Wireless Motor Sensor for Predictive Maintenance – Leap Sensors

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 machine condition based monitoring system as part of a condition based maintenance program.

• Monitors the top 3 predictors of impending motor failures.
  • Motor vibration monitoring sensor detects maximum and average vibration on 3 axes to detect upward trends or spikes in vibration.
    • Multiple vibration modules may be daisy-chained together on one CAN bus that goes to the device node.
  • Motor temperature monitoring sensor (thermocouple) mounts on the motor or gearbox to detect over-heating.
  • Motor current monitoring sensor (amp clamp) detects increased electrical current to motors to detect overloads.
• Fast and easy to install.
  • Magnetic or screw 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 an industrial CAN cable.
  • Long cables (if needed) are possible between the sensor and transceiver node.
• Multiple vibration modules (up to 30) can be connect to the tranceiver node by daisy-chaining the modules on one industrial CAN bus cable.
• 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 – friction, rubbing, grinding
  • RMS velocity weights the lower frequencies – misalignment or fatigue, unbalance, belt issue, poor mounting
  • Peak acceleration will detect serious impact forces such as bearing defects and chipped gear teeth.
  • Crest Factor – Instability usually from impulses
• 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

• Connects to K-type thermocouple using standard miniature flat pin connectors.
  • 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 1 wire (one phase) of the 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).

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 condition monitoring.

• 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 starting with a Password Authenticated Key Exchange (PAKE).

This wireless sensor is ideal for:

• Critical motor monitoring
• HVAC  motor monitoring
• Blower  motor monitoring
• Conveyor motor monitoring
• Grinder motor monitoring
• IoT condition monitoring
• Motor condition monitoring
• Part of a predictive maintenance system

Patents pending.