Industrial Grade Equipment Utilization Sensor with Downtime Monitoring – Wireless

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Equipment Utilization and Downtime Monitoring Sensor Specifications

Accurate Machine Downtime Monitoring

This system functions as a comprehensive equipment utilization and downtime tracking solution for availability analysis and continuous improvement efforts.

• Sensor integrates with a current switch, amp clamp, or other on/off contact to detect true/false or open/close conditions.
• Each transition between active and inactive states is time-stamped and stored.

Machine Cycle & Stop Count Monitoring

The sensor uses a split-core amp clamp or a proximity sensor to function as a machine cycle counter. Ideal for supporting structured machine downtime tracking and reliable production reporting.

• When using a split-core amp clamp, the counter increments each time current exceeds the defined “on” threshold.
• Proximity sensors may also be used to detect open/close mechanical movement.
• Configurable debounce settings prevent false multiple counts caused by signal flicker

Downtime Tracking & Reduction Capabilities

Detailed level of visibility helps operations teams identify recurring causes and implement strategies to reduce equipment downtime and minimize downtime across production lines.

• Tracks every downtime event individually
• Measures total uptime and downtime since last reset
• Maintains a running total for machine availability calculations
• Stores historical data for long-term downtime analysis

Automated Downtime Alerts

When downtime exceeds user-defined thresholds, the system can trigger:

• Text alerts
• Email notifications
• Telephone alerts

Real-time notifications support faster response times and proactive downtime prevention, helping reduce lost production hours.

OEE & Manufacturing KPI Monitoring

For operations focused on continuous improvement, the system tracks seven key manufacturing KPIs:

• Machine utilization
• Production counts
• Downtime events
• Stop counts
• Total downtime
• Total active time
• OEE (based on uptime percentage since last reset)

Power Requirements

• Because the sensor must continuously detect state transitions, it remains powered at all times using a 12VDC supply (typically via 120V wall outlet transformer)

The wireless equipment utilization sensor with downtime monitoring is ideal for:

• Equipment utilization monitoring for capital asset utilization verification.
• Continuous process production monitoring.
• Real-time production line downtime alerts.
• Downtime recording with time of downtime and duration.
• Tank and hopper bin empty condition monitoring.
• Remote monitoring of critical relay contacts and switches.

Patents pending