At Sea Mechanical Failures Expected to Drop with Vibration Imaging Technology

Sensors Inc. a developer of portable emissions measurement systems, has received a global manufacturing and distribution license to develop a diagnostic system using SRI International’s vibration imaging technology. The new technology and license is expected to open up a new market for predictive failure analysis products that will make boating and offshore industrial operations much safer and much more cost-effective.

SRI’s graphically oriented failure analysis technology, which uses a video camera and wireless links, generates failure-targeted topographical maps generated from the vibration of objects. The maps, much like online weather radar maps, are used to pinpoint abnormal vibration characteristics, allowing for not only the accurate prediction of equipment failures, but also the type of component failure and the anticipated date of failure.

Sensors Inc. is expected to apply the technology to a wide range of different predictive maintenance applications in the maritime industry as well as many other related segments. “Sensors Inc. can now complement its broad range of transportation emissions testing equipment with a system that expands our field of operation into the noise, vibration and harshness (NVH) arenas,” said Andrew Reading, Ph.D., president and CEO of Sensors Inc. “We are also looking at the possibility of entering into the alternative energy market with diagnostic tools for wind turbines and other power generating systems, thereby tapping into business segments offering strong growth and international opportunities.”

Because of the emergence of offshore alternative energy markets and new types of vessel engines, Sensors Inc. is expected to have its hands full applying the technology. Offshore wind farms and offshore ocean energy systems will need approaches that minimize the costly labor associated with on-site offshore maintenance. New cargo diesel and yacht hybrid engines will also welcome technology that lowers engine repair bills and minimizes at sea engine failures.

The easily integrated and portable system is expected to be a much more cost-effective approach to determine and prevent failures in not only the marine environment but in a number of other industries. According to Alex Beavers Ph.D, an executive director of technology commercialization at SRI, “SRI’s vibration imaging technology is highly portable and cost-effective, operates in real time, and can be used as a standalone system or integrated into standard monitoring systems. By taking our technology to the worldwide market, Sensors Inc. can enhance its technical capabilities in a wide range of industries.”

The vibration imaging technology, which consists of just a video camera and highly sophisticated image analysis software, is used to compare the vibrations from an engine or engine powered device with those of a failure-free operating device. Because machinery failures are most often preceded with abnormal vibration, the image analysis system is able to identify equipment out in the field that has a high probability of an upcoming failure.

Traditionally, the collection of vibration data has been through the use of accelerometer sensors that are hard wired to an object’s surface. Although workable, this approach is problematic and expensive in that wired connections tend to break when an object vibrates. Additionally, the costs to wire the objects can be expensive.

SRI’s camera approach overcomes these problems. Different types of cameras can be used to monitor vibrating objects from distances as close as a few centimeters to hundreds of meters away. And this data can be transmitted over wireless links where maintenance engineers can examine the vibration-structured topographical maps for abnormalities as well as perform remote control image testing of devices.

Furthermore, the video approach allows for a vibration analysis at a much greater level of detail than accelerometers can provide. A video camera can record the vibration activity down to the pixel level, giving the system the capability to analyze failure vibration modes at the microscopic level, something that is nearly impossible with accelerometers.

The computer centric system is expected to evolve over time. With sophisticated manufacturing and quality control statistics analysis software, such a system will undoubtedly be able to accurately predict the probability of any type of mechanical engine failures before heading out to sea.