Radio Frequency Smart Sensors-Installation

Physical Installations:
The first step in the installation process should be a site survey. Typically, the PDM program determines the locations of the RF Smart Sensors. The location of the RF Transceiver, however, is dependent on the plant environment (i.e., building layout) as well as the location of RF Smart Sensors 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 Smart Sensors 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 Smart Sensors 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 Smart Sensors are then ready to be mounted on the desired machine, with the recommended method. Once the RF Smart Sensors are installed, placements 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 Smart Sensors. 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 Smart Sensors 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 Smart Sensor 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 Smart Sensors that would otherwise be out of range.

RBMware Use:
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 Smart Sensor points can be included in any route. Once RF Smart Sensor data has been collected, the route is uploaded to RBMware as usual. Analysis and trending of RF Smart Sensor data uses the standard RBMware tools.

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 Smart Sensors and RF Transceivers are created in RBMwizard during database setup via an RF Smart Sensor 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 is an aid during physical installation.

Four measurement points (vibration, PeakVue, battery life, and temperature) are automatically generated in RBMwizard for each RF Smart Sensor created. Individual measurement points can be edited by any of the RBMware tools. However, only in RBMwizard can the entire RF Smart Sensor or RF Transceiver be edited. In addition, only one instance of the same RF Smart Sensor measurement point can exist on any given application.

Data Collection and Analysis:
RF Smart Sensor 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 Smart Sensor contains up to four measurement points and because data is collected from the RF Smart Sensors via the RF Transceiver, the user is offered a variety of collection options. These include collection of a measurement point, an entire RF Smart Sensor, 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 Smart Sensors are likely to be out of range. RF Smart Sensor 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 is 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.)

Prospective Applications:
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.

Conclusions:
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 Smart Sensor, 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. Research on improving this technology is on by many industries as there is wide potential in analysis and maintenance of machines using this technology.