Product category:
Maintenance planning, services and equipment
News Release from: Bosch Rexroth | Subject: Remote system monitoring for hydraulic systems
Edited by the Manufacturingtalk Editorial
Team on 31 May 2005
GSM and telemetry remotely monitor
hydraulics
Using the open GSM communications network, a hydraulics components supplier has developed the first real-time, intelligent remote system monitoring for hydraulic applications.
Rexroth, working in close association with wire-free telemetry specialists, Box Telematics, has developed the first real-time, intelligent remote system monitoring for hydraulic applications, which uses the open GSM (Global System for Mobiles) communications network The system centres on a lightweight, compact multifunctional telemetry device, incorporating a GSM modem, 'flash' programmable processor and on-board data logging capability, with 40 digital and analogue I/Os, which can be mounted on or near mobile plant and programmed to provide a wide range of monitoring functions, where rapid two-way data flow is critical
This article was originally published on Manufacturingtalk on 17 Jul 2001 at 8.00am (UK)
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The remote system monitoring (RSM) project, which has been led by Rexroth Service Automation teams in Britain and Canada, has already been trialled at a UK steelworks, where arduous round-the-clock duties and water-based fluids impose particular stresses on hydraulic pumps.
The system, which is interrogated every 20 minutes by a PC base station, flagged up a potential problem with one of the pumps, by detecting a deviation from the normal operating trend.
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This was communicated to Rexroth's on-site service engineers, who alerted the customer and scheduled a replacement into the normal maintenance programme.
In response to global customer demand for ever improving after-sales support, Rexroth's Service Automation teams on both sides of the Atlantic have been actively seeking advanced methods of providing 24/7 cover for installed hydraulic equipment and the means to record operating trends over an extended period, to prevent breakdowns and minimise machinery downtime.
Some two and a half years ago, exploratory conversations were begun with Box Telematics on the feasibility of real-time intelligent remote system monitoring, in a rugged industrial environment.
An offshoot of The Mobilefone Group, for many years market leaders in the sale and supply of cellular mobile phones, radio systems and paging, Box Telematics was formed in 2000 to exploit the market potential of telematics or telemetry, which is defined as the process by which data is collected at remote locations and automatically transmitted.
The technology is known as 'wire free', since it involves the use of cellular, radio and satellite networks to transmit data, and was borne out of the development of vehicle tracking systems.
Box was also the country's first service provider for the Orange data network, which allows GSM interfacing on either 900 or 1800MHz bands and provides comprehensive data and SMS coverage for the new Rexroth system.
Box Telematics clearly had the proven telemetry technology and the ability to develop bespoke hardware and software solutions; while Rexroth, with its huge installation base, understands the requirements of the industrial market, regarding robustness of equipment, machinery input/output connections, data storage and management reporting.
The result is a bespoke version of a GSM-enabled telematic 'box', measuring 125mm x 160mm x 35mm and weighing only 750g, which works across the dual-band Orange data network, providing international roaming in more than 170 countries, and which is upgradeable to GPRS (General Packet Roaming Service) to cover the future North American market.
A GPS (Global Positioning Satellite) engine is also available to enable tracking and monitoring of mobile plant and hydraulic equipment installed on ships and railways.
Each device incorporates a 16 bit flash-programmable microcontroller, with 16Mb of memory for up to 40,000 records.
It has 16 analogue and 16 digital inputs, for monitoring the status of switches, transducers and pressure/temperature/flow sensors on hydraulic equipment, and 8 digital on/off outputs.
In addition, there are two industry-standard RS232 communications ports for connecting peripherals, such as laptops and hand-held PDAs, whilst the 'transparent' GSM/GPRS data networks allow the use of remote diagnostics software.
There will be three basic RSM models available: a 'master' unit for standalone applications, where a single point of communication is required; a 'hub' unit, which communicates with up to 15 slave devices using short range radio and forms the centre of a local wireless network, covering multiple machines; plus a 'tracker' unit for mobile plant applications, where GPS satellite positioning is needed to poinpoint or 'geo-fence' hydraulic plant and equipment.
IP67 and IP68-rated enclosures can also be supplied for marine, offshore and similar environments.
Each RSM unit is configured using Rexroth/Box firmware to suit the attached I/O devices and stores the electronic pulses on its built-in memory, which can be remotely accessed by dialling into the unit and downloading the information.
At Rexroth Service Automation headquarters, a dedicated PC serves as the base station, which has differently configured screens to suit the remote units being interrogated, and this calls up the device when required or at predetermined times (every 5 minutes, hourly, daily, weekly), using an automatic polling system.
A full memory download can be retrieved at that time or just a 'snapshot' of input readings to monitor machinery status.
The remote device can also be programmed to trigger an alarm or warning state, whenever there is a sudden change of status, deviation from set points or readings above a given threshold.
It will then initiate a data transmission call, displaying the unit's code and alarm status on the PC base station screen, and/or sending a text message to an engineer's mobile phone or landline, using SMS transmission again supported by the Orange 900/1800 data network.
Although Rexroth is still developing its remote system monitoring solution, the company has the capability of exporting key RMS information to a customer database, together with service recommendations, and is trialling a password-protected dedicated website, where authorised site and senior managers can log on and review critical data.
Seen as a high tech means of providing preventive maintenance and avoiding costly machinery breakdowns, it is likely that RMS will be offered as part of Rexroth's comprehensive maintenance package, with units leased to customers and monitored on an ongoing basis; although there may be scope for units to be supplied outright and incorporated into OEM machinery, as part of a Rexroth hydraulics system.
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