TAFE Queensland SkillsTech Predictive Maintenance Systems - MOVUS

The healthy functioning of equipment is a common core throughout all industries. Typically 90% of all industrial assets have no continuous health monitoring capability for their equipment.  Normally, scheduled maintenance is predominately time based and performed by programmed inspections by maintenance staff or fixed post failure. 

PREDICTIVE MAINTENANCE SYSTEMS facilitate increased uptime, more efficient maintenance processes, time and money savings, and offer just in time ‘pre-failure’ maintenance data that is imperative to industry which can be retrofitted to most legacy equipment.  The MOVUS system combines a highly sensitive sensor that learns about your equipment condition whilst pushing crucial maintenance data to the cloud via a WiFi Internet of Things (Iot) that offers an organisation a unique and total end-to-end predictive maintenance solution.  That’s what the MOVUS FitMachine does.

The MOVUS FitMachine system offers a unique end-to-end predictive maintenance solution that provides insights that facilitate improved planning and more accurate forecasting of Maintenance, Repair and Operation components and replacement parts.

The MOVUS FitMachine Platform offers a range of advantages over traditional time based, programmed inspections.

      The FitMachine ‘Puck’ (see left) attaches quickly via a powerful (Rare Earth) magnet enabling a no tool, fast installation process (Other fixing methods are also available);

     The Puck requires no programming to function – once attached FitMachine quickly goes to work collecting samples, calibrating to the current condition of the machine;

      FitMachine communicates via WiFi to the MOVUS cloud-based platform called MachineCloud. MachineCloud is accessible via standard browsers or mobile devices and provides a simple traffic light showing (amongst other things) changes in condition and speed of change (degradation).

The platform offers timely alerts and real-time trending details and information; leading to actionable digital insights. Digital Insights are a key benefit of the FitMachine solution – whilst a lot is being written about Big Data, the reality is most front line maintenance/engineers don’t need more data – they need insights that allow them to work smarter.

The process is cost competitive and works like most, commercial cloud-based solutions via the Software-as-a-Service model (SaaS). MOVUS FitMachine is licensed under per sensor per month fee.

The unit can measure a range of important parameters. Currently the parameters measured are: temperature, vibration, and noise, with an additional six parameters built into the unit that when unlocked will capture a range of environmental factors such as dew point, ambient temperature, light etc.

The below dashboard screen shot shows all MOVUS devices in the particular plant with “green” (OK) condition – showing crews that no maintenance intervention is required. Users can also drill down to all the historical monitoring of each device for the relevant minutes, days, weeks, months and years. The dashboard is easily accessible via desktop or mobile application.

The simplest way to think of FitMachine is an early warning system.  Augmenting the expertise of your front-line maintenance and engineering teams by providing continuous condition monitoring that is ready to generate advisories and alerts about machine condition before it becomes a major machine failure.  This leads to a more detailed investigation and identification of the root-cause, allowing for planned downtime and repairs. 

For more details contact Mark Parker on mark.parker@movus.com.au or go to https://www.movus.com.au/.  Cheers Garry Hargreaves

TAFE QUEENSLAND – SKILLSTECH - Augmented Reality (AR) Welding Simulators

Supporting Advanced Welding Practices TAFE Queensland has purchased 15 Soldamatic Augmented Reality Welding Simulators to support both Accredited and non-accredited programs

AR offers an enhanced version of reality by overlaying digital information on top of real world images being viewed through a device (such as a smartphone camera). In this specific case, the welder uses a modified hand piece to read a coded coupon to generate a real-time digital video (with both audio and visual) of the welding process the user is undertaking. The coupon code matches a specific welding procedure which is then viewed by the user on a screen built into the welding mask.

Welding Training Centres
Welding training centres need to train a higher number of qualified welders saving costs and time, Soldamatic helps to:
• Increase in about 400% the number of students leveraging existing lab infrastructures.
• Provide trainers with cutting-edge technological tools to help them in their work.
• Save 68% consumables on average.

Future Welders
For future welders who want to be qualified to enter the labour market in a good position and want to have fun while learning, Soldamatic:
• Is attractive Methodology: Augmented Reality with great dose of gamification. Videogames are great for learning.
• Provides unlimited practices with the AR Simulator.
• Facilitate access to international Training Programs:

“The AR welder offers the user a heads-up display (HUD) with additional information such as technical specifications of the weld in real time.”

The included information includes info such as volts, current, and the speed and angle of the welding rod. An overall percentage grade is presented to the user at the end of each welding experience. This information is stored in the unit and each welder’s video can be replayed for individual/instructor reviews, remedial feedback and for peer group assessment by connecting the welding video to a classroom projector.

AR, like Virtual Reality (VR), is a new and emerging technology. This new approach presents a number of significant advantages over traditional welding units such as:
• No welding sparks or hot metal generation.
• No welding fumes.
• Reduces CO2 emissions and reduces the carbon footprint of traditional welding programs.
• Extremely portable (approximately the weight of a desktop PC).
• Allows for faster transfers from simulator to traditional welding.
• The high-camera resolution for AR facilitates different welding positions and provides a realistic welding experience.
• Allow users to practice all aspects of a specific weld procedure before trying to execute a real weld.
• Educate users 4x faster while also freeing up existing welding machines for workshop use.
• Most welding simulators are based on leading-edge and patented AR welding training technology (following AWS and according to ASME Section IX, UNE-EN 287-1 and EN ISO 6947).
• Saves substantial costs on welding consumables, coupons, gas, rods and wires returning a 68% on average saving when compared to traditional welding approaches.
• AR welders can be updated with new welding procedures such as aluminum and exotic metals like titanium. Software updates are also free and conducted remotely.
• Improve safety for workers (reinforces PPE requirements for each specific job task and each workplace device).

Garry Hargreaves
garry.hargreaves@tafe.qld.edu.au

TAFE Queensland SkillsTech – Leading the way in Instrumentation and innovation

With technology advancing at an unprecedented rate in the manufacturing and instrumentation sector, educating students to have the latest and most applicable skills for industry is a priority. One of the most successful ways of ensuring this currency is to partner with key industry vendors, such as Yokogawa Australia, a relationship which was forged over 30 years ago.

Yokogawa has continued to provide the latest equipment, including the CENTUM VP R6, fully equipped with Yokogawa pressure and temperature transmitters.

The TAFE Queensland Eagle Farm campus is equipped with 4 x field control stations (FCS) and 9 x engineering workstations, allowing students to develop their programming and tuning skills for PID control, ratio, cascade and feedforward control. The students are also able to complete their own projects connected to a live working plant.

TAFE Queensland teacher Glen McMurtrie comments "We look to provide the highest levels of technical training to our students, maintaining a high degree of relevance to their day to day activities for when they are back on site.

"We get the students to program and test temperature loops using a domestic sandwich toaster. Temperature probes are inserted inside the sandwich and the heating element controlled by the DCS using a traditional feedback loop. Set points are adjusted on the operator workstation as the heating elements set to work toasting the sandwich, ensuring its heated all the way through. The students have great fun, yet take it very seriously especially in cases where their lunch is the content of the sandwich press!”

Practical application is at the heart of TAFE Queensland programs, and helps students to remember their training long after they have graduated. Adding an element of fun into practical activities enhances the learning process further.

“With our scaled down process plant, and the majority of our students using Yokogawa’s CENTUM DCS in their daily work, these are practical skills which are immediately useful."