csir manufacturing cluster – sensor systems capability in
TRANSCRIPT
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CSIR Manufacturing Cluster –
Sensor Systems Capability in the
Industrial Sensors Impact Area
Jeremy Wallis,
Manager: Industrial Sensors Impact Area,
CSIR Manufacturing Cluster
Mobile: +27 83 468 1934
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The CSIR Mandate
CSIR MANDATE
“The objects of the CSIR are, through directed and
particularly multi-disciplinary research and technological
innovation, to foster, in the national interest and in fields
which in its opinion should receive preference, industrial and
scientific development, either by itself or in co-operation
with principals from the private or public sectors, and
thereby to contribute to the improvement of the quality of
life of the people of the Republic, and to perform any other
functions that may be assigned to the CSIR by or under this
Act.”
(Scientific Research Council Act 46 of 1988, amended by Act 71 of 1990)
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CSIR (new) Vision and mission
VISION
We are accelerators of socio-economic prosperity
in South Africa through leading innovation
MISSION
Collaboratively innovating and localising
technologies whilst providing knowledge solutions
for the inclusive and sustainable advancement of
industry and society
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CSIR’s position in the NSI
Technology development
Development of technology
(process, product, service)
Strategic basic & applied research
Generation of new knowledge and application of
existing knowledge
Technology transfer
& implementation
Impact on economyand society
Fundamental research
Understanding fundamental
principles
Industry/public sector
CSIR
Tertiary Education
Institutes
The CSIR spans the research and innovation
value chain but its role is differentiated from
TEIs and industry/public sector
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Contract income: R1 771 m
Royalty and licence income: R4.61 m
*SET base: 1 850
Black South Africans: 1 139 (59%)
Female South Africans: 674 (35%)
The CSIR at a glance
The CSIR is a science council, classified as a national government business enterprise.
Total staff base: 2 619
Staff with PhDs: 348
Staff with M-qualifications: 631
Pipeline development: 725
Total income: R2 506 m
IN NUMBERS:
New technology demonstrators: 60New patents: 19Publication equivalents: 546
Journal articles: 317
years
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Cape Town StellenboschPort Elizabeth
Durban
JohannesburgPretoria
1945 - 2019
Total investment in
HCD:+ R150 m
*Science, engineering and technology
Figures as at 31 March 2018
Industrial Sensors Impact Area (ISIA)
- Innovation in Inspection & Monitoring -
Jeremy Wallis,
CSIR Manufacturing Cluster
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PRIMARY HEALTH CARE
- POC DIAGNOSTICS
ELECTRO-OPTICAL INSPECTION SYSTEMS
Multi-Spectral Imaging for
power line inspection
Gas leak detection
GUIDED WAVE ULTRASOUND
- RAIL BREAK DETECTION
South African & Foreign Navies
Gun Shot
Detection
SAFETY & SECURITY
Electronics, Firmware, Software, Signal Proc., Num. Modelling, Mech. Design, Opto-Mech Design,Trd Design, Product Development, Quality Systems (9001 & 13485), Small Scale Manufacturing
Small Scale Manufacturing
Technology Platform : Ultrasonics Technology Platform : Electro-Optics
Industrial Sensors – Innovation in Inspection & MonitoringResponding to South Africa’s Challenges with Sensor Innovations
- Targeting Intelligent Sensor Systems Connected Through Advanced Information Networks -
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PRIMARY HEALTH CARE
- POC DIAGNOSTICS
ELECTRO-OPTICAL INSPECTION SYSTEMS
Multi-Spectral Imaging for
power line inspection
Gas leak detection
GUIDED WAVE ULTRASOUND
- RAIL BREAK DETECTION
South African & Foreign Navies
SAFETY & SECURITY
Electronics, Firmware, Software, Signal Proc., Num. Modelling, Mech. Design, Opto-Mech Design,Trd Design, Product Development, Quality Systems (9001 & 13485), Small Scale Manufacturing
Small Scale Manufacturing
Technology Platform : Ultrasonics Technology Platform : Electro-Optics
Industrial Sensors – Innovation in Inspection & MonitoringResponding to South Africa’s Challenges with Sensor Innovations
- Targeting Intelligent Sensor Systems Connected Through Advanced Information Networks -
Gun Shot
Detection
Skills Areas
• Electronics• Firmware• Software• Signal Processing• Machine Learning• Numerical Modelling / FEM• Electro-Optical design• Mechanical & Opto-Mechanical Design & packaging• Transducer Design• Product Development• Quality Systems (9001 & 13485)• Small Scale Manufacturing
Electro-Optical Systems
for Industrial Inspection
Jeremy Wallis,
CSIR Manufacturing Cluster
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Track record in electro-optical industrial inspection
CSIR has a long history of developing electro-optical inspection systems with Eskom.
