Condition Monitoring

Information
Technology Product and Service Offerings

Jon Greiner
Connected Worksite Division
Agenda
On Board
ƒ Current VIMS
– Upgrades, Retrofits
ƒ Future VIMS
– 3G

Off Board
ƒ VIMS Office
ƒ Dealer’s Condition Monitoring Services
ƒ Predictive Analysis Services
ƒ Haulage Optimization
What Can Your Equipment Tell You?
On-Board System

ƒ Collects Data
ƒ Monitors
Machine Events
ƒ Stores
Information
ƒ Communicates
 Off-Board System
VIMSpc VIMS Supervisor
Single-machine Solution Fleet Management Solution
VIMS File Types
Machines Utilizing VIMS
Mining Trucks Wheel Loaders/ Dozers
ƒ 797 ƒ 994
ƒ 793 ƒ 992
ƒ 789 ƒ 854
ƒ 785
ƒ 777 (attachment)
Mining Shovels
ƒ 775 (attachment) ƒ 5130
ƒ 773 (attachment) ƒ 5230

Track Tractors(VIDS)
ƒ D10
ƒ D11
VIMS On-board Systems
Onboard Hardware Versions
ƒ 68k Hardware – Older version of hardware
with service and telemetry ports only
ƒ ABL Hardware – Current production hardware
with service, telemetry, and CAN ports
(added to allow wireless file downloads)
ƒ A4N Hardware – Next generation production
hardware with service, telemetry, CAN and
ethernet ports
VIMS Status
Version 10.5 Released – January 2007
ƒ Key features
– Corrected inaccurate payload on 797
with improperly adjusted strut
– Corrected histogram overflow prior to
recommended reset value
– Improved scoreboard response time
– Engine over-speed events now align with
ECM events
– Engine shutdown events modified to
coincide with elevated idle ranges
VIMS Status (con’t.)
Version 10.5 Released – January 2007
ƒ Conditional datalogger available
on LWL’s
ƒ Alignment of 994F/992G SMH with
ECM diagnostic hours
ƒ VIMS TMPH/TKPH available on
all large truck models
VIMS Status (con’t.)
Version 10.52 Under Development –
April 2008 Release
ƒ Changes
– High altitude exhaust temp snapshot events
– High altitude derate events
– 793/797 scoreboard issue
– Corrected LWL payload full not downloading
– 776D strut flat line correction
– LWL payload data retention issue
– 992G steering lock, parking brake, tilt rod
pressure issues
VIMS Status (con’t.)
Version 11.0 and Advisor Update
ƒ 777F Phase 1 software update
in production
– 777F Phase 2 Beta software finished –
TPG test underway
– 993K update in production
– 773F/775F Phase 1 software under
development – includes 777F Phase 1 fixes,
Software Enabled Attachments and payload fix
– 777F Advisor software under development
 Basic VIMS System
CAT DATA LINK
ET ET SERVICE
ED
F ACB
PORT
GHI

SERVICE
PORT
VIMS CAN PORT A
C

VIMSpc ABL

LAPTOP PC

VIMS
Supervisor

BROADCAST PORT
(TELEMETRY)
 VIMS System (With Product Link)
ENGINE
LAPTOP PC
ET
VIMSpc

ET SERVICE
SERVICE PORT ED
F ACB TRANSMISSION
PORT GHI

VIMS
ABL
B

CAT
A
C

DATA LINK

IMPLEMENT
BROADCAST PORT
(TELEMETRY) C

Location, Hours, GPS & DATA PRODUCT

Events, Geo-Fencing ANTENNA LINK
Equipment Manager
VIMS Wireless
With Broadband Radio
Communicator(current)
Telemetry Port
Gen 2 HIM (future)
VIMS or
Guardian Service Port
VIMS FTP
Download Server
With With
Schedule File Forward Ethernet
Port
Broadband
Radio –
Cellular, Data
MESH, Hot Forwarding Internet
Spot, Blue Software
Tooth, etc VIMS Data Folder

