iVP3 -
Smart
Vibration Sensor

and early defect detection systems based on it

Why is it necessary?

Large industrial facilities that operate rotating equipment and are interested in implementing advanced lifecycle optimization systems face the following challenges:

  • The high cost of available systems on the market, making it uneconomical to equip up to 70% of the rotating equipment fleet with fixed systems that could potentially be equipped with them if the cost of these systems were significantly reduced, which is not possible with the current architecture of their design.
  • High cost of «entry», leading to the fact that enterprises cannot do a pilot implementation of systems in order to obtain meaningful information about the feasibility of large-scale application of systems of this class at the enterprise.
  • Moral obsolescence of systems even before they are put into operation.
  • High cost of the life cycle of these systems.

Elimination of the above disadvantages could, according to our estimates, increase the market capacity of early defect detection systems for rotating equipment by an order of magnitude. Now in annual terms, we estimate the Russian market in the order of 5-7 billion rubles.

What we offer?

IVP3 - Smart Vibration Sensor

Our company NPP VartPro has developed an approach that allows to eliminate all the disadvantages of existing systems on the market and give the market a budget ultra-modern system built with the latest advances in the field of digitalization.

The system consists of three components:

  • The iVP3 smart vibration sensor
  • The cloud-based iVPCloud system
  • iVPScada, a tool for building user interfaces.

The iVP3 is the only non-standard hardware component in the vibration channel. The general view of the sensor is shown in the figure.

Dimensions

The sensor dimensions are the same as a conventional industrial piezoelectric sensor and have identical connection dimensions.

High-performance digital processor

The sensor is equipped with a high-performance BlackFin digital processor. This allows not only digitization, but also deep digital signal processing. Digital filtering in the system and user bands, signal integration, calculation of a large set of detectors (RMS, peak, sweep), envelope extraction, spectral processing are implemented.

Unlimited measurements

The sensor calculates user-configurable diagnostic signs of defects, the number of which is almost unlimited.

Interfaces and Security

The sensor is equipped with an Ethernet PoE type A interface. Supported protocols are http, udp, tcp, mqtt. Work on public channels is carried out over a secure connection (TLS v1.2). Authentication and authorization of each sensor is supported when communicating with the cloud. The sensor is explosion-proof (1Exd).

Sync

The sensors can synchronize the sampling to within a few microseconds, which allows phase response diagnostics to be performed at various points on the machine without the use of a RPM marker.

iVP3

General view of sensor

Benefits

Typical components

Radically reduce the nomenclature of non-typical components at the site. No specialized devices other than the sensor itself are needed to collect information from the sensor. These devices (elements of industrial LAN) are widely available on the market, have high reliability and low price. There is a wide choice of alternative suppliers.

Easy Maintenance

Radically simplify system maintenance. This can be done by specialists of IT department of an enterprise. No special knowledge and skills, other than the ones possessing these specialists, are required.

Reduced traffic

Substantial reduction of network traffic. According to the most conservative calculations, you can cut the traffic by two orders of magnitude. This feature will be explained in the description of the iVPCloud service.
Reducing costs.

Reducing costs

Significantly simplify data integration into existing systems in case an operator has a desire to avoid using cloud components of our solution.
Get an easily or, in the case of the cloud, an unlimitedly scalable solution without having to incur additional capital costs.
Significantly save on design, installation and commissioning costs. In the case of cloud deployment, all commissioning is done remotely.

IVP3 Smart Vibration Sensor

IVP3 Smart Vibration Sensor

iVPCloud

Although the iVP3 is designed to be used efficiently in a traditional on-premise fashion, where the entire top-level infrastructure is deployed on the operator’s physical premises, the real power of the device comes when it is used in conjunction with iVPCloud.

