OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 1Vibration Institute 29th Annual Meeting
The Vibration Institute
29th Annual Meeting June 13-17, 2005
Wireless Vibration Monitoring – When, Where, How, Why?
Wayne W. Manges, Dr. Glenn O. Allgood, Teja KurugantiOak Ridge National Laboratory
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 2Vibration Institute 29th Annual Meeting
Wireless Is Now – Even In Nuclear!
Wireless Vibration Sensor
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 3Vibration Institute 29th Annual Meeting
Two Guys Making It Happen!
“CBM is the next killer app for wireless” – Dr. Jay Lee at the University of Wisconsin, Milwaukee –Fortune Magazine, April 2002
Ramesh Shankar of EPRI & Clinton Carter of TXU Energy
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 4Vibration Institute 29th Annual Meeting
Deployment is Key
National Academy of Sciences Identified Needs in 1997– Interference rejection – Hybrid Spread Spectrum– Security – Not just encryption– Standards – IEEE 1451.5, ISA SP100– Reliability - Qualification, Awareness
Goal – Acceptance, market penetrationCore Technology – Ubiquitous, wireless sensingNovel/Transformational Elements – Low cost, reliable, secure communications
US DOE Program Spawned from this report – www.oit.doe.gov
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 5Vibration Institute 29th Annual Meeting
Wireless Vibration Monitoring
…it’s not cellular telephony
…it’s not WiFi...(and it just may be the next big thing)
(anyone heard of M2M?)
Each dot represents one cell phone tower.
Wireless devices circa 1930 RF Tags – expected to be >$2.6B by 2005
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 6Vibration Institute 29th Annual Meeting
DOE Strategy Focuses on Supporting Wireless Vision For Industrial Wireless
WINA –– Self-sufficient – paying members, end users– Standards-based – de facto and de jure– Ubiquitous sensing business models – low cost,
extensibleDOE Projects –– Eaton - Refinery – Honeywell – chemicals processing– GE – material processing– ORNL’s Extreme Measurement
Communications Center (EMC2)Users’ Expectations –– Characterizations – RF, environmental– Simulation – playback of combinations – Qualification – standards and proprietary
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 7Vibration Institute 29th Annual Meeting
DOE’s Laboratories Are Central to Its Mission
Savannah River
Idaho
National Renewable Energy Lab
National Energy Technology Lab
Los AlamosSandia
Lawrence Livermore
Thomas Jefferson
Princeton
Fermi Lab
Ames Lab
Stanford
Brookhaven
Argonne
LawrenceBerkeley
Pacific Northwest
Oak Ridge
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 8Vibration Institute 29th Annual Meeting
ORNL Facts and Figures The Oak Ridge National Laboratory is managed and operated by UT-Battelle, LLC for the U.S. Department of Energy on a fixed-fee basis.
Staff: 5000 total, 1500 scientists and engineers
Budget: $500M; 80% DOE, 20% Work for Others
Replacement cost of buildings: $7 billion
Total land area: 58 square miles
Guests: 4000 annually; one-third from industry
Visitors: 30,000 annually, plus 25,000 pre-college students
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 9Vibration Institute 29th Annual Meeting
Exploiting Defense and Commercial Wireless For Industrial Applications
Reliability -– Mesh – Billions of $ from DOD– Spread Spectrum – FHSS, DSSS, Ultra-
Wideband Power – Harvesting – vibration, RF, PV – Low-power Designs – ASICs, FPGAs, DSP– Protocols – Low-duty cycle - ZigBee
Security– Encryption – AES, WPA, WEP– Physical – RF layer, FIPS 140-2– Integrated – impacts on throughput, latency, reliability
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 10Vibration Institute 29th Annual Meeting
Barriers and Pathways – Acceptance and Deployment
Demonstrations – DOE Three Projects at refineries and other processing sitesPublications/Presentations – EPRI and Comanche Peak, Sensors Magazine, ISA Show and Sensors ExpoStandards – IEEE 1451.5 to be voted this year, ISA SP100 draft in early 2006Qualification – against standards, environments, interoperability, co-existenceSimulations – vs “Can you hear me now?”
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 11Vibration Institute 29th Annual Meeting
Strong Relationships with ISA & Sensors
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 12Vibration Institute 29th Annual Meeting
Energy Savings Projected By Presidential Advisors in 1997 10% of 35Q
Improved Monitoring and Control through low cost, ubiquitous sensing – motors, compressors, processes, utilities, etc.Assumes Ubiquitous/Pervasive Market Penetration –Moore’s Law?, cost of ownership – not just initial costCurrent Energy Consumed in Industry = 35 Quads
Presidential Advisors also predicted 15% reduction in emissions with wireless sensors!
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 13Vibration Institute 29th Annual Meeting
Important Metrics – Deployment vs Cost
Wiring - $20 per foot at low end, $200 per foot nominal, over $2000 per foot in nuclear power plantCurrent Wireless Systems - $1,000 per point per year in nuclear power plantTrue Moore’s Law – lower cost + more capability every year with re-sale into same market
For real impact – likely need about $200/pt/yr!
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 14Vibration Institute 29th Annual Meeting
Partnerships Solutions in the Field
WINA - 19 dues-paying members -approaching self-sufficiencySP100 – 72 members, end-user co-chairSensors Magazine – wireless supplements, website, and Sensors Expo sessionsEMC2 Facility/Capabilities - $0.75M instruments characterizing sites and components – paid services for non-ITP industries.