CoroCAM 504 (UV) MultiCAM1 (UV & IR)
Uvirco were established in 2008 as a CSIR spin out to commercialise the technology.
Sales of 100’s cameras into 44 countries, substantial world market share. Manufacturing in
Pretoria.
Latest system from CSIR: Quvir - Quantifiable IR & UV
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1991 - CCI 1994 - CCIII
1999 - CCIV 2005 - CC504
2006 - MultiCAM
2011 – CC6D
2015 – CC8
Night Cameras
Day Cameras
MultiSpectral Cameras
2014 – CC6N
2016 – CC7
CSIR Spin-Out Company – Uvirco
- Product Overview
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Latest Power Line Inspection System
- Quantifiable UV & IR Sensing
• Adds quantification of UV / Corona sources
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Version 2: GasCAM Prototype Version 3: GasCAM ADM
CSIR, Eskom & TIA have also cooperated on the development of
novel gas detection techniques for Sulphur Hexafluoride leak
detection in electrical switchgear.
The GasCAM technology was expanded to detect and locate
hydrocarbon gas leaks (VOCs)
A GasCAM prototype has been tested at Transnet’s Tarlton depot
Rapid leak detection in plant start up & operations
Version 1: GasCAM Prototype
Gas leak / plume detection
GasCAM
- Gas Leak Detection by Optical Means
Point of Care
Medical Diagnostic Devices
For Low / Middle Income Countries
Jeremy Wallis,
CSIR Manufacturing Cluster
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Umbiflow
- A Point of care medical device that reduces the still-birth rate by 50%
• CSIR and the SAMRC have developed the Umbiflow medical ultrasound system
that has been shown to reduce the still-birth rate at the clinics it is used in by
50%
• Umbiflow, for the first time, puts ultrasound technology into the hands of non-
specialist operators (registered nurses at primary health care clinics) at an
ffordable cost.
Hand-held probe with USB port to
connect to tablet, computer, notebook Self-contained software program to
calculate Resistance Index (RI)
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UmbiflowAll data stored in the cloud in real-time
Umbiflow
- A Point of care medical device that reduces the still-birth rate by
50%
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Umbiflow
- A Point of care medical device that reduces
the still-birth rate by 50%
• Umbiflow is ready for the implementation of national patient health
records in that it can wirelessly communicate diagnostic data to
remote servers for storage and further analysis, in the 4IR paradigm
of health care
• Umbiflow has received international recognition
– Mamelodi trial results presented to Bill Gates of B&MGF in 2016
– B&MGF funded evaluation of Umbiflow in Pakistan
– Canadian Grand Challenges are funding technology upgrades and
transition to scale in low & middle income countries
– The World Health Organisation is sponsoring clinical evaluation in
Rwanda, Kenya, Ghana & India
– The WHO study is being augmented with data from an SAMRC funded
study in all 9 SA provinces
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Industrial Sensors
Air Ultrasonic Instrumentation
© CSIR
The ‘Airhead’ Ultrasonic Level Measurement Device
• Measures time of flight of sound in air to calculate level & volume
• Two wired, loop powered, 4-20 mA device
• Compact unit used in open channel flow as well as closed vessels
• Real-time temperature compensation
• IP68 (exposure) and EEX ia T6 rated (intrinsically safe)
• Setup procedures for in-situ calibration
• Chemically inert tefzel transducer
• Special algorithms to allow for operation in small diameter pipes
• Can track fast moving level changes (up to 8 m / minute)
• Range of operating frequencies for different distance ranges
• E.g. Dam & river levels, power station coal bins, chemical tanks
• Exported to USA, China, Mexico, Europe, Brazil
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The ‘iSonic’ Intelligent Ultrasonic Meter / Controller / Data Logger
• Measures & logs level, volume & open channel flow
• Low cost PLC replacement, requiring lower skill operators
• Specialised algorithms for different weir / flume geometries
