Wireless Mesh Network “Killer Apps” – From Niche to Mainstream

Exactly six years ago, just after I joined a start-up company called Spinwave Systems, we sat around our conference room table, our polished crystal ball positioned in the center, and tried to predict the future of the building automation market.

Ideas started erupting:
  • “In order to make existing buildings more energy-efficient, more data is needed to feed smart control algorithms.”
  • “Making building automation systems smarter requires easy integration with wireless sensor points.”
  • “Installation cost is a major concern for energy retrofits. Wireless is the answer.”
  • “Our competition is wire; we need to match its reliability and simplicity while significantly reducing installed cost.”
  • “Wireless sensors are just the beginning. The market will require wireless I/O and controllers.”

And so on …

Excitement built and it seemed to be certain that the wireless market would develop rapidly.

Well, vision and excitement is what fuels start-ups and keeps you going through the ups and downs (and chasms and tornadoes) of innovating and introducing new technology to an existing market.

The reality of new technology marketing is that you initially sell to early adopters and that you have to convince the “early majority” that your product works and is a real solution to a problem.

From Niche …

In the early days we sold products to a very select number of applications, e.g. to be installed in museums with marble walls or not-to-be-disturbed asbestos filled buildings. A few gutsy integrators bought our wireless products because there was no way to use wires at all.

… To Mainstream

Six years and more than 30,000 devices later, our products have been used by several hundred different customers in a wide variety of applications, including:

  • Demand Response
  • Energy Efficiency
  • Data Center Monitoring
  • Energy Use Monitoring
  • Food and Drug Temperature Monitoring
  • Energy Management
  • Soil and Crop Temperature Monitoring
  • Energy Auditing

… To Killer Apps

Let’s define a “Killer App” as being an application where wireless products provide a compelling solution to a real-world problem. Another, very selfish, requirement is that solving this problem results in a meaningful business opportunity.

Over the years, four “Killer Applications” have presented themselves to us:

Wireless Metering

Wirelessly transmitting meter data (electric, water, gas) to a building automation system or central monitoring station is a strong segment. Our SWS-DPC Wireless Digital Pulse Counter is a very popular product in this segment.

It allows to wirelessly enable existing meters with pulse output and monitor consumption remotely. Our turnkey products SWS-DPC-N4BAT and SWS-DPC-N4PSI are popular due to the extended range of the A3 radio and the plug and play aspect of the DPC packaged in a NEMA 4 enclosure which has been factory bound to a receiver unit. Installation is quick and does not require shovels, pitchforks and jackhammers.

  • Reuse of existing meters
  • Easy and quick to install turnkey solution
  • No trenches or conduit

Energy Efficiency

The SWS-T wireless zone temperature sensor is increasingly being used in retrofit energy efficiency applications to transmit temperature data to a building automation system.

A very popular segment is precise boiler control in multi-family, hi-rise residential buildings.

  • Cost-effective acquisition of multiple temperature points for smarter control
  • Significantly reduced installation cost and time
  • Significantly increased occupancy comfort and energy-efficiency

Mission Critical Facilities

Spinwave’s A3 mesh network is ideally suited for Data Centers, where monitoring environmental conditions is mission critical to: ensure equipment uptime; deliver on energy efficiency programs; and meet service level commitments.

Self-forming deployment is quick and simple as nodes automatically join the network when powered up.

Flexible mounting options and support for multiple external temperature probes are ideal for monitoring temperature and humidity on server racks. The system easily interfaces with existing management and building automation systems.

  • Increased equipment uptime
  • Increased cooling efficiency
  • Quick and flexible to deploy
  • Easy integration

Regulated Industries

Hospitals are required to adhere to stringent temperature monitoring of freezers and refrigerators used to store pharmaceuticals, blood, organs, tissues, food and other items. Regulatory requirements (e.g. FDA, AABB, cGMP) are closely watched by regulatory bodies to ensure patient safety. Many hospitals today use a manual process of checking and recording each refrigeration unit on a daily basis, a time consuming and error prone activity.