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 15Vibration Institute 29th Annual Meeting
DOE Project Next Steps – Deployment Support
SP100 – First Draft in 2006WINA – book, paper, standards – late 2006Partners –characterization of environments, components, systems Simulations – improving likelihood of successful deployments – early 2006
Standardized methodology to – Assess environment – light to
harsh, RF and other– Assess application – latency,
throughput, etc.– Assess options – technologies,
products, standards– Assess deployment – initial
stability, ease– Assess performance – against
requirements– Maintain – tools, costs, upgrades
Mesh networking topology
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 16Vibration Institute 29th Annual Meeting
Future Activities for DOE/EMC2
WINA – self sufficiency – September 2005SP100 – First Draft – January 2006EMC2 – simulation of complex co-existence environments – April 2006EMC2 – Collaborative R&D Environment – September 2005
WINA and EMC2 to become qualification center for ZigBee, Bluetooth, and IEEE 1451.5
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 17Vibration Institute 29th Annual Meeting
Wireless Options Available – Not Great
802.11b2.4 GHz, DSSS11 chips/bit11Mbps+20 dBm50m128 devicesCSMA/CAOptional WEPOptional
HomeRF2.4GHz, FHSS50 hops/s1 Mbps+20 dBm50m128 devicesCSMA/CAOptionalOptional
Bluetooth2.4 GHz, FHSS1000+hops/s1Mbps0, +20dBm1-10m, 50m8 devices, PiconetEncryptionYes
ParameterTechnology
Data RatePowerRangeTopology
SecurityVoice Channel
ZigBee (proposed)2.4 GHz,DSSS15 chips/bit40 kbits/s0dBm100m100s devices, CSMA/CANot yetNo
Bluetooth – aka IEEE 802.15.1
ZigBee – aka IEEE 802.15.4
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 18Vibration Institute 29th Annual Meeting
EMC2 Supports Deployment
A Broadband Noise Source detected
EMC2 – self-sufficiency for industrial wireless supportWINA – funded R&D at ORNL through WINAPartnerships – continued university partnerships Technology – Hybrid Spread Spectrum, embedded intelligence, power efficient designs, and embedded security supports industrial deployment
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 19Vibration Institute 29th Annual Meeting
Everybody Wins
WirelessWarrior
High CostLow VolumeHigh QualityHigh Integrity
NationalDefense
ConsumerMarket
High QualityHigh VolumeLow CostLow Integrity
Wireless Intelligent Network
Government LabsAcademiaIndustry High Quality
Low CostHigh VolumeHigh Integrity
Manufacturing/IndustrialMarkets
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 20Vibration Institute 29th Annual Meeting
Wireless Ecosystem
Replacing the Wire is Only the First Step!
Chip
Sensor
Asset
ApplicationData
Collection
Analysis &Simulation
Display & Alarm
Response
Communication
(Module)
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 21Vibration Institute 29th Annual Meeting
What Is The Next Generation Sensor System?
First Generation - Dumb Sensors• data focus• flat architecture• no intelligence
Second Generation - Smart Sensors• application focus• hierarchical architecture• local intelligence
Third Generation - Sensor Agents• goal focus• dynamic architecture• network intelligence
From data to information to knowledge!
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 22Vibration Institute 29th Annual Meeting
How Will You Know It When You See It?
Next generation network will self-organize in response to specific events
Present-day systemshave fixed hierarchy
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 23Vibration Institute 29th Annual Meeting
The Sensor is the Network!A Completely New Paradigm!– Efficiency– Safety– Asset Management– Hostless architectures
Extreme Measurement Communications Center (EMC2)
Extreme Measurement Communications Center (EMC2)
Operational CapabilityThe DoE EMC2 provides modeling, simulation and characterization support for industrial wireless networks.
This facility is equipped with parallel computing resources as well as state-of-the-art measurement equipment for high performance wireless and wired network characterization from the physical layer to the application layer
Broadband RF record and playback instrument can simulate and generate characteristic waveforms to help in-lab study of the wireless device’s behavior in harsh industrial environments
Milestones, Deliverables, & Contact:Key Milestones: Alliance with WINA and member companies for technology assessment and characterization; Provides modeling and simulation support for developing fault-tolerant electric-grid communication infrastructure
Deliverables: Standards-based report generation for different wireless devices and network layouts; Software development for characteristic network testing;
Contact Information: Wayne [email protected], 865-574-8529
EMC2 Program Benefits:• EMC2 formalizes the testing of industrial wireless networks to quantify the latency, throughput, security and fault-tolerance (Interference and Noise)
• Wireless Industrial Networking Alliance (WINA) hasaccepted EMC2 as its product testing and characterizing center to member companies
• Currently supports exhaustive modeling and simulation of the communication infrastructure for future electric grid
• Help develop or improve existing standards in industrial wireless networks to include measurement, verification and reliability of network and device parameters
• The center is being developed both as a user facility and an on-site testing provider using portable test equipment
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 26Vibration Institute 29th Annual Meeting
Risks Remaining – Be Careful!
Technical – security, latency, reliabilityCommercial – acceptance, cost, marketingPolitical – assumptions of either too hard or too easy
Solving a multi-disciplinary problem!Wireless – radio, packaging, antennaIndustrial – harsh environment, fault tolerant, safety related, costSensor – filters, sampling, sensitivity, interferers, controlsNetworks – real-time, latency, throughput, security, integrity, vertical integration
OAK RIDGE NATIONAL LABORATORYU. S. DEPARTMENT OF ENERGY
Wayne W. Manges / 27Vibration Institute 29th Annual Meeting
Who Will Lead, Who Will Follow, Who Will Whine?
Technology is ready - driven by cellular personal/business communicationsMarket is ready - $2000/ft for wires in some plantsAre we ready? - partnerships, consortia, standards, and collaborations
“CBM Is the Next Killer App For Wireless”– Dr. Jay Lee, Fortune Magazine, July 2002