Project: MOBIle-based tool for Mechanical Manufacturing Equipment

Keeping machinery and productions equipment in good operating conduction to prevent failures and a consequent production loss is the COtenance department’s primer objective. It is proven than a successful implementation of predictive COtenance practices is likely to be a very worthwhile endeavor for almost any industrial plant. Life Cycle Engineering (LCE) reported the following results from over 500 plants around the world, in various industries, that had been practicing predictive COtenance for at least three years:_x000D__x000D_• COtenance costs reduced by 50-80%_x000D_• Machine breakdown reduced by 50-60%_x000D_• Spare parts inventory reduced by 20-30%_x000D_• Machine downtime reduced by 50-80%_x000D_• Overtime premiums reduced by 20-50%_x000D_• Machine life increased by 20-40%_x000D_• Productivity increased by 20-30%_x000D_• Profit increased by 25-60%_x000D__x000D_However, predictive COtenance program and services are very often unaffordable for SMEs since they required a major expenditure, training is needed for personnel and high COtenance costs of the system (hardware, software updates, etc). These elements required considerable funding and high costs that might be sustainable for large corporations but it is definitely not sustainable for SMEs. Therefore there is a need for low-cost monitoring system for detecting malfunctions._x000D__x000D_The most important challenges for an effective predictive COtenance tool of equipment comprises of three major elements with key different aspects. The first one covers the collecting method, which has to provide relevant, accurate and reliable data from the production equipment. The second one is related to the intelligent analysis and how it is integrated into the production, which has to offer a real-time prediction using historical data extracted from different data sources (sensors, actuators, etc). The third one, and the most important for the end-users, is the representation and interpretation of the results of the smart analysis to plan and schedule the COtenance operation of the production equipment in an intuitive._x000D__x000D_This project will address the above challenge by developing a low-cost and sustainable tool for COtenance of production equipment based on wirelessly monitoring. An advanced wireless sensor network fitted vibration-based energy harvester to prolong operation of battery-powered sensor node, it will be designed to collect measurements of the production equipment (vibrations, energy consumption, etc). All the monitored data will be processed and analyses at the node level taking advantages of the new microprocessors and memory capacities of embedded devices. Algorithms will be designed and implemented at node level to provide real-time and adjusting predictions to new conditions. A visual and intuitive mobile-based user interface will be designed and implemented in order to transform the problem of information overload into an opportunity providing insights in a visual and intuitive manner in order to facilitate the interpretation of the recommendation and results of the COtenance of the productions equipment. The developed tool will be installed, validated and assessed in a Lithuanian factory. _x000D__x000D_Enclosed with this application form, it is submitted a draft of the consortium agreement where IPR access, exploitation and management issues are presented. In accordance with the CA, the generated knowledge will be the property of the Ps generating it. The project brings the following Ps that will carry out the following activities to achieve the project goals:_x000D__x000D_• INETSIS: Advanced Modular Sensor Node (Design and Implementation of hardware and Embedded software)_x000D_• KTU – Faculty of Mechanical Engineering: Energy harvester to prolong operation of battery-powered sensor node and methodology for vibration signal analysis in order to detect tool anomalies in advance_x000D_• MTP: WSN software development and Web Application to access web-services included in the node._x000D_• BCT: As Lithuanian SME mechanical manufacturer, definition of predictive COtenance requirements and validate of the prototype in their premises._x000D__x000D_The exploitation plan will have different lines in order to exploit the above project results as a whole as well as to offer the above know-how generated by individual exploitation plans. The general project plan line will be the exploitation of the demonstrator (advanced wireless nodes and visual applications) for SMEs manufacturing companies._x000D_

Acronym MOINFO (Reference Number: 7288)
Duration 01/10/2012 - 30/06/2015
Project Topic This project aims to develop an innovative, low-cost, low-power and modular wireless node that will monitor and foresee failures on mechanical machinery. Based on a web-service approach, a mobile tool will be designed in order that plant operators can access node information using a mobile device.
Project Results
(after finalisation)
Summary of results - Spanish Consortium Level_x000D_=================================_x000D_• A wireless WSN node integrated with a sensor-aggregator board (temperature, vibration and energy consumption), developed exclusively for the MOINFO Project. In addition, the node integrates an energy harvester module capable of supplying enough energy to sustain the node operating autonomously along large periods of time._x000D__x000D_• A SW system that allows for real-time monitoring of the aforementioned parameters. Sensor measurements give instant insight of the state of operation and working conditions of drilling/milling machinery, which enables for the control and assessment of future failures (predictive COtenance)._x000D__x000D_• Validation of the complete system in a representative environment to assess the overall quality of the prototype based on its functional and non-functional requirements. The prototype's infraestructure was installed in BCT's factory (Kaunas, Lithuania) and configured to monitor two milling machines. The system's website allowed MTP to monitor data throughput remotely from Madrid_x000D__x000D_• Preparation of contract deliverables and dissemination of project material. COtenance of the project website. _x000D__x000D_• Generation of market analysis, competence and exploitation context for resulting tools and systems developed during the project_x000D__x000D_Overall, the developed prototype is consistent with the expected quality requirements:_x000D__x000D_• Cost /// Hardware components prices are currently below 10 euros, both the wireless node and the set of sensors selected._x000D__x000D_• Flexibility /// It is a highly modular system with regard to the software, It was conceived and designed to easily integrate with other hardware and middleware platforms in a flexible way_x000D__x000D_• Usability /// by providing an intuitive web-based tool that lets you view and control the application through a web browser (IE, Chrome or similar)_x000D__x000D_• Reliability /// the continuous operation of the system was checked. It ran without critical bugs during validation testing activities , which allowed to positively evaluate its performance in a production environment._x000D__x000D__x000D_
Network Eurostars
Call Eurostars Cut-Off 8

Project partner

Number Name Role Country
4 Kaunas University of Technology Partner Lithuania
4 Ingeniería de Sistemas Intensivos en Software S.L. Observer Spain
4 Baltec CNC Technologies Coordinator Lithuania
4 Métodos y Tecnologías de Sistemas y Procesos S.L Partner Spain