Industrial Grade Equipment Utilization Sensor with Downtime Monitoring – Wireless

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

Equipment Utilization and Downtime Monitoring Sensor Specifications

Because the sensor node must always be on to detect any transition, this sensor node is powered by 12VDC – typically from a 120V wall outlet.

• Machine cycle (activity) counter sensor
  • If using an amp clamp, counter increments each time the current passing through the amp clamp switch exceeds the “on” setting to track the number of equipment stops or inactive events.
  • Easy to reset using the count-reset button on the top of the enclosure.
  • Other sensors may also be used to detect a machine cycle. For example, proximity sensors are often used to detect metal parts of the machine that open or close when a line is running.
  • If using a proximity sensor, configurable de-bounce setting to allow adjustment for products that cause switches to flicker, avoiding multiple counts of single events.
• Manufacturing downtime tracking
  • Once the sensor fails to register activity, it starts tracking downtime until the equipment becomes “active” again.
  • The sensor also keeps track of the amount of time the equipment is running for machine availability calculation.
  • Each active and inactive event is timed individually, and the length of each event is time-stamped and stored for future reference or equipment availability analysis.
• Stop counts
  • Each time a production stop is identified, the stop count increases. The reset button will reset both the stop count and the production count.
• Total uptime and downtime
  • While the sensor tracks the time of each individual stop and production run, it also tracks total uptime and downtime since the last time the count was reset. A running total is always available.
• Overall Equipment Effectiveness (OEE)
  • For organizations focused on OEE, this sensor calculates OEE, based on uptime as a percentage of total time since the last count reset.
• Fast and easy installation
  • Open the split core amp clamp and attach it around a wire to a motor that runs at a higher current level when producing product than when idling.
  • Plug the wall transformer into a wall outlet to power the sensor.
  • Turn the sensor node on and start collecting data.
  • 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.

The wireless equipment utilization sensor with downtime monitoring is ideal for:

• Equipment utilization monitoring for capital asset utilization verification.
• Continuous process production monitoring.
• Real-time production line downtime alerts.
• Downtime recording with time of downtime and duration.
• Tank and hopper bin empty condition monitoring.
• Remote monitoring of critical relay contacts and switches.

Patents pending