PC
CMS, Predictive Analysis,
MQ Solution Dealer MineStar Health
Communicator Features
ƒ Provides Connectivity for Broadband Wireless
Solutions for VIMS
ƒ Handles VIMS Files Including Dataloggers
ƒ Triggers Datalogger Through an Internal Scheduler
ƒ Scheduler Managed Through a Web Interface
ƒ Pushes Files Offboard When Radio Connectivity
is Established
– Good for Poor Coverage and Hotspot Applications
ƒ Highly Reliable File Transfer
ƒ Provides Channel Polling for Up to 6 Channels
MQ Solution
ƒ File Transfer and Management
Software Application
ƒ Web Based
ƒ Can Transfer Files From One Location
to Multiple Other Locations/Addresses
ƒ Schedules File Transfer
ƒ Tracks Scheduled File Transfers
ƒ Reports Exceptions
VIMS Guardian

On-board Retrofit System

for Non-VIMS Machines to
Provide Additional
Technical Information
Monitoring Capability
VIMS Guardian
ƒ VIMS system for non-VIMS machines
ƒ No operator interface/display
ENGINE
LAPTOP PC
ET
VIMSpc

ET SERVICE
SERVICE PORT ED
F AC B TRANSMISSION
PORT GHI
B

CAT
A
C

DATA LINK
CAN PORT

Currently VIMS
Track type IMPLEMENT
BROADCAST PORT tractors
GUARDIAN

Available (TELEMETRY)

D11, D10, D9
68k to ABL Retrofit
ƒ Currently
available ET
CAT DATA LINK
ET SERVICE

for all 68k ED

F AC
GHI
B
PORT

SERVICE
equipped PORT
VIMS CAN PORT A
C

ABL
trucks* VIMSpc

LAPTOP PC

ƒ Refer to
IRM PELJ0370
and BROADCAST PORT
(TELEMETRY)

Special
Instruction * 789 VIMS config
being finalized now
REHS2142
777D VIMS Retrofit Kit
ƒ Similar to VIMS on Large Mining Trucks
ƒ Available November 2006
ƒ Two Versions Available
– For Trucks With TPMS Attachment
– For Trucks Without TPMS Attachment
ƒ Approximately 25 Kits Installed and
Running To Date
VIMS Support Materials
ƒ VIMS Resource Kit – AEXC0682
– Customizable PowerPoint Presentation
– Marketing Brochure
– SalesGrams and Info Sheets
– Answers to Frequently Asked Questions
– VIMS Case Studies – Value Stories
– Library of Images and Illustrations
ƒ VIMS Simulator – SERV7041
ƒ VIMS Application Guide – SELD7001
 Future On-Board
Information Monitoring
Technology

VIMS 3G
Future On-board System
VIMS Onboard Hardware Versions
ƒ 68k Hardware
– Older version of hardware with service
and telemetry ports only
ƒ ABL Hardware V IMSwith service,
– Current production hardware
telemetry, and CAN ports 3 G
– Added to allow wireless file downloads
ƒ A4N Hardware
– Next generation production hardware with
service, telemetry, CAN, and ethernet ports
797F/793F VIMS System
VIMS 3G
ECM’s

