Reducing data footprint with DTECTS

Reducing data footprint with DTECTS

With the availability of our D.Hat PDK, users can now explore the benefits of DTECTS (Detection and Tracking of Energy and Condition Trends System) technologies in their product designs. In this post we discuss how DTECTS KPI Event Vector technology can dramatically reduce data BW and storage requirements while preserving meaning beyond simple level crossing alerts.

While D.Hat implements a conventional three channel power meter adaptable to many different load configurations, including non-energy sensor reading, it also includes an implementation of Ergsense’ DTECTS KPI Event Vector IP that can reduce data footprint dramatically. This technology replaces conventional time series data with compact ‘KPI Event Vectors’ (KEVs) describing changes significant to the user without loss of meaning. These KEVs are based on our expert knowledge of electrical systems and may be customized based on collected system data through manual or machine learning means. Similarly, the user defined KEV trigger levels may be set manually or through machine learning process.

The KEV is useful as an alert and alarm trigger to initiate notification or other processes, and it goes beyond that, carrying useful information regarding the event itself. In the D.Hat PDK FW we have defined the KEVs to deliver data from fast RMS readings of voltage and current in the format:

KEV = {t0 A0, t1 A1, t2 A2, … tn An}, where the terms are in order but not evenly spaced time series data.

  • t0 A0 is the pre event level of the signal
  • t1 A1 is defined as the 10% point of the signal event amplitude
  • t2 A2 is defined as the trigger crossing of the signal event amplitude
  • tn-1 An-1 is defined as the 90% point of the signal event amplitude
  • tn An is the post event level of the signal

With the D.Hat FW we have defined a 5 point KEV for both rising and falling events. D.Hat generates a fast RMS signal each approximately every 100us from which filtered and averaged power metrics are assembled into a time series data packet that is sent as fast as every 15s. Watching this time series data can certainly tell the user that events had happened in approximate time, but not exactly when or with what qualities. Using the HW and FW to generate a value crossing trigger can add exact timing to an event, a good step, but still carries no internal information about the event.

To gain deeper meaning from the event, high frequency data must be used. The choice without local intelligence is to send fast time series data to the cloud for analysis at the cost of connectivity and complexity. Sending six channels of data upstream at 10ksps incurs a minimum BW charge of 1.44Mbps, far too costly over cellular networks to be useful on a continuous basis. What is needed is a way to analyze the fast data on the spot and send only the data that is useful in making decisions.

This is where our KEVs come in play. Replacing the time series data normally associated with industrial sensors by a much more compact KEV reduces the transmission of data greatly. Before estimating the savings, we first look at an example of what we can do with the data inside a typical KEV for phase current.

  • event duration — tracking a change here can indicate unexpected changes in loading or input source resistance
  • rise (or fall) time — can track this to determine process or bearing loading condition changes
  • overshoot — for both transformers and motors, an inrush overshoot during startup is normal and not expected to change. Tracking the peak overshoot of an event can tell us if the motor or transformer structure has been compromised.
  • starting and final current — useful to maintain a watch on process parameters

The examples above demonstrate how a KEV adds value to a simple trigger by allowing analysis of conditions to be done and tracked.

Now let’s look at how using KEVs dramatically reduce BW and storage related costs of sensor data. The following table compares the BW and cost of four cases. Assumed parameters are listed with IoT BW cost being current published data from the internet page of ATT.

Data Use and Cost Comparisons

The KEV at 0.2 cents per month and the KEV + Report, which is a KEV appended with a snapshot of the full D.Hat record of 24 channels, at 10 cents per month than the full time series data at 15s interval provide much more insight than a simple Alert while replacing a time series data cost of $12 per month.

The storage requirements for KEVs and KEV + Reports drop similarly allowing much less reliance on storage at the edge or in your cloud. Machine Learning and AI can operate upon the KEV and Report snapshot data much more efficiently than if crawling through full time series.

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All content on this page is an announcement of an engineering evaluation prototype and does not constitute a formal specification or provide for any product performance warranty, fitness for use in any application or imply any regulatory compliance.  