The IVPCloud is a system built using standard components of any modern cloud infrastructure, viz:

IoT services such as:

  • Pub Sub Broker service (Subscription and Publication Broker)
  • Device Shadow (digital twin of a device)
  • Device provisioning (software updates, update testing)

IAM service (identification and access control):

  • noSQL database (high-performance data storage)
  • Serverless (dynamic allocation of processing power, lambda functions)

API Gateways (gateways for creating data access points)

Ability to integrate with other cloud services when available — alerting systems, load balancers, fault monitoring, machine learning tools, and much, much more.

services allow:

Apply push technology to pull information from sensors.
All diagnostic systems without exception use pull technology (this is the way all major industrial protocols are designed). The master device continuously polls the slaves and pulls current information from them. Most units operate in stationary mode and nothing happens to them, but data are collected at intervals of once every second or two and stored in the archive. The result — the load on the network, puffing archives with empty, unnecessary information. Moreover, in the case of vibration measurements, oscillograms are very often collected. From one measuring point up to 30000 samples have to be picked up in one second!!!
In our system, the sensor can independently analyze the need for data transmission. Seeing the problem, it uses the mqtt protocol to publish the data to the appropriate IoT topical of the broker. And then this data goes to the services subscribed to this information. This approach RADICALLY reduces the load on the network and on computing resources. Data is transmitted only when it contains meaningful information, and only to those who need that information.

Apply the most advanced multi-level system of identification, authorization and access control, thereby eliminating unauthorized access to data.

Perform distributed processing of measurement results on several levels, further compressing storage capacity and increasing informativeness of the data.
This property is extremely useful and has a whole spectrum of use cases. Here is a typical example: in conventional diagnostic system diagnostics is performed by executing programs on the server collecting the data. Any change in the algorithms, not to mention the expansion of the functionality of the program itself, requires the intervention of specialists from the system supplier. It is long and expensive and, moreover, may cause errors which may potentially cause failure of the whole system. In addition, expanding capabilities is limited by the hardware resources of the server and is not always possible in principle.
In our proposed system, each algorithm (or group of algorithms) is a lambda function, triggered by a rule included in the IoT service, bound to the broker tops that contain the data it needs. The cloud runs as many lambda functions as needed. The result of these functions can be placed in a database, republished in other broker tops, and alerts can be sent using the cloud’s notification services. This gives flexibility, unlimited possibilities to increase the functionality, the possibility of service failure as a whole is excluded, the client receives new features in real time, there is no need to update anything on the spot.

You pay only for the resources you need.
When installing hardware, the client must set aside reserves for development. In addition, these costs have to be incurred RIGHT AWAY. In the case of cloud serverless technology, the customer only pays for the computing power that is currently in use. The bottom line is, firstly, that he pays less. And secondly, the payment is spread over the lifetime of the system, reducing the net present value of costs and increasing the financial performance of the project.

Have the ability to expand the system unlimitedly, without fear that the network and/or computing resources are not enough.

Always use the latest system features, without the need for software upgrades. All you need to use the system is a browser on the most resource-constrained machine.

Easily integrate your corporate information systems with the data supplied by this system.

IVP3 Smart Vibration Sensor. Dimensions

IVP3 Smart Vibration Sensor. Dimensions

iVPScada

Conventional SCADA is a software product consisting of two parts — the executive environment and the configuration environment. The executive environment is a monolithic software, which is executed at the customer’s facilities and performs all the basic functions inherent in the upper level of the control system:

  • Collecting information from terminal devices and/or exchanging information between nodes
  • Information normalization and processing
  • Providing a control interface
  • Event logging
  • Generation of trends
  • Displaying mimics with measured process parameters
  • Data archiving and logging

The configuration environment is used to configure the runtime environment to work with specific hardware and control/monitoring object.
This approach has a number of serious drawbacks, such as:

  • The need to purchase and install specialized system and application software on workstations.
  • Difficulties arising when updating this software in order to remove bugs and add extra functionality.
  • High probability of failures of the whole system in case of failure of any of subsystems. For example, an unprocessed error in a trend visualization subsystem can lead to a failure of the entire system.
  • High latency when the information scale increases. The system starts to «slow down» noticeably.

The iVPScada uses a different approach. All the main functions of the executive subsystem are performed in the cloud. And all the work is organized as the interaction of microservices. Only visualization works on a client’s workplace, which uses an ordinary browser as an environment. The interfaces are made in the form of controls, subscribed to updates of services. The configuration subsystem allows you to configure the microservices using the SDK and/or cloud component APIs.