• Accepts dual ultrasonic transducer inputs & 2 analogue inputs
• Totaliser feature (e.g. all throughput over time)
• Choice of power options and range of digital & analogue outputs
• Low power / sleep mode
• Can provide power to external devices
• PID control with 5 relay outputs & event log
• Stores data (max of 1 month data at 1 measurement / minute)
• Setup via graphical LCD display or PC software
• Reporting software
• Remote communication protocols: RS232/RS485, Modem, GSM Modem
• Can network up to 32 iSonics
• E.g. Municipal waste water (Tshwane has ~100 units installed)
Industrial Sensors
Air Ultrasonic Instrumentation
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The ‘Loop Controller’ Intelligent Controller & Data Recorder
• Similar to iSonic except designed to work with up to 4 analogue
(loop powered) measuring devices
• E.g. Swiss hydro-electric power facilities, sewerage processing stations
Airhead Loop ControlleriSonic
Level / flow industrial instrumentation
Industrial Sensors
Air Ultrasonic Instrumentation
Real-time, Distributed
Infrastructure Monitoring / NDT
Using Guided Wave Ultrasound
Jeremy Wallis,
CSIR Manufacturing Cluster
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The Ultrasonic Broken Rail Detection SystemReal-time detection & alerts of rail breaks on welded lines
• CSIR has an R&D capability in a specialised NDT technology: Guided Wave Ultrasound
• Ultrasound injected into structures to travel long distances
UBRD V4
• CSIR has jointly, with the Institute for Maritime Technology,
developed a heavy freight railway monitoring system for Transnet
Freight Rail (TFR)
• GWU useful for structural health monitoring
• Over distance – e.g. continuously welded railway lines,
pipeline corrosion
• Buried structures – e.g. foundation rods, anchor bolts
• The railway system is a world first achievement & operates on the
entire Sishen-Saldanha (iron ore) line as well as tunnels & bridges on
the coal line
• Test sections currently under evaluation in India
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The Ultrasonic Broken Rail Detection SystemReal-time detection & alerts of rail breaks on welded lines
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Remote, solar powered
sensor station
UBRD System currently on the 860 km Sishen-Saldanha Iron Ore Line
The Ultrasonic Broken Rail Detection SystemReal-time detection & alerts of rail breaks on welded lines
Ultrasonic Transducer
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Real-time condition monitoring of heavy freight
railway lines
• Research is underway to develop a next generation technology that detects defects in the rail before they become breaks and preliminary findings are positive for the concept.
• This technology would see individual sensor stations every ~2kms which analyse 1000’s of kms of railway line ultrasonically, conduct signal processing to detect and classify defects and then communicate the status wirelessly to a control centre.
• The provision of real time sensor data in a usable form is at the heart of the 4IR paradigm and would enable development of an intelligent hardware / software system as well as a management information function conducting real-time data analytics that would provide rail network operators with the ability to conduct planned / predictive maintenance.
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CSIR’s Role in Sonar
Maintain a local expert knowledge & resource base in sonar wet-end technology
By partnering with the SA Navy &
Armscor on SAN’s current & future
sonar needs
By conducting R&D
in the sonar domain
Support naval
acquisition
processes
Maintain local
skills level in
wet-end sonar
Contribute to local
content goals
Provide quicker
reaction times & do
so at local rates
Sonar consultation
/ troubleshooting
Provide support to
keep SAN sonars
operational
Local T&E
according to OEM
requirements
Local 9001 sonar
manufacturing
capability
Transducer &
array development
for special needs
Explore future
sonar concepts /
technologies
SA Defence Review 2015:
Asks for local support, maintenance & repair of critical equipment & systems
Trd & Array refurb.
