The Industrial IoT Wireless Predictive Maintenance Sensor boasts up to a two-mile range using a wireless mesh networking architecture. The Predictive Maintenance Sensors are also known as Condition Based Monitoring Sensors. This IoT Preventative Monitoring Sensor consists of four of our most popular sensors in a single package to help control costs in most predictive maintenance applications. This Sensor include a Vibration Sensor, Thermocouple, 100 Amp AC Split Core Current Sensor, and a Machine Body Temperature Sensor.
How NCD’s Predictive Maintenance Sensors Work
Our IoT Wireless Predictive Maintenance Sensor samples vibration, acceleration, velocity, displacement, frequency, RMS current and temperature data. After data collection, our sensor will send a fixed user-designed transmission interval over your wireless network. This device comes with a 1.25-meter, split core current sensor, a 2-meter vibration probe (which will also measure machine body temperature) and a 1-meter thermocouple probe that makes installation straightforward and simple.
Exclusive NCD Predictive Maintenance Sensors Features
Our 3-Axis Vibration Sensor Characteristics include: Incorporating a 16-bit vibration and temperature sensor. This sensor will transmit highly accurate vibration data at user-defined