Predictive Analysis
Module (A4:N2)
 Information Monitoring
Distribution Strategy
Customer
Dealer Dealer/Cat
Basic Advanced Svcs Premium Svcs
ƒ Off-board Data Source ƒ Equipment ƒ Advanced
—SOS, etc. Management Diagnostics/Prognostics
ƒ On-board data provided process w/Intellectual Property
by machine implementation ƒ Option to Provide
ƒ Customer uses at his ƒ Health solution through Advanced Service
discretion Dealers Support to Less Capable
ƒ Customized Reports Dealers
ƒ Advanced Tools Not
Dealer drive to Available to Customers
participate in value
ƒ Diagnostic Drill Down
added services Capability
VIMS 3G Features
Location Flexible Histograms
Hours Standard Snapshots
Geo-Fencing Continuous Data Logger
Events VIMS Trends
Total Fuel Consumption Abuse Monitoring
Fuel Level Percentage Flexible Events
Scheduled Reporting Distributed Trends
Event Chronological List Flexible Trends
Event Active List Flexible Data Logging
Totals-Configurable Flexible Snapshots
VIMS Histograms Tire Monitoring – TMPH/TKPH
Standard Data Logger Road Analysis Control – RAC
Distributed Totals Payload Control System – PCS
Resettable Totals Truck Payload Mgt. System
Distributed Histograms Haulage Optimization
Machine Start/Stop Time Predictive Analysis Service
 VIMS 3G Features
g e 1 Location Flexible Histograms
a
Pack Hours Standard Snapshots
Geo-Fencing Continuous Data Logger
Events VIMS Trends
Total Fuel Consumption Abuse Monitoring
Fuel Level Percentage Flexible Events
Scheduled Reporting Distributed Trends
Event Chronological List Flexible Trends
Event Active List Flexible Data Logging
Totals-Configurable Flexible Snapshots
VIMS Histograms Tire Monitoring – TMPH/TKPH
Standard Data Logger Road Analysis Control – RAC
Distributed Totals Payload Control System – PCS
Resettable Totals Truck Payload Mgt. System
Distributed Histograms Haulage Optimization
Machine Start/Stop Time Predictive Analysis Service
 VIMS 3G Features
g e 2 Location Flexible Histograms
a
Pack Hours Standard Snapshots
Geo-Fencing Continuous Data Logger
Events VIMS Trends
Total Fuel Consumption Abuse Monitoring
Fuel Level Percentage Flexible Events
Scheduled Reporting Distributed Trends
Event Chronological List Flexible Trends
Event Active List Flexible Data Logging
Totals-Configurable Flexible Snapshots
VIMS Histograms Tire Monitoring – TMPH/TKPH
Standard Data Logger Road Analysis Control – RAC
Distributed Totals Payload Control System – PCS
Resettable Totals Truck Payload Mgt. System
Distributed Histograms Haulage Optimization
Machine Start/Stop Time Predictive Analysis Service
 VIMS 3G Features
g e 3 Location Flexible Histograms
a
Pack Hours Standard Snapshots
Geo-Fencing Continuous Data Logger
Events VIMS Trends
Total Fuel Consumption Abuse Monitoring
Fuel Level Percentage Flexible Events
Scheduled Reporting Distributed Trends
Event Chronological List Flexible Trends
Event Active List Flexible Data Logging
Totals-Configurable Flexible Snapshots
VIMS Histograms Tire Monitoring – TMPH/TKPH
Standard Data Logger Road Analysis Control – RAC
Distributed Totals Payload Control System – PCS
Resettable Totals Truck Payload Mgt. System
Distributed Histograms Haulage Optimization
Machine Start/Stop Time Predictive Analysis Service
 VIMS 3G Features
g e 4 Location Flexible Histograms
a
Pack Hours Standard Snapshots
Geo-Fencing Continuous Data Logger
Events VIMS Trends
Total Fuel Consumption Abuse Monitoring
Fuel Level Percentage Flexible Events
Scheduled Reporting Distributed Trends
Event Chronological List Flexible Trends
Event Active List Flexible Data Logging
Totals-Configurable Flexible Snapshots
VIMS Histograms Tire Monitoring – TMPH/TKPH
Standard Data Logger Road Analysis Control – RAC
Distributed Totals Payload Control System – PCS
Resettable Totals Truck Payload Mgt. System
Distributed Histograms Haulage Optimization
Machine Start/Stop Time Predictive Analysis Service
 VIMS 3G Features
g e 5 Location Flexible Histograms
a
Pack Hours Standard Snapshots
Geo-Fencing Continuous Data Logger
Events VIMS Trends
Total Fuel Consumption Abuse Monitoring
Fuel Level Percentage Flexible Events
Scheduled Reporting Distributed Trends
Event Chronological List Flexible Trends
Event Active List Flexible Data Logging
Totals-Configurable Flexible Snapshots
VIMS Histograms Tire Monitoring – TMPH/TKPH
Standard Data Logger Road Analysis Control – RAC
Distributed Totals Payload Control System – PCS
Resettable Totals Truck Payload Mgt. System
Distributed Histograms Haulage Optimization
Machine Start/Stop Time Predictive Analysis Service
 VIMS 3G Features
g e 6 Location Flexible Histograms
a
Pack Hours Standard Snapshots
Geo-Fencing Continuous Data Logger
Events VIMS Trends
Total Fuel Consumption Abuse Monitoring
Fuel Level Percentage Flexible Events
Scheduled Reporting Distributed Trends
Event Chronological List Flexible Trends
Event Active List Flexible Data Logging
Totals-Configurable Flexible Snapshots
VIMS Histograms Tire Monitoring – TMPH/TKPH
Standard Data Logger Road Analysis Control – RAC
Distributed Totals Payload Control System – PCS
Resettable Totals Truck Payload Mgt. System
Distributed Histograms Haulage Optimization
Machine Start/Stop Time Predictive Analysis Service
VIMS 3G Features
Location Flexible Histograms
Hours Standard Snapshots
Geo-Fencing Continuous Data Logger
Events VIMS Trends
Total Fuel Consumption Abuse Monitoring
Fuel Level Percentage Flexible Events
Scheduled Reporting Distributed Trends
Event Chronological List Flexible Trends
Event Active List Flexible Data Logging
Totals-Configurable Flexible Snapshots
VIMS Histograms Tire Monitoring – TMPH/TKPH
Standard Data Logger Road Analysis Control – RAC
Distributed Totals Payload Control System – PCS
Resettable Totals Truck Payload Mgt. System
D V A N CED
Distributed Histograms Haulage Optimization A ERVICES
S
Machine Start/Stop Time Predictive Analysis Service
VIMS 3G Connectivity
ƒ MineStar Fleet ƒ Satellite
Commander/Health
ƒ Cellular Radios
ƒ Third Party Back
Office Systems ƒ Broadband Radios
– Modular Mining
Systems ƒ Communicator
Functionality
ƒ Electronic
Technician – ET – File Push