- local & overseas
navies
SA’s Local Wet-End Sonar Capability at CSIR
Research Development Manufacturing Logistics
Next Generation Sensor Materials & Sonar Systems
Includes design & prototyping of sonar transducers,
electronics, signal processing and display software
Test & Evaluation: Electrical, Piezoelectric, Acoustic, Pressure / Depth, Polymer Materials, ISUS DAP
ISO 9001 Quality System / Configuration Management
Sonar Transducer
Manufacturing
Including training on Atlas
& Thales sonar suites on
SA vessels (REWA, FAS,
ONA, PRS, CHA, HMA)
Sonar Transducer
Refurbishment /
Obsolescence Replacement
SA & foreign navy experience
Piezoelectric sensor
materials
Mechanical design / materials processing: Full Workshop, Mould Design, Polymer Casting of sonar transducers
Electronic design & testing: Analogue & digital electronics
CSIR’s Sonar Related Facilities
Underwater acoustic (~120 m^3)
Pressure / depth to 1,000 m
Electrical characterisation
Prototyping / machine workshop
Mechanical testing (metals, polymers)
Piezo Ceramic & Composite Manufacturing
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Piezoelectric Composite Processing
© CSIR
Patterned linear
arrayPatterned electrode &
curved sector
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Manufacturing Facility(mechanical assembly, workshop, priming, casting, stores, electronic assembly etc)
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Tracker Array for the SA Daphne Class Submarines(local refurbishment & performance improvement by IS)
© CSIR
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Sonar Systems on board the SA 209 class Submarines(90% of transducers and arrays manufactured by CSIR-IS)
© CSIR
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CTA Array for the SA 209 class submarines(South African technology, developed and manufactured by CSIR-IS)
© CSIR
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Submarines – Past and Present
• ATLAS Elektronik partner for ISUS wet-end
• Custodian of ISUS wet-end IP in South Africa
• Manufacturing, technical support and assistance
– ISUS wet-end
– UWT wet-end
• Investigations on failed sonar transducers
• Manufacture replacement sonar transducers
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Corvette – Past and Present
• Thales Defence Mission Systems partner for HMS wet-end
• Custodian of HMS wet-end IP in South Africa
• Manufactured original HMS arrays
• Investigations on failed sonar transducers
• Investigations on operational aging and corrosion
• Manufacture replacement sonar transducers
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SONAR TECHNOLOGY PLATFORMS
Broadband Underwater Data Communication
Broadband 2D & 3D multifunctional Imaging Sonar
Broadband Synthetic Aperture Sonar
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3D Underwater Imaging Sonar for the SA NavyFirst Field Demonstrator Tested in Harbour
Sensor Array
Prototype
Transmit / Receive Electronics
Prototype
Display / Interface
~250 kHz bandwidth ultrasound system, provides feature resolution ~ 3 mm
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Ladder was placed vertically in
the tank but skew
N.B.: It is significant that this imaging example was in the acoustic near-field
High Resolution Sonar System - Example
Side Scan Sonar Demonstrator
Example specs of demonstrator version:
• Transmit frequency: 100-450 kHz
• Beam widths
• Transmit
• Horiz: 0.7 – 3.0
• Vert: 30-56 deg
• Receive:
• Horiz: 0.3-1.5
• Vert: 30-56 deg
• Source level: 210 dB
• Receiver: -190 dB
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High Frequency Arrays developed by IS(SA & Overseas Navies)
Upper : 100 kHz Detection Array
Lower : 400 kHz Classification Array
270 kHz piezoelectric composite
transmit / receive array
(curved transmitter)
© CSIR
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GunShot Detection & Classification - System Hardware
Vehicle-mounted microphone array Computing and acquisition hardware with display
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PRIMARY HEALTH CARE
- POC DIAGNOSTICS
ELECTRO-OPTICAL INSPECTION SYSTEMS
Multi-Spectral Imaging for
power line inspection
Gas leak detection
GUIDED WAVE ULTRASOUND
- RAIL BREAK DETECTION
South African & Foreign Navies
SAFETY & SECURITY
Electronics, Firmware, Software, Signal Proc., Num. Modelling, Mech. Design, Opto-Mech Design,Trd Design, Product Development, Quality Systems (9001 & 13485), Small Scale Manufacturing
Small Scale Manufacturing
Technology Platform : Ultrasonics Technology Platform : Electro-Optics
Industrial Sensors – Innovation in Inspection & MonitoringResponding to South Africa’s Challenges with Sensor Innovations
- Targeting Intelligent Sensor Systems Connected Through Advanced Information Networks -
Skills Areas
• Electronics• Firmware• Software• Signal Processing• Machine Learning• Numerical Modelling / FEM• Electro-Optical design• Mechanical & Opto-Mechanical Design & packaging• Transducer Design• Product Development• Quality Systems (9001 & 13485)• Small Scale Manufacturing
Thank you
Jeremy Wallis,
Manager: Industrial Sensors Impact Area,
CSIR Manufacturing Cluster
Mobile: +27 83 468 1934