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This groundbreaking sensor integrates a current switch (or other on/off contact) to track machine availability and equipment utilization rate. This sensor is the ideal solution for many applications monitoring on/off, true/false, open/close types of discrete conditions. Edge computing at the sensor node calculates the amount of time electrical current is flowing above a set threshold, as well as the time not running. It then counts the number of transitions, along with the percentage of time equipment is active. The system triggers text, email, and telephone alerts when the downtime exceeds certain user-set limits. A count-reset button on top of the enclosure resets the count at the end of a shift. Resets can also be configured to automatically be triggered at a certain time.- Works as a idle machine sensor, while also tracking 7 manufacturing KPIs, including: machine utilization, production counts, downtime events, OEE, stop counts, total downtime, and total active time.
- Current state of the equipment, up or down, is also displayed.
- Because the sensor node must always be on to detect any transition, it is powered by a 120V wall transformer via jack at the bottom of the enclosure.
- The sensor transceiver node wirelessly transmits the data via a gateway to the Leap SensorManager user software, PLC, or other plant monitoring software.
- Quickly download data to an Excel spreadsheet to use in machine availability calculations, or display the data on your production floor using our custom dashboard option.
- Ideal for monitoring machine utilization and ROI on large capital investments.
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Our production tracking system helps you track production counts, downtime events, OEE, stop counts, total downtime, and line rate using just a wireless photo eye sensor and our proprietary edge node logic. Works as a conveyor belt stop sensor, while also tracking 10 manufacturing KPIs. The sensor transceiver node wirelessly transmits the data across the production floor to a gateway, which collects the data and passes it to the Leap SensorManager real-time manufacturing tracking software, PLC, or other plant monitoring software. Quickly download data to an Excel spreadsheet to analyze downtime.- Calculates the time between each product's pass to identify when downtime occurs and its duration.
- Triggers text, email, and telephone alerts when the downtime exceeds certain user-set limits.
- Count-reset button on top of the enclosure resets the count at the end of a shift.
- Displays current state of the line, up or down.
- Tracks line rate, total downtime and uptime along with Overall Equipment Effectiveness (OEE) since the last count reset.
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This groundbreaking sensor node integrates a discrete pulse flow meter to count units of flow (i.e. gallons, liters, etc) as liquid flows through a line. Unit can also be used as an incremental encoder for monitoring machinery speeds and total output. The transceiver node times individual pulses and their accumulated counts as they occur. It then uses edge computing to determine current flow rates and total volume of liquid passing through the meter. The edge logic also identifies when flow has stopped, duration of flow events, and duration of stop events. For ease of analysis, the node calculates both instantaneous rate of flow and its duration since the last sensor data reset, as well as a value to indicate if flow is currently occurring.- Monitors 11 different output variables, such as pulses, flow rate, total pulses, total volume, etc. See specifications for more details.
- Transceiver node is powered by a 120V wall transformer that plugs into a jack on the bottom of the enclosure (no battery powered options available.) Data is transmitted wirelessly via a gateway to the software.
- Connects to the Leap Wireless Sensor System with a secure 2.4GHz, FCC-certified radio.
- Count-reset button on top of the node enclosure resets the total flow at the end of a measurement period. Users can also set automated resets based on time of day.
- This unit is a variation of the Leap production counter, with modifications to account for flow measurement and volume totals.
Frequently Asked Questions about Production Monitoring
There is a push-button on the node enclosure that will zero the count.
The electro-optic sensors that detect the boxes require wall power to “watch” all the time. The data from the device node is transmitted wirelessly to the gateway.
Yes. The production counter takes a time reading between each box that goes by. You can set telephone, text, and email alerts if the time between the boxes exceeds a certain amount of time. You can set that downtime alarm limit in the software configuration screen. You can have the message set to anyone.
Common Applications for Production Monitoring
- Wireless production counter
- Wireless downtime monitor
- Wireless downtime alert system
- Line rate sensor wireless
- Line counter wireless sensor
- Downtime alert system
- Wireless sensor for downtime
- Wireless sensor for production count
- Wireless pulse counter