In engineering, combining a number of solutions and technologies can result in more effective systems than using only one approach on its own. In particular, it has been shown that in condition monitoring (CM), smarter maintenance systems may be obtained by integrating various sensors together. This paper extends this idea by integrating various non-homogeneous technologies horizontally. The proposed system is an internet-based condition monitoring (e-CM) prototype that can identify abnormal tension in moving belts. It is shown that by applying a classification technique, known as novelty detection, it is possible to decide the status of belt tension by processing the belt vibration signals from an optical sensor (i.e. an indirect sensing approach). A novel method for industrial network communication using XML to create a single standard format for sensor information is also used to link the sensor to the process controller via the internet using the flexible CAN bus technology; this is used together with low-cost microcontrollers with a built-in ethernet link for data acquisition and transmission. The resulting integrated approach is more efficient because: (a) it can reduce waste by minimizing process interruptions caused by direct belt inspection methods while obtaining high detection accuracy (99.67 per cent) and (b) it can provide on-line remote CM that is cost-effective, simple, standardized, and scalable across a wide area and for a relatively large number of sensors. This improvement is especially important when applied to bottleneck processes and critical components.
Automated Condition Monitoring (ACM) has become a necessity for complex modern day systems. The advent and ever increasing popularity of Internet has given a new dimension to ACM. Many Internet Based Condition Monitoring (IBCM) solutions have since been implemented. There are many types of Industrial Networks that are used in the industry to implement ACM. The protocols and information sent through these networks are very different from one another. Sharing information between industrial networks and presenting it for consolidated monitoring can be a daunting task. This paper describes a novel way for extracting sensor information from different industrial networks into a single standard format using Extensible Markup Language (XML). Implementation of the solution with an Industrial Network, Controller Area Network (CAN), is also shown. The results demonstrate that by using this approach communication between automated systems and mechatronic devices will become more integrated, more efficient and less complex.
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