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Abstract—Traditional wired vibration and acoustic sensors based on old platforms developed for networking research with
used for machine and structural monitoring are currently being limited processing capabilities and memory (e.g. TelosB and
replaced by low-cost MEMS-based wireless sensor networks MICAz), which limits also the sampling rate of the sensors, or
(WSN). However, existing platforms are lacking in computing
capabilities and integration, as well as the necessary software on more powerful platforms with higher power consumption
features to manage wireless sensing experiments. In this paper, we and that do not support current standard WSN operating
present a novel hardware-software platform designed to monitor systems such as Contiki-OS [12]. Moreover, accelerometer
machinery in remote deployments and expedite collection of and acoustic sensors are rarely used together in these studies,
experimental data, which could also be used for structural even though the literature shows methods that can combine
monitoring. The hardware module is composed of a single PCB
with an IEEE 802.15.4-compatible microcontroller, waterproof both sources of data to improve fault detection [4], [13], [14].
Micro-USB connector, battery, battery charger/monitor, humid- In addition, the use of different modules for communications,
ity/temperature sensor, IMU, and a MEMS microphone. The acquisition, and sensors attached with cables or connectors
software developed allows for wireless experiment control and instead of a single integrated board complicates the packaging
data collection through a gateway node connected to a laptop. and encapsulation, as well as increasing the cost and power
Additionally, the user interface supports the placement of the
nodes in a 3D view of the environment, as well as visualisation consumption.
of the collected data. The platform was tested in the laboratory To accommodate the high data rate of the sensors used
in two different motor setups by measuring vibration and sound for machine and structural monitoring, a hardware-software
in normal operation, showing that the system can facilitate the co-design is necessary that ensures the complete system can
execution of sensing experiments in rotating machinery and perform as needed while keeping a low power consumption
similar equipment.
and compatibility with the standards. Although some work
I. I NTRODUCTION has been done in developing hardware-software platforms for
WSN [15], [16], most of the software tools are designed
Vibration and acoustic sensors have been widely used for to work for the mentioned obsolete platforms and they are
prognostics and fault diagnosis of bearings [2], motors [3], and focused on networking, protocols, and wireless planning and
different types of machinery [4], [5]. To reduce cost and ease characterisation instead of sensing.
installation, high-end wired sensor systems for vibration based In this paper, we developed a hardware and software ar-
machine and structural monitoring are being replaced with chitecture designed primarily for monitoring marine energy
low-cost wireless sensor networks (WSN) using MEMS and platforms and their machinery, which can also be used for
other COTS sensors [6]–[8]. This becomes important specially more general monitoring of ships, industrial machinery, and
in remote locations and off-shore deployments such as marine structural health. The hardware module is a single board based
platforms and ships, where their difficult access and harsh on a state-of-the-art IEEE 802.15.4-compatible microcontroller
environment conditions further complicate their maintenance with MEMS vibration, microphone, and humidity/temperature
and monitoring. sensors, battery, and battery management, encased in a custom
In [9], a WSN is used to monitor the condition of a marine 3D printed box designed for easy encapsulation. The firmware
gearbox, with nodes based on the assembly of several off- and software developed for this platform allow for wireless
the-shelf boards: a Zigbee module, an accelerometer, and an data collection and visualisation, experiment control, and 3D
energy harvester. Similarly, Severino et al. [10] showed a plat- view support of the environment and node location.
form for structural health monitoring using a TelosB [11] mote The remainder of the paper is structured as follows: Sec-
connected to an acquisition board and accelerometer. While tion II presents the overall hardware-software system char-
these experiments demonstrate the feasibility of using wireless acteristics. Section III describes the custom wireless node
sensors and MEMS to monitor these environments, most of the designed and sensors used, while Section IV introduces the
platforms used present a series of drawbacks: they are either main features of the firmware/software platform. In Section V
the system is evaluated in two laboratory setups, with a motor
This material is based upon works supported by the Science Foundation
Ireland under Grant No. 12/RC/2302, the Marine Renewable Energy Ireland attached to a wind turbine and a gearbox. Section VI ends
(MaREI) Centre research programme [1]. with the conclusions and improvement plans for the platform.