ƒ VIMS PC 3G ƒ Hot Spot Capability

ƒ TC900C Radios
Off-Board Products and
Services
ƒ VIMS 3G PC
ƒ Dealer Condition Monitoring Services
ƒ Predictive Analysis Services
ƒ Haulage Optimization
VIMS PC – 3G
ƒ Support New VIMS 3G On-board System
ƒ Replace Legacy Off-Board Support
Tools
– Current VIMS PC
– VIMS Supervisor
– TPMS
– PCS
– Download Utility
Tool for WL’s
Dealer Condition
Monitoring Services
ƒ Customer condition monitoring
expectations will be met by a
combination of Cat products
ƒ Caterpillar is actively working to
rationalize off-board CM tools
ƒ Dealer’s goal is to utilize CM tools
and intellectual property to provide
a differentiated condition monitoring
service
 Information Monitoring
Distribution Strategy
Customer
Dealer Dealer/Cat
Basic Advanced Svcs Premium Svcs
ƒ Off-board Data ƒ Equipment ƒ Advanced
Source Management Diagnostics/Prognostics
—SOS, etc. process w/Intellectual Property
ƒ On-board data implementation ƒ Option to Provide
provided ƒ Health solution through Advanced Service
by machine Dealers Support to Less Capable
ƒ Customer uses at his ƒ Customized Reports Dealers
discretion ƒ Advanced Tools Not
Dealer drive to Available to Customers
participate in value ƒ Diagnostic Drill Down
added services Capability
Predictive Analysis
Services
If this truck is showing signs
that it is going to break down
next week...

Wouldn’t we want to know… TODAY?