DTECTS is Patented (US Patent 10876928) and all its IP is protected under US Patent Law

DTECTS & ergsense are trademarks of Energy Research Group, LLC, WA and Tomm V. Aldridge (c)2017 Energy Research Group, LLC, WA

D.Hat Product Development Kit Available

D.Hat Product Development Kit Available

The D.Hat PDK is an energy meter for both single phase and three phase industrial application based on our patented Detection and Tracking of Energy and Condition Trends System (DTECTS). It is configurable as either a stand-alone system, or a cloud-based solution.
Our Product Development Kit accelerates the evaluation and adaptation of DTECTS technology, enabling custom products to meet your unique requirements.
Ergsense supplies the D.Hat PDK, and also is ready to provide custom HW, FW and SW development to meet your needs

Contact tomm@ergsense.com to discuss your DTECTS needs.

D.Hat Product Development Kit Availability:

Orders are being taken now.  The D.Hat PDK includes:
Integrated D.Hat System
— 1 Ergsense D.Hat board pre programmed with DTECTS FW
— 1 Raspberry PI4B – 4GB SBC setup for USB boot (no SD required or supplied)
— 1 128GB USB3 Flash with OS, DTECTS Server SW and user instructions
— 1 Machined Aluminum enclosure

Accessories
— 2 600VAC rated VTs with ratios of 12.5, 25 and 50:1
— 2 150A:333mV CTs for use on loads up to 40kW 3ph 480V motors
— 1 14 position mating screw terminal block connector
— 1 24VDC / 1A PSU (80 – 264VAC input, input blade kit supplied)
— 1 35mm DIN mounting clip with hardware for the system box

Resources
Registered purchasers of the PDK receive access to:
— D.Hat HW design files with option to purchase licenses to DTECTS FW
— Access to a secure repository supporting the SW stack.  The DTECTS Server SW is licensable as an option
— Access to the ergsense/DTECTS community support page

Pricing — contact tomm@ergsense.com to receive a quote.

______________________________________________________________________________________________________________

All content on this page is an announcement of an engineering evaluation prototype and does not constitute a formal specification or provide for any product performance warranty, fitness for use in any application or imply any regulatory compliance.  

DTECTS is Patented (US Patent 10876928) and all its IP is protected under US Patent Law

DTECTS & ergsense are trademarks of Energy Research Group, LLC, WA and Tomm V. Aldridge (c)2017 Energy Research Group, LLC, WA

Customer Success Story

Customer Success Story

Ergsense client, Xylem AWS division, has released its Optimyze pump and motor sensor. Optimyze was developed under contract to Xylem from its architecture through proof of concept.

Once the PoC was approved, we developed the productions system in concert with Xylem engineers and market specialists. The final production concept was used to pass all validation and regulatory test.

Ergsense sensing expertise allowed the FW integration of vibration, flux and remote temperature sensors into a cost effective wireless low power architecture. Our testing lab included three phase VFD motor testing, controlled thermal target testing and swept frequency vibration testing at ANSI and ISO limits.

Our ability to respond quickly to changing needs and to support the customer’s remote SW teams in the development of Android and IoS user apps was a big part of the success of the Optimyze release to manufacturing.

The Ergsense team produced work output in the customer SW dev, ECAD and MCAD environments making a seamless engineering team environment possible.

We worked closely with the chosen CEM source in Asia to define and refine automated board and system testing and to resolve supply chain issues on hard to source parts.

Patent Granted on IoT technology

Patent Granted on IoT technology

Ergsense founder, Tomm Aldridge, has achieved a significant milestone in our history by receiving notice that his U.S. Patent 10876928,

METHOD AND DEVICE TO MONITOR AND AUTOMATICALLY REPORT ELECTRIC MOTOR AND TRANSFORMER CONDITIONS

has been issued as of December 29, 2020.

ABSTRACT
A method for monitoring and reporting conditions of motors and transformers, the steps including: first, collecting measurements and data using at least one sensor to measure performance indicators of at least one motor or transformer; next, analyzing and processing the data using local computing hardware and software connected to the at least one sensor: then, transmitting the data to a cloud based analytics system for further processing and storage of the data and analytics results; lastly, making the stored analytics results available to a user through user interface processing.

This IP, and that pending at the European Patent Office, is the basis for our Detection and Tracking of Energy Conditions and Trends System (DTECTS) which is now available under license for development of next generation motor and load condition monitoring.