Wireless Motor Monitor Sensor – Vibration, Temperature, 3 Phase Current – Leap Sensors

Watch the video tutorial below.  (Demonstration starts at 10:00 mark).

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

Wireless Motor Sensor for Predictive Maintenance – Specifications

Designed specifically for use in a motor condition monitoring system as part of a predictive maintenance program.

• Monitors the top 3 predictors of impending motor failures.
  • Motor vibration monitoring sensor detects maximum and average vibration on 3 axis to detect upward trends or spikes in vibration.
  • Motor temperature monitoring sensor (thermocouple) mounts on the motor or gearbox to detect over-heating.
  • Motor current monitoring sensor (amp clamps) detects increased electrical current to motors to detect overloads.
• Fast and easy to install.
  • Magnetic mounts for temperature and vibration sensors.
  • The amp clamp is a “split core” – allowing it to quickly install around a wire – without disconnecting it.
• Standard monitoring scenario: Sensor transmits readings every 15 minutes.
  • Temperature alerts are typically set based on normal readings.
  • Electrical current alerts are typically set above normal readings.
  • Vibration is sampled at 5 kHz on 3 axes for a few seconds in the range of 0 to 8Gs.
    • The data is edge-processed on board the sensor using proven methods where a change in trend is indicative of an impending failure.

Wireless Motor Vibration Sensor

• Mount with the provided magnet or with threaded stud.
• Vibration sensor is connected to the Leap sensor transceiver node via a shielded cable.
  • Long cables (if needed) are possible between the sensor and transceiver node.
• 3 axis g-force reading taken and edge-processed into RMS acceleration, RMS velocity, and peak acceleration. Any increase in these values indicate a motor is functioning differently and likely has a problem. Each of these readings is calculated for both radial (rotating) vibration and axial vibration (parallel to the shaft of the rotating equipment).
  • RMS acceleration weights the higher frequencies.
  • RMS velocity weights the lower frequencies.
  • Peak acceleration will detect serious impact forces such as bearing defects and chipped gear teeth.
• G-force readings up to +/- 8 G.
• Accelerometer operating temperature: -40C to 85C (-40F to 185F)
• On-board storage for 174,762 sets of 3-axis (x, y, z) g-force samples with 12 bits of resolution.
  • Data is typically processed by a powerful onboard microprocessor using FFT algorithms. Processed vibration analysis is then sent to the transceiver node.
• Typical sampling and analysis (can be adjusted to each application):
  • Accelerometer is checked every 15 minutes.
  • Each axis is sampled at 5 KHz. (Up to 5 KHz sampling available, if needed).
  • Samples are taken for 3 seconds.
  • RMS acceleration, RMS velocity, and peak acceleration are transmitted.
• Advanced Fast Fourier Transform (FFT) edge computing available
  • Sensor has a powerful microprocessor and large memory to take vibration samples and process the data at the sensor.
  • Custom edge computing algorithms using FFTs and other sophisticated methods are available.
• Configurable high G-force event – instant wake-up and transmit function – optional.

Wireless Motor Temperature Sensor

• Standard Option:  Temperature sensor is located with vibration sensor in the metal enclosure.
• Optional K-Type Thermocouple
  • Connects to K-type thermocouple using standard miniature flat pin connectors (see photos).
    • Connectors come with protective rubber boot.
    • See example of typical magnetic mount thermocouple. Adhesive-mount thermocouples are also available.
    • Can be easily modified for your needs.
  • Standard type K accuracy
    • Leap Sensor thermocouples are compensated for non-linear thermocouple characteristics at cold temperatures to ensure accurate readings at cold temperatures.
    • Cold junction compensation is on the Leap Sensor circuit board.

Wireless Motor Current Sensor

• Monitors all 3 phases of AC electrical current.
• Split core for easy installation. Clamp opens, then snaps shut around the wire.
  • Typically supplied with an AcuAmp ACTXXXX-10.  See datasheet.
• Configurable up to current readings from 2 to 2000 amps.
• 0-10V signal is sent to the Leap sensor transceiver node via a shielded cable.
• Operational temperature rated from -20C to 50C (-4F to 120F).
• Contact us with your specific current sensing requirements.

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 off-the-shelf Tadiran  TL-5930/F 3.6V battery with tethered connector – designed for high vibration industrial environments.
  • Typical battery life of at least 5 to 8 years. Replaceable in less than a minute.
• Bi-color LEDs integrated into the power switch blink to provide user feedback on sensor functions.
• Rugged sensor enclosure
  • IP68 enclosure rated to 120C (248F). Panel connectors and glands rated to IP68. Power switch with LEDs rated to IP66.
  • Rugged polycarbonate composite enclosure. UL 94 V0 rated, flame-resistant and self-extinguishing.
  • 4.4 x 3.2 x 3.4 in  (113 x 80 x 90 mm), not including optional mounting feet.
• Long-range antenna inside the enclosure: Keeps the total footprint small and prevents damage to the antenna.
• Mounting options
  • See all enclosure mounting options.
  • Optional mounting feet may be installed horizontally or vertically.
  • Enclosure may also be mounted with screws directly to surface.
  • Magnetic mount option.
• Cable connection options
  • Standard: Metal IP68 cable glands seal cables to the enclosure. Industrial spring terminal blocks connect the cable to sensor board.
  • Optional: M8 panel connector and cable: Molded M8 cable connects M8 panel connector to sensor.
    • Cable length may be shortened in the field if desired.
  • More information here.
• Industrial power switch: Latching push button. IP66 rated.
• Operating temperature: Standard sensor -40C to 85C (-40F to 185F).
  • High operating temperature option available: -40C to 125C* (-40F to 260F). Unique to Leap Sensors.
• 2-way communication with the sensor through the user interface:
  • Name the sensor (device), set sensor sampling time interval, set wireless transmit time interval, over-the-air firmware updates.
  • Gateways send an acknowledgement to the device 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 250 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.

This wireless sensor is ideal for monitoring:

• Motor monitoring
• Blower monitoring
• Pump monitoring
• Conveyor monitoring
• Rotating equipment monitoring

Patents pending.