Predictive Analysis
Finds the “Needles in The Haystack”
ƒ Turns thousands of lines
of data into exception-based BOOST LEAK
intelligence. FUEL DILUTION

ƒ Provides more time to react BROKEN PISTON RING

than regular alarms.

ƒ Finds losses in performance,
bad sensors and equipment
doomed for failure.
ƒ Provides direction and
priority and improves
manpower efficiency.
Predictive Analysis Powered by Smart Signal ®
 Predictive Analysis
Early Detection
Personalized Empirical Model

ƒ Create a model
Real-time ƒ Gather actual data
Sensor Data Boost
ƒ Run data against model Statistical
EGT
ƒ Identify anomalies Deviation
RPM
Detection
ƒ Analyze results
Oil ƒ Determine repair Determines
recommendations
Pressure
If Operation
Is Abnormal

Diagnostic Rules Engine

Predictive Analysis Services
Early Warning Condition
Monitoring
ƒ 3x797 Gillette, Wyoming
ƒ 39x793 Gillette, Wyoming
ƒ 2x793D (w/C-175) Field Follow
Mining Components
Monitored With Predictive
Analysis Services
ƒ 3516 Engine – mining machines
ƒ Under development
– Transmission – mining trucks
– Hydraulic pumps – 994 wheel loader
– Rear axle – mining trucks
Predictive Analysis Summary
5 - 10+ Days of Early Warning
ƒ Boost leak ƒ High oil filter
– Leaking seals differential pressure
– Found a rag in the filter
ƒ Valve failure – Cam lobe spalling
– Occurred after a valve – Loose sump bolts
adjustment allowing dirt entry
– Broken piston ring
ƒ Low oil pressure – Found shop oil supply
– Cross over tube found in bypass
to be leaking
ƒ Failing exhaust
– Leaking fuel injector temp sensors
– Erratic readings
Predictive Analysis Benefits
ƒ Proactive Alerts of Developing Problems
ƒ Reduce Labor to Identify Problems
ƒ Reduce False Alerts
ƒ Reduce Unscheduled Downtime
ƒ Extend Component Life Cycles
– Fewer catastrophic failures
– Provide early detection of component degradation
– Reduce maintenance expenditures
ƒ Identify Training and Process Opportunities
– Maintenance Practices
– Operator Practices
797F/793F VIMS 3G System

Predictive Analysis
Module (A4:N2)
Haulage
Optimization
 What is Haulage Optimization?
GPS

Embedded technology

Data Analysis and Simulation

Mine Haul Road

Haulage Operation
Improvement
Recommendations

“Haulage Optimization” integrates sophisticated on-board powertrain

information with high precision GPS and off-board analysis and simulation
to identify hauling operation improvement recommendations that positively
impact site throughput, fuel usage, component life, and greenhouse emissions.
Haulage Optimization
Haulage Optimization could Service Offering
quantify …
ƒ Grade irregularities
ƒ High rolling resistance spots
ƒ Premium Service
ƒ Cut downs, Switchbacks
ƒ Road defects ƒ Consulting Business
ƒ Traffic congestion spots Initially
ƒ Productivity mismatches
ƒ Payload mismatches to haul road condition ƒ Continuous
ƒ Underperforming Trucks Monitoring Later
& quantify resultant improvements
in terms of … ƒ Leverage Predictive
ƒ Overall site productivity improvement Analysis Service
ƒ Optimal payload capacity
ƒ Decreased fuel consumption Capabilities
ƒ Decreased gaseous emissions
ƒ Increased component life ƒ Limited Commercial
ƒ Overall cost reduction Availability
Based on customer’s highest – Early 2009
priority needs.
Condition Monitoring
Enablers Summary
ƒ Current VIMS System Stable
ƒ VIMS 3G Will Provide Additional CM and
Performance Monitoring Capability
ƒ VIMS Retrofit/Upgrade Strategy Being
Developed
ƒ Cat’s goal is to empower dealers with CM
tools and intellectual property which enables
a differentiated condition monitoring service
ƒ Premium CM Services Under Development –
Available Commercially 1Q2009