Bearing and Machine Sensor – Temperature and Vibration, Wireless

Available Q1 2022

This unique Leap wireless sensor can install in the threaded grease zerk hole in bearings.  Remove the grease zerk, install the sensor, then re-install the zerk back into the sensor. Grease guns may be used to continue grease the bearing using the zerk mounted on the Leap sensor.

Mounting adapters also facilitate easy installation on any type of machine.

Accelerometer readings (in all 3 axes) are taken at 5 KHz, then edge-processed into the top predictors of failures.

Temperature and 3-axis vibration sensors are mounted in the stainless steel base.

Send text, email, and phone alerts when temperature vibration limits are exceeded. Data integrates easily into PLCs or other plant monitoring software.

Bulk accelerometer reading downloads are also available as an option.

Contact us to talk to an expert and find the best solution.

Part of the breakthrough Leap Sensors® system.


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Leap Sensors are specially designed to easily adapt to your specific needs. If this isn’t exactly what you need, please contact us.


The Leap Bearing sensor reports temperature and vibration on the axial (parallel to shaft) and the radial (perpendicular to shaft) directions.  It uses a male-to-male adapter to conveniently mount in the existing grease zerk threaded hole – or to any machine surface.

Standard Monitoring Scenario:

  • Sensor wakes up every 15 minutes and takes sensor readings and transmits them.
    • Temperature alerts are typically set based on normal readings.
    • Vibration is sampled at 5 KHz on 3 axis for a few seconds in the range of 0 to 8Gs.  The X, Y, and Z axis are converted to axial (parallel to shaft) and radial (perpendicular to the shaft) readings.
      • The data is edge-processed on-board the sensor using proven methods where a change in trend is indicative of an impending failure.
        • The Motor Monitor output are: RMS Acceleration, RMS Velocity, and Peak Acceleration
          • Each of these readings is calculated for the radial and axial direction.
          • Any increase in these values indicate a bearing or machine is functioning differently and likely has a problem.
          • The RMS Acceleration weights the higher frequencies
          • The RMS Velocity weights the lower frequencies.
          • The Peak Acceleration will detect serious impact forces such as bearing defects and chipped gear teeth.
          • See screen-shot above for data output.

Optional Bulk Accelerometer Raw Data Download for FFT Analysis

  • Optional bulk data download sends ~20,000 accelerometer readings on each axis so the FFT analysis can be done off-line.
  • This mode requires significantly more battery power and is typically done once a week or once a month.

Leap Wireless Sensor Transceiver Node Specifications

  • Transmission distance to gateway: typically 1500 feet in open air. Several hundred feet in an industrial environment.
  • Battery
    • Field replaceable pair of AA batteries.
    • Typical battery life of last 2 to 8 years. Replaceable in a few minutes.
  • Size: 2.5 inches tall from base.
  • Long-range antenna inside enclosure: Keeps the total footprint small and prevents damage to the antenna.
  • High operating temperature: Standard sensor -40C to 85C (-40F to 185F).
  • 2-way communication with the sensor through the user interface:
    • Name the sensor, set sensor sampling time interval, set wireless transmit time interval, over-the-air firmware updates.
    • Gateways send an acknowledgement to the sensor that the data was received for high reliability.
  • Sensor data logging: When sensors do not receive an acknowledgement from the gateway that the radio transmission was received, the sensor will store the time-stamped data on-board (up to 10,000 readings) until the gateway connection is established.
  • Reliable industrial over-the-air radio communication
    • Industry-standard 802.15.4 with Direct Sequence Spread Spectrum (DSSS).
    • Gateway “handshake” acknowledgement of successful transmission and sensor data logging for extra reliability.
  • Over-the-air protocol: Standard and established 6LoPan and Thread.
  • Data security: “gold standard” internet security with AES encryption.
  • FCC certified.

Leap Wireless Sensors Gateway (Receiver) and User Interface Software

  • See the Leap Sensors gateway page and the Leap Sensors User Interface options page for more detailed information.
  • Leap Sensors wirelessly transmit data to a gateway*.
    • Gateway can support over 60 sensors that are in range. (Additional gateways can extend sensor coverage.)
    • The gateway then passes the data to the Leap user interface software. The user interface software may be hosted on the gateway (and connected to a PC with a USB cable), on the password-protected Leap Sensors Cloud web site, or an on-site server.
  • User interface supports: logging-in, set user rights, view sensor data, set email and text alerts (cloud version), graph sensor data, download data to excel, add or subtract sensors, update firmware, and other functions.

*Custom-ordered leap sensors are available with a direct-to-cellular option where no gateway is needed and the data is sent directly to a cloud server. Contact us for more information.

About Leap Sensors®

Better Design – Better Data – Better Decisions™

Based on Phase IV Engineering’s 25 years of wireless sensor experience, Leap is THE system designed from the ground up to meet the specific needs of industrial users. These sensors are a true leap advancement in Industrial IoT wireless sensing.

  • Modular design makes it easy & cost-effective to adapt to your specific needs – and update easily for a “future-proof” system.
  • Edge computing manages large amounts of data before transmission to software – only get information you need.
  • Bank standard data security: Multi-layered Thread network security using AES-128 data encryption.
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Prices, Quotes, Questions...

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This wireless sensor is ideal for monitoring:

  • Bearings
  • Gearboxes
  • Motors
  • Machines
  • Grinders
  • Blowers
  • Compressors

Patents pending.

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