Reliability and maintainability of tooling systems can be improved through condition monitoring of motors. However, it is difficult to deploy sensor nodes due to the harsh environment of industrial plants. Sensor cables are easily damaged, which renders the monitoring system deployed to assure the machine's reliability itself unreliable. A wireless and powerless sensing node integrated with a MEMS (Micro Electro-Mechanical System) sensor, a signal processor, a communication module, and a self-powered generator was developed in this study for implementation of an easily mounted network sensor for monitoring motors. A specially designed communication module transmits a sequence of electromagnetic (EM) pulses in response to the sensor signals. The EM pulses can penetrate through the machine's metal case and delivers signals from the sensor inside the motor to the external data acquisition center. By using induction power, which is generated by the motor's shaft rotation, the sensor node is self-sustaining; therefore, no power line is required. A monitoring system, equipped with novel sensing nodes, was constructed to test its performance. The test results illustrate that, the novel sensing node developed in this study can effectively enhance the reliability of the motor monitoring system and it is expected to be a valuable technology, which will be available to the plant for implementation in a reliable motor management program.
Keywords: EM pulse; Sensor networks; monitoring system reliability; motor monitoring system; wireless and powerless sensing node.