McMaster University in conjunction with an industrial partner has been designing wireless vibrational condition monitoring sensors for implementation on a vibrating screening machine used in mining applications. A limitation with the current sensor design is their dependency on battery power. In order for the sensors to provide real-time continuous streaming of acceleration data, an alternate power supply was required outside of traditional sources such as batteries or wired power. This thesis outlines the research and development of a power system that harvests the kinetic vibrational energy of a mining screen and converts it into electrical energy for use by a wireless sensor node. During development, multiple prototypes were built and evaluated under laboratory conditions. The core concept of the system is an eccentric pendulum mass excited by the external vibrations of the screening machine used to drive a stepper motor generator. The major design obstacle of the project was how to get the system to self initiate. Both a mechanical and an electrical solution were developed to solve this concern. The final prototype design is fully autonomous, able to react to the start up or shut-down of a screening machine, while also providing a continuous power supply to a wireless vibrational analysis sensor as tested in the lab. With minor optimization, this prototype can be turned into a commercial product for industrial implementation and sale. / Thesis / Master of Applied Science (MASc)

<p>Vibrating screens are industrial machines used to sort aggregates through their high rotational accelerations. Utilized in mining operations, they are able to screen dozens of tonnes of material per hour. To enhance maintenance and troubleshooting, this thesis introduces a vibration based condition monitoring system capable of observing machine operation. Using acceleration data collected from remote parts of the machine, software continuously detects for abnormal operation triggered by fault conditions. Users are to be notified in the event of a fault and be provided with relevant information.</p> <p>Acceleration data is acquired from a set of sensor devices that are mounted to specified points on the vibrating screen. Data is then wirelessly transmitted to a centralized unit for digital signal processing. Existing sensor devices developed for a previous project have been upgraded and integrated into the monitoring system. Alternative communication technologies and the utilized Wi-Fi network are examined and discussed.</p> <p>The condition monitoring system's hardware and software was designed following engineering principles. Development produced a functional prototype system, implementing the monitoring process. The monitoring technique utilizes signal filtering and processing to compute a set of variables that reveal the status of the machine. Decision making strategies are then employed as to determine when a fault has occurred.</p> <p>Testing performed on the developed monitoring system has also been documented. The performance of the prototype system is examined as different fault scenarios are induced and monitored. Results and descriptions of virtual simulations and live industrial experiments are presented. The relationships between machine faults and detected fault signatures are also discussed.</p> / Master of Applied Science (MASc)

<p>Vibrating screens are mechanical machines used to sort granulated materials based on their particle size. Utilized in the mining industry, these machines can sort tonnes of materials per hour. In the past, McMaster University developed sensor devices that measure and transmit vibration data of these machines to a central data acquisition unit for analysis, tuning, and maintenance purposes. In this thesis, I present the development of two new software systems that are used to process, manage, and present the information gained from these measurements. The first system, the offline vibration analysis software, is used to analyze the vibration data in both time and frequency domain, and presents the measured and calculated data in textual and graphical forms. The second system, the online vibration analysis software, is used by vibrating screens manufacturers and their customers to gather and manage vibration data collected from their vibrating screens by utilizing a central storage. The development process of these systems followed an iterative and incremental approach with continuous feedback from stakeholders. It included extensive requirements gathering to define a model, in terms of data representation, that captures the business logic and practices of the industry. Furthermore, it used standard architectures such as Model View Controller (MVC) and advanced technologies such as Object Relationship Mapping (ORM) for data access to increase flexibility and maintainability. Finally, comprehensive unit testing and thorough security risks evaluation were conducted in order to ensure that these systems are secure and bug free.</p> / Master of Applied Science (MASc)