IoT Wireless Machine Run Time Hour Meter

The IoT Wireless Accelerometer + Magnetometer Runtime Sensor combines a 3-axis accelerometer with a 1-axis magnetometer to detect when machines start, stop, and run through full cycles. By analyzing motion and magnetic field changes, this device automatically calculates runtime, downtime, and cycle counts — providing real-time visibility into production efficiency. Data is transmitted using DigiMesh wireless networking, a robust, self-healing mesh protocol built for industrial facilities. Powered by a replaceable D-cell lithium battery, this sensor delivers multi-year operation with zero maintenance, even in harsh environments.

This sensor is purpose-built for OEE (Overall Equipment Effectiveness) monitoring, helping manufacturers reduce downtime, boost throughput, and streamline maintenance, this device makes it easy to collect key performance data — wirelessly — from your machines. Powered by DigiMesh long-range wireless communication, this production counter is ideal for machine builders, OEMs, and manufacturers looking to optimize OEE (Overall Equipment Effectiveness) and reduce unplanned downtime.

How It Works

The sensor uses a dual-sensing approach to capture both machine vibration and rotation:

1. Accelerometer Monitoring

   • The 3-axis accelerometer continuously senses vibration and motion.

   • When vibration exceeds a configurable threshold, the device identifies the machine as “running.”

   • When vibration falls below the threshold, it marks the machine as “stopped” or “idle.”

2. Magnetometer Detection

   • The single-axis magnetometer is oriented near a rotating shaft, motor, or magnetic field source.

   • Each magnetic field fluctuation corresponds to a machine cycle or revolution.

   • This enables precise cycle counting in addition to run/stop detection.

3. Onboard Processing

   • Built-in firmware algorithms correlate accelerometer activity with magnetometer cycles.

   • The sensor outputs runtime, downtime, and cycle events with timestamps.

4. Wireless Transmission

   • Data packets are sent via DigiMesh wireless mesh to an NCD IoT Gateway.

   • From the gateway, data flows into MQTT brokers, Node-RED dashboards, AWS IoT, Azure, or custom applications.

Applications

• Production Cycle Counting – Monitor each machine cycle automatically

• Downtime Tracking – Log idle periods without manual input

• Machine Utilization Monitoring – Compare runtime vs. scheduled hours

• Predictive Maintenance – Detect anomalies in machine activity before failure

• Distributed Facilities – Deploy sensors across plants without Wi-Fi or wired infrastructure