AbstractRadio-frequency identification (RFID) is an emerging technology, which promises to advance the modern industrial practices in object identification and tracking, asset management and inventory control. This technology is being evaluated and implemented successfully in many manufacturing and distribution environments, retail stores and defense installations.

The scope of RFID is rapidly shifting from tracking objects (present or absent) to monitoring the condition (where and how) of engineering systems. The integration of sensors with RF tags (Smart Sensors) enables RFID technology to gather and process sensor data in addition to identifying and tracking the object. The deeper ramification of such RFID systems for monitoring manufacturing systems remains largely unexplored and untapped.

The focus of the presentation will be to present the results of our in-depth review of the current and emerging technologies and applications based on RFID and Smart sensors for depot support and logistics environments and for machine condition monitoring.

Radio-Frequency IDentification (RFID)

Radio-Frequency identification (RFID) is generic term for technologies which use RF waves to identify, track or categorize any object

RFID is fast, reliable, and does not require physical sight or contact between reader and the tagged object

RFID System Components Tags (Transponders)

Attached to the object to be identified, stores information (unique code) about object and sends this information back to reader when receives appropriate frequency signals

Reader/InterrogatorReader sends signals of appropriate frequency and

facilitates data transfer

AntennaAntenna radiates the RF signal to, and receives signal from the

transponder

InterfaceThis unit interfaces the reader to an intelligent device / controller

Host/Controller (PC/Laptop)Computer with suitable software controls RFID readers

How system works?

Controller activates RFID reader to send RF signals Reader sends the signal of appropriate frequency (LF,HF,UHF,MW) Tag receives and modifies the signal Tag sends modified signals back through tag antenna Reader antenna receives the modified signal and reader decodes it Controller analyzes the results

RFID and Smart Sensors

Sensors can be integrated with RF tags (Smart Sensors) and sensor data can be communicated using RF waves

This enables RFID systems to gather and process sensor data in addition to identifying and tracking object

Applications: Machine Health Monitoring, Fluid Composition Detection.

Applications in Depot Support Environment

Appropriate technician informed as per schedule via

mobile communication

Vehicle tag detected by

readers mounted in the gates

Vehicle sent to appropriate

machines and database updated

after each operation

Vehicle brought to maintenance

shop

Vehicle InspectionMaterial request

sent to the warehouse and

material retrieved as per history

sheet

Operation Sequencing and Scheduling done as per availability

of machines

ERP SystemShop

Benefits

Automatic Operation

Time Management

Quality Management

Poka - Yoke

Material Management

Vehicle history sheet retrieved

Warehouse

Applications in Logistics

Real Time Inventory Tracking

Eliminating Inventory Shrinkage

Benefits

Cycle time Reduction

Information Visibility

Delay Reduction

Warehouse

Parts recognized and database updated at warehouse gate

Transit

Mode of transit tracked at every designated halt by Through satellite communication

Supplier Site

Readers mounted on forklift trace and track the parts out of the warehouse to appropriate shop

Parts properly tagged at supplier site and inventory database updated

Request sent to ASRS

ERP System

Parts grouped and stored in the ASRS

Applications in Monitoring Health of Machines

Lubricant levelBearing condition Tool wear Table alignment

MACHINE CONDITION MONITORING DATABASE

RFID based Smart Sensors send critical information about machine parameters to the central database

Lubrication & Coolant

Tribology Tool Engineering

Metrology

DEPARTMENT OF MACHINE MAINTENANCE

Reduction in response time

Quality management

Reduction of scrap

Predictive maintenance

BenefitsThe database sorts data & sends to appropriate department

Tag Selection Guide Factors affecting Tag Selection

TAG / TRANSPONDER

Frequency Range

Read Range Application

Functionality Environmental Conditions

Standard Compliance

What is application?

LF 125,134 KHz

HF 13.56 MHz

UHF 902-928 MHz

Microwave 2.45 GHz

Short Range

Long Range

Passive Active Semi Passive

RF friendly

Vicinity of Metals & Liquids

ISO/IEC

EPC Gen 1, 2

Form Factor

Reader Selection Guide Factors affecting Reader Selection

Reader/Interrogator

Frequency Range

Read Range Application

Functionality Environmental Conditions

Standard Compliance

What is application?

LF 125,134 KHz

HF 13.56 MHz

UHF 902-928 MHz

Microwave 2.45 GHz

Short Range

Long Range

Passive Active Semi Passive

RF friendly

Vicinity of Metals & Liquids

ISO/IEC

EPC Gen 1, 2

Form Factor

Coupling, field & applications based on frequency

902-928 MHz

13.56 MHz

125-134 KHz

2.45GHz

Induction Coupling Propagation or Backscatter Coupling

Near Field Communication

Far Field Communication

Short Range Applications

Long Range Applications

Cou

plin

g, F

ield

& A

pplic

atio

n

Powered by EM field Powered by Radio-waves

Micro-Wave LF HF UHF

Geo

grap

hica

l Reg

ions

Micro-Wave LF HF UHF

Region 1

Region 2

Region 3

125 – 134 KHz

868-870 MHz

2.4 – 2.48 GHz

13.56 MHz

125 – 134 KHz

902-928 MHz

2.4 – 2.48 GHz

13.56 MHz

125 – 134 KHz

950-956 MHz

2.4 – 2.48 GHz

13.56 MHz

Europe, Middle East, Africa, Former Soviet Union

US & Canada, Pacific East of international date line

Japan

Frequency Allocation as per region

Micro-wave LF HF UHF902-928 MHz

13.56

MHz125-134 KHz

2.45GHz

ISO

/IEC

180

00-2

ISO

/IEC

180

00-3

ISO

/IEC

180

00-6

ISO

/IEC

180

00-4

EPC

Gen

1

EPC

Gen

1, G

en 2

Air

Inte

rfac

e Pr

otoc

ol

Air Interface Protocols standards over frequency range

Max. Possible Read Range based on frequency range

Typical applications based on frequency range

UHF902-928 MHz

HF 13.56 MHz

LF 125-134 KHz

Micro-Wave2.45 GHz

Dock Door ReadingAsset management in WarehouseOverhead readingSmart ShelvesBaggage Tracking

Long Range ApplicationsApplications requiring large data transfer

Electronic Door Locking SystemContact less Smart Card SystemPOS applications

Animal IdentificationItem Level Tracking – Baggage handlingSmart Shelves

Short Range Systems

Short Range Systems: up to 1 m Applications in vicinity of metals and liquids

Long Range Systems: Range>1m

Automatic Toll Collection SystemsSupply Chain Applications

Typical Applications

Freq

uenc

y R

ange