All updates are performed automatically, the client always works with the most recent versions of microservices
Every microservice failure does not affect other microservices. The system is much more reliable
The system is infinitely scalable, the processing power is dynamically allocated
No problem with hardware obsolescence
Number of jobs and their location is arbitrary.
System is reliably protected from unauthorized access
Hardware failure/data loss is nearly impossible, but even if an abnormal event does occur, it can be resolved within minutes.

Comparison to competitors

In the table below we have given a comparison with both sensors and vibration monitoring and diagnostic systems. This is done to demonstrate that the sensor has the cost of the channel at the level of the most budget sensors. At the same time, it provides the functionality of specialized systems, which have a higher channel cost, without taking into account the top-level software.

Besides, the following important points are often not taken into consideration when choosing one or another solution:

  1. Installation of the sensor with built-in or remote electronics, which performs the function of detection (say, calculation of RMS and transmission of the signal proportional to its value), destroys all the diagnostic information contained in the signal, which could be used for early detection of defects.
  2. Obtaining information from the sensors requires digitizing the analog signal, which means purchasing, in addition to the sensor, devices that perform this operation. Even the most budgetary devices add about 3-5 thousand rubles to the price of the channel. However, in many cases expensive analog AC inputs (10-15 thousand per channel) are used to receive the signal, which are always in short supply and could be used for other purposes.
  3. Many sensors with a digital output also require an additional specialized device for each channel or group of channels. For example, the RS-485 interface has limitations on the length of bus leads of the order of a meter, while typical solutions involve running cables from sensors to the cabinet for tens or even hundreds of meters, which makes combining them into a bus in that cabinet impossible.
  4. Most sensors with a digital output also transmit the detectors calculated in the sensor itself and are not designed to collect diagnostic information, let alone process it in the sensor itself.

The iVP3 lacks all of these disadvantages. Even if the customer does not consider early diagnosis of the equipment, limited to measuring the overall vibration level, the use of iVP3 will provide an advantage compared to the cheapest solutions on the market. What’s more, if diagnostics are still needed later, you don’t have to retrofit anything — you just have to install the appropriate top-level software.

If the customer needs a diagnostic solution, iVP3 obviously offers significant savings compared to specialized complexes, while some of its features, such as high-precision synchronization of any number of measurements, are not available even for these systems.



Availability of matching devices, secondary devices

IoT protocols support

Channel synchronization without marker

Built-in diagnostic feature calculation with Modbus TCP/IP transmission

PoE power supply

Explosion-proof design

Digital output

Real-time digital processing

Spectral processing with Modbus TCP/IP transmission of results

Sensor dimensions

Ethernet, Modbus TCP/IP

iVP3

no need

yes

possible

yes

yes

yes

yes

yes

yes

h43, Ø25

yes

Vibrobit 300

need

no

no

no

no

no

yes

yes

yes

not applicable

yes

Bently Nevada 3300

need

no

no

no

no

yes

yes

yes

yes

not applicable

yes

IFM

need

no

no

no

no

yes

yes

yes

yes

not applicable

yes

B&K

need

yes

no

no

no

yes

yes

yes

yes

not applicable

yes

SPM

need

no

no

no

no

yes

yes

yes

yes

not applicable

yes

PCB

need

no

no

no

no

yes

no

no

no

h42, Ø17

no

IVD-3

no need

no

no

no

no

yes

yes

no

no

h65, Ø47

no

VK-310

no need

no

no

no

no

no

no

no

no

h58, Ø40

no

VK-312,

VK-315

need

no

no

no

no

no

no

no

no

h38, Ø21

no

VTV122

need

no

no

no

no

no

no

no

no

h63, Ø22

no

DVA dig.

need

no

no

no

no

no

yes

yes

no

h43, Ø39 or

h60 Ø23

no

МВ-43

need

no

no

no

no

no

no

no

no

h45, Ø22

no