detailed: https://www.wiseguyreports.com/reports/global-piezoelectric-smart-materials-market2016-2020

Global Vibration Sensor Market is Expected to Exceed USD 33 Billion by 2020

Technavio analysts forecast the global vibration sensor market to post a CAGR of over 6% during the forecast period. In order to calculate the market size, Technavio considers revenue generated from the sales of vibration sensors in the following application segments: aerospace, automotive, industrial machinery, healthcare, and consumer electronics.

The four major factors responsible for the growth of global vibration sensor market are as follows:

1. Stringent road safety regulations
2. Rising need for machine monitoring
3. High demand for effective maintenance
4. Slow replacement cycle of old machines

Read full article: http://www.businesswire.com/news/home/20160201005500/en/Technavio-Expects-Global-Vibration-Sensor-Market-Exceed 

Contact-Free Monitoring - Enabling Technologies & Emerging Opportunities (Technical Insights) : Monitoring every moment without physical presence

Contact-free monitoring (CFM), an emerging technology domain is likely to impact applications related to automation, digitalization and smart devices. This technology aids in monitoring and detecting motion of a moving object or human activity. CFM employs advanced sensors to monitor properties such as temperature, vibration, speed, phase, velocity and direction of the object. CFM introduces new dimensions to healthcare market by effectively measuring patient movements, pulse rate, heartbeat, sleep timing and many other vital parameters. The report captures advanced sensor technologies used for contact-free monitoring such as Micro Doppler sensor, Thermography sensor, Micro Wave sensor and Fiber Bragg Grating. The main application of contact-free monitoring is automation; however the technology finds use in many new sectors such as Health Care, Industrial Process Control, Automotive & transportation and Aerospace & Defense. Smart cities, smart house, Internet of Things also enable faster adaption of contact-free monitoring. The research service focusses on covering emerging opportunities of contact-free monitoring. The modules of the report include: technology significance, current trends, applications landscape, enabling technology and emerging opportunity assessment.

Key Findings – Enabling Technology and Application Impact

Sensors play a key role in facilitating adoption

Sensor technology has advanced to an extent that it now plays a vital role in many application segments such as Health care, Aerospace, defence, Automotive and transportation. Sensor technologies are used for monitoring, tracking and detecting purpose, thereby helping us analysing object and activities. 

-Contact-free monitoring is an enterprise system that embeds multiple applications to monitor and provide solutions without touching the object or humans. 

Contact-free monitoring finds potential use in health care applications where there is a need for continuous and real-time monitoring of patients. This improves the quality and accuracy of the treatment. Moreover, Contact-free monitoring is enabled by wireless communication, touch-free technology, advanced sensors, and smart devices.

Application Impact

The impact of contact free monitoring in applications areas such as healthcare and security industry is immense and is expected to delivers numerous benefits to the users. 

-Applications which are majorly impacted in the healthcare industry include monitoring patient activity in hospital beds, analysing their’ physical conditions and their response to medical treatment. 

-Future applications of contact-free monitoring in this industry would include analyzing, monitoring, and recording details about the specific body functions such as, functioning of heart, blood profile, pulse, brain activity, kidney, and liver.

-Contact-free monitoring is expected to have a high influence in the security industry for applications such as tracking of speeding vehicles, detecting driver information from vehicles, remote monitoring of vehicles, monitoring cargo movement, and remote tracking of illicit cargo activity.

Read the full report: http://www.reportlinker.com/p03551346-summary/view-report.html

India to develop its FIRST anti-tank mine

Instead of procuring from US or Israel, country's defense forces will soon be self-reliant with the first indigenous off-route or anti-tank mines. These are improvised explosive devices (IEDs), which explode like a projectile while camouflaged and placed on a tripod stand.

The mine, unlike conventional mines, is not buried underground and needs no pressure when placed underneath a vehicle for activation. To be developed by the Terminal Ballistic Research Laboratory (TBRL), a Defense Research and Development Organization (DRDO) laboratory in Chandigarh, and the Central Scientific Instruments Organisation (CSIO), the mine is used in surfaces where underground burial is not possible. The project began six months ago and was reviewed by DRDO experts early this week. It is expected to be completed in another four years.

The incoming target combat vehicle shall be detected using seismic and acoustics sensors, which shall be made by the CSIO. The sensors fitted in these mines can detect seismic vibrations produced when vehicles such as tanks head towards ambush area. When acoustic and seismic sensors detect approach of a suitable target, the infra-red sensors (IR) in it are also activated. These IR sensors can send images of the target for attack. Consequently, after the target is confirmed, all these sensors trigger the warhead of the mine to project towards the target as it comes before it.

The TBRL plans to have a smart mine trap using these anti-tank mines. "Until the target does not approach, the off route mines can be kept on sleep mode, which can conserve the battery required for its operation," said Manjit Singh, director TBRL. He said, "We are working with CSIO on production of special seismic sensors, which can detect the potential target approaching us and also give a wake-up call to the operator as soon as the target approaches."

The anti-tank mine is portable and suitable for both offensive and defensive operations. The range of the off-route mine is 2 to 97 meters. The collaborators are working towards enhancing the range. The CSIO already has special sensors, being used in Delhi metro, to provide advanced earthquake warning system. "These sensors shall be improvised and worked upon for defense application," said CSIO director R K Sinha.

How it works

• The off-route mine is placed in the range 2-97 m from the target on a tripod stand
• It does not require any pressure of a vehicle for explosion
• These mines cannot be detected easily
• Its acoustic vibration (seismic) and infra-red sensors are triggered when a combat vehicle nears the trap, the mine is activated and shoots off a projectile.

Read the full article: http://timesofindia.indiatimes.com/city/chandigarh/India-to-develop-its-first-anti-tank-mine/articleshow/50214894.cms