II. OVERALL SYSTEM DESIGN IMU Serial Com/Power Memory Humidity/Temperature Microphone
Battery PCB
Spacer
Switch
Bottom MicroUSB
Enclosure Opening
devices and supporting most common low-power communica- used. The file writing is also buffered in the external memory
tion standards. The application is based on Contiki-Shell, an SRAM buffer before committing. This architecture ensures
interactive text-based console that allows for definition of dif- that both sensors can be sampled and saved at the required
ferent command functions in the node, to be triggered locally data rate without loss of frames.
over a serial USB or remotely from the gateway to one or
multiple nodes. One of the limitations of Contiki-Shell is that B. Software and user interface
when launching remote commands in a node, the node will not
send back a response to the gateway. Thus, the Contiki-Shell To support the remote control of the nodes, a custom Python
core was modified to receive responses from the nodes when application is developed running on a laptop, which connects
necessary. All wireless communications use the RIME stack, through the serial port to a gateway node. On top of the
which provides a layered set of lightweight communication script, a PyQt-based graphical interface is built to facilitate the
primitives. Although the system architecture is designed to be experiment management and node control as well as adding
used in single-hop networks, it could be modified to work in extra features. The gateway console tab handles the serial
multi-hop by using different RIME primitives. ContikiMAC connection to the gateway, displays the full activity log, and
is used for radio duty cycle, which keeps the radio off 99% allows for manually sending commands.
of the time, saving power but increasing the communication In Fig. 4 we see the network management tab, divided
delay. in three different areas. The top side contains controls for
The two modes of operation described in Section II, on- network discovery and a list of the nodes in range with
demand and periodic unattended, are supported through the information about the RSSI, Battery, Temperature, etc. for
remote shell commands. The periodic experiments can be each individual node. From this list every node accelerometer
any command available in the node, which will be called and audio can be calibrated, as well as launching commands
from the gateway with the period and other parameters. These remotely. The bottom left shows the files in the memory of
parameters will be saved in a file in the memory, then read the selected node and allows to download individual files, as
and executed when the node is powered on or after reset. The well as deleting and formatting the memory, while the bottom
memory also stores the calibration file for the IMU as well right lists the current periodic experiments set up on the node
as the data files collected from every experiment, using the and permits adding, deleting, and stopping experiments.
Contiki file system. The main primitives of this file system are Fig. 5 shows the data analysis tab, where we can display
also implemented as shell commands, to be able to remotely plots of the selected downloaded audio or accelerometer data
read and write files, format the memory, etc. in time (left side), as well as its power spectral density (right
Due to the performance constraints of the system, sampling side), to quickly identify the peaks and frequencies of interest.
high data rate sensors such as the audio and accelerometer at A 3D view tool is shown in Fig. 6, where we can load
the same time while saving the data to the memory presents an STL CAD file of the target environment where we are
a challenge, which can be overcome by using the different deploying our network, as well as manually placing the
resources already available in the microcontroller and IMU individual sensor nodes in the exact position. This tool can be
IC. To unburden the CPU from the microphone sampling, the useful to study the environment, make deployment decisions,
ADC is used with DMA, and the blocks of data are stored and aid in the development of propagation models by the
in two ring buffer arrays in the microcontroller RAM. For the automatic calculation of distances between nodes in 3D space,
accelerometer sampling, a combination of the IMU IC internal in contrast with other tools that only allow to arrange the nodes
buffer and another buffer in the microcontroller firmware is in a 2D space.
Sensor Module Motor
Wind Turbine
Fig. 5. UI Data view. Fig. 7. Experiment setup of a motor connected to a wind turbine.
X Y Z
[mg2 /Hz]
0.2
0.5
[g]
0.1
0.0
0.0
0 1 2 3 4 5 0 50 100 150 200
(c) Audio (time) (d) Audio (PSD)
[Amplitude]
0.1 −50
[dB/Hz]
0.0 −100
−0.1
−150
0 1 2 3 4 5 0 1000 2000 3000
Time [s] Frequency [Hz]
Fig. 6. UI 3D Environment view. Fig. 8. Accelerometer and audio data collected at 1200 W load.
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