Spinwave Systems’ wireless temperature sensors can automate the record keeping process. They are available for a wide temperature range to monitor fridges and freezers.

  • Can be installed without disrupting hospital operation.
  • Easily integrates with the existing Building Automation System, using its inherent logging, monitoring, alarming and reporting capabilities and avoiding the cost of a separate isolated solution.
  • The hospital can easily expand the system to monitor additional equipment.
  • Automatic record keeping, alarming and reporting makes it easier for the hospital to comply with regulatory requirements.

Conclusion

Wireless mesh networks have matured and become mainstream. Hundreds of thousands of nodes have been deployed successfully in a range of applications. For a number of those applications only wireless products can provide an economical solution.

Whether your project is in need of a “Killer App” or you have a new problem for us to solve, please don’t hesitate to contact us.

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New Product Announcement – Cloud Gateway

Spinwave Systems Inc. is proud to announce its new line of embedded mesh gateways. This powerful platform offers a completely self contained wireless mesh solution with built-in configuration tools, extended device support, on-board and cloud-based data logging and Modbus TCP support for stand-alone and integrated monitoring solutions.

Powerful open platform

The new gateway is an extremely energy-efficient powerful embedded Linux device with Apache web server, PHP and SQLite.

Spinwave System's wireless mesh gateway is cloud-ready

New Linux-based Mesh Gateway

The device boots from a Micro SD card. The SD card is also used for long-term data logging. Dynamic and static IP addressing is supported. The battery-backed real-time clock can be internet synchronized. Up to two (2) wireless mesh radios are connected (and powered) via USB.

Part Numbers:
SWRF-CLOUD-1: Supports up to 75 wireless devices, included one mesh radio
SWRF-CLOUD-2: Supports up to 140 wireless devices, includes two mesh radios

 

Extended device support

The SWRF-CLOUD gateways now support all A3 sensors and transceivers, in addition to Spinwave’s repeaters, thermostats (SWC-TSTAT-3), and select Modbus RTU devices. The number of devices per mesh gateway has been increased to 140 (from previously 50).

Wireless Mesh Network Architecture

Wireless Mesh Network Architecture

 

Maintain remote sites with ease

All tools to configure and maintain your wireless mesh networks are now built into the gateway. Wireless devices can be discovered and configured using a standard web browser.

Embedded Mesh Network Configuration Tools

Embedded Mesh Network Configuration Tools

Device-specific data can be monitored and adjusted easily. Just select a device in the project tree and the associated information is displayed in your browser. The gateway even accumulates and logs HVAC equipment runtimes.

Monitor wireless device data using web browser

Monitor wireless device data using a web browser

Plug and Log

Do you need to conduct a site survey in preparation of an energy efficiency project? Do you need to map server inlet temperatures in a data center? The new gateway, in combination with easy-to-install wireless sensors, is ideal for standalone monitoring solutions. Wireless device data can be logged for months on the gateway’s on-board Micro SDcard. Powerful embedded tools make it easy to select and analyze environmental variables and energy consumption. Data base maintenance is performed automatically; old records are periodically purged.

Analyse wireless device data

Analyse wireless device data

A simple click on a button exports and downloads device data to an EXCEL compatible CSV file for further analysis.

Download log data to EXCEL compatible CSV files

Download log data to EXCEL compatible CSV files

Cloud-ready

The embedded web client can push data to cloud-based data storage and analysis services. All you need is internet access at your remote site. The gateway supports dynamic IP addressing and uses HTTP to push data to the cloud. No public IP address or firewall acrobatic is required.

At launch, the gateway supports KGS Buildings’ Clockworks cloud service. Please contact us if you would like to connect to a different service.

Automation System ready

Building automation systems can easily retrieve wireless sensor data and change device set-points via the gateway’s Modbus TCP server. Wireless device data is accessed using Modbus holding registers.

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Case Study: The Beet Goes On

What does a pile of sugar beets 1,100 feet long, 240 feet wide, 30 feet tall and 242 x 7.5 hp fan motors have in common?
They are actually part of an engineered process where at the end of harvest season the beets are fashioned into a geometric shape (also called a clamp). The fans pump air into the piles from the sides in an attempt to lower the temperature of the mass of beets rapidly. This is done in northern climates in states such as Wisconsin, Minnesota, Michigan and North Dakota at many hundreds of locations.
Wireless Temperature Sensor Network, monitoring Sugar Beet Piles

Sugar beet pile fan control using wireless temperature sensor network

This process starts in early October with the onset of sub-freezing temperatures often enjoyed by the residents of these areas. The beet piles are maintained at below freezing temperatures until March when the piles are recovered and then sent on to processing facilities.
The problems that were inherent with controlling those fans and the 1,364 KW of power input associated with a single pile was monitoring the core temperature of the material and managing that process efficiently.
System integrator Kahler Automation has had many years to look at the problem in concert with their client companies. They had previously tried wired sensor networks which used to be the conventional approach. But that posed another problem. What goes along with sub-freezing temperatures is snow accumulation. Snow has to be cleared off the tops of the piles with snow blowers, to allow for the crucial process airflow through the piles.
That meant that the wired sensors had to be removed periodically to allow the snow removal process to take place. In other words: An awful lot of labor dollars expended each year.
Spinwave Systems introduced an alternative method to Kahler by providing that sensor input without the need of having to remove the temperature sensors multiple times every winter season.
Each of three test piles were designed to have 27 to 39 wireless temperature sensors each in rows of three, perpendicular to the long axis of the piles. The A3 wireless sensor networks easily covered the large area. There are a total of 7 piles at this particular customer site.
Kahler fabricated custom enclosures in which the A3 transceivers and temperature probes are housed and added several features that will further save labor to the overall process. They added a “Tilt Switch” to the battery circuit which, when the Sensor is removed for storage during the spring and summer seasons, will disconnect power to the sensor without having to physically disassemble the package. This also prolongs battery life for several season cycles.
One on line web-based training session was all the crew at Kahler needed to enter the world of wireless applications and streamline a previously labor intensive process.
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Case Study: Wireless Temperature Monitoring at Louisiana Hospital

Challenges

Hospitals are required to adhere to stringent temperature monitoring of freezers and refrigerators used to store pharmaceuticals, blood, organs, tissues, food and other items. Regulatory requirements (e.g. FDA, AABB, cGMP) are closely watched by regulatory bodies to ensure patient safety. Many hospitals today use a manual process of checking and recording each refrigeration unit on a daily basis, a time consuming and error prone activity.

One of the newest regional medical centers in Louisiana needed to add temperature monitoring to the nearly 200 stand alone refrigerators for pharmaceutical and food storage throughout the 6 Floor facility.

The Hospital was virtually completed when the requirement was presented to the system integrator, meaning the addition of network wiring, input / output modules, not to mention thousands of feet of sensor wiring would have been costly and disruptive to the move-in of the hospital staff.

Solution

The system integrator investigated several solutions and turned to Spinwave Systems to supply them with a wireless temperature monitoring system that could be easily deployed and integrated with the existing Building Automation System (BAS).

The temperature monitoring system was structured into 6 wireless mesh networks, one per floor. Each mesh network consists of one Receiver/BACnet IP Gateway and a number of SWS-T-EXT battery powered remote probe wireless sensors. The remote thermistor probes were installed inside the refrigerators on all the patient floors on the 3rd through the 6th floor.

The 1st and 2nd floor Networks included sensors for food storage and preparation in freezers and coolers as well.

All of the temperature sensor data is archived on the existing BAS for monitoring, alarming and reporting.

Wireless Mesh Network Architecture

Results

  • The wireless temperature monitoring system was installed without disrupting hospital operation.
  • The system easily integrated with the existing Building Automation System, using its inherent logging, monitoring, alarming and reporting capabilities and avoiding the cost of a separate isolated solution.
  • The hospital can easily expand the system to monitor additional freezers and refrigerators. Spinwave provides additional sensors, capable of monitoring ultra-low temperature freezers and able to interface to CO2 sensors, pressure sensors, etc.
  • Automatic record keeping, alarming and reporting makes it easier for the hospital to comply with regulatory requirements.

 

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Spinwave Systems expands line of wireless Data Center Sensors

Spinwave has recently introduced a new sensor line with significantly more range than earlier models. The new sensor has an open field range of 1,000 Ft. (300 m), which is a 60% increase over the 600 feet in earlier models.

The redesign provides increased configuration flexibility, enabling the introduction of several new sensors, designed for monitoring of server racks in data centers. A single sensor can now monitor temperatures at the top, middle and bottom of a rack. Additionally, sensors that monitor both temperature and relative humidity and analog input sensors are available.

A single receiver/gateway now supports up to 50 wireless sensors/transceivers and 200 measurement points.

Click here for Data Sheet …

Background

Growth in the data center market is exceeding the overall growth in other markets by a wide margin. A recent survey by Datacenter Dynamics Research reports investment of about $30 billion during 2010-2011 and is projected to rise by over 16% to $35 billion in the coming 12 months.

This growth is fueled by escalating connectivity requirements, explosion of cloud computing, and an increasing emphasis on data mining, which is driving a major expansion of data center capacity. The result is a demand for more computing power, server density and a corresponding increase in heat loads, resulting in rapidly escalating energy costs.

Data center operators are faced with two major and seemingly contradictory challenges:

Uptime: Customers demand connectivity! Maintaining uninterrupted operations is Priority 1.

Energy Management: 50% of energy costs in data centers are to power servers. The other 50% ia spent to cool them. Given the escalating cost of energy, energy management has rapidly risen to Priority 1A.

Sensor-based Environmental Monitoring Systems help to achieve these seemingly contradictory objectives!

Environmental monitoring, based upon data provided by sensors deployed throughout a facility, provide a real-time picture of the state of a data center. This enables operators to detect existing problems and potential problems, allowing timely corrective actions to ensure uninterrupted operations.

The data provided enables operators to develop energy management strategies such as running the data center at higher temperatures or running air conditioning units based on actual cooling demand.

Data centers are a dynamic and changing environment, characterized by frequent server upgrades, infrastructure changes and rack re-configurations. Wireless sensor networks are ideal in this environment, due to installation flexibility and ease of deployment.

Spinwave is enjoying increasing market share in data centers due to its highly reliable sensor networks and products.

Spinwave Products Feature:

High Reliability: A Spinwave network utilizes a mesh architecture and a wireless protocol which allows multiple routes for data to reach its destination. It utilizes a frequency hopping scheme (A3) that avoids RF interference by continuously and seamlessly scanning all 16 channels in the 2.4 GHz spectrum for interference and automatically selecting the best channels to ensure maxiumum transmission reliability.

Low Installation Cost: Wireless – no conduit, wiring trays, or other construction related activities.

Easy Deployment: A complete temperature, humidity, and air pressure monitoring network can be installed rapidly with no disruption to data center operations.

Multiple Data Gateways: Integration with data center monitoring systems can be quickly and easily accomplished using common industry protocols – BACnet, LON, Modbus and SNMP.

Flexibility and Scalability: Spinwave’s system can be used to monitor servers in a closet or scale to a major data center. Since the sensors are wireless, they can be easily moved as configurations change or can be used on a temporary basis to monitor a specific zone, aisle, or rack.

Proven: Spinwave products are field tested with thousands installed in data centers, commercial buildings, industrial plants, hospitals, warehouses and educational facilities.

 

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Spinwave releases new Modbus RTU, BACnet MS/TP and N2 Receiver/Gateway

The latest version of Spinwave Systems’ SWRF-MODBUS-RTU and SWRF-BACNET-MSTP receiver/gateway now allows changing communication parameters, like baud rate and Node ID, via DIP switch settings.

Additionally, three protocols are supported by the same module and the user can field-select between:

  • MODBUS-RTU
  • BACnet-MSTP
  • Johnson Controls N2
The new product release reduces stock part numbers and allows to easily change protocol settings in the field, without the need of additional software tools.
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