Production Line Counter Wireless Sensor with Downtime Monitoring – Leap Sensors

See the video demonstration below

This groundbreaking sensor integrates proximity sensors to count products as they come off the production line. A count-reset button on top of the enclosure resets the count at the end of a shift.

With edge computing, the sensor also calculates the time between each product’s pass to identify when downtime occurs and its duration. It can then trigger text, email, and telephone alerts when the downtime exceeds certain user-set limits.

Set email, text, and telephone alerts when downtime time limits are exceeded (with internet-connected systems).

The sensor transmits the data wirelessly across the production floor to a gateway that collects the data and passes the data to the Leap SensorManager user software, PLC, or other plant monitoring software. Data can quickly be downloaded to an Excel spreadsheet to analyze downtime.

Data Sheet

 

Part of the breakthrough Leap Sensors® system.

 

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Description

Production Line Counter with Downtime Monitoring – Specifications

Using proximity sensors, this wireless sensor counts and timestamps items as they pass by on a conveyor, using the time intervals to monitor downtime. A reset button on the top of the sensor resets the counter to zero. Set custom email, text, and telephone alerts for both the production counter and the downtime timer.

  • Production Line Counter
    • Counter increments as each item passes by the sensor.
    • Easy to reset using the count-reset button on the top of the enclosure.
  • Production Event Timer
    • The production event timer reports the time since the previous item passed the proximity sensors.
    • Ideal for tracking downtime. (See screenshot of the SensorManager software and Excel file.)
      • Timestamps and production count are recorded with the downtime timer records.
  • Fast and easy installation.
    • Mount proximity sensors and connect the cables to the Leap Sensor enclosure.
    • Plug the wall transformer into a wall outlet to power the proximity sensors.
    • Wireless transmission of data to the gateway – transmission range of several hundred feet, depending on factory conditions.
    • The data may be displayed with the SensorManager software or may be passed from the gateway to a PLC or other plant software.

Typical Industrial Wireless Sensor Applications

This wireless sensor is ideal for monitoring:

  • Manufacturing production counts.
  • Real-time production line downtime alerts.
  • Downtime recording with time of downtime and duration.

Patents pending.

About Leap Sensors®

Better Design – Better Data – Better Decisions™

Based on Phase IV Engineering’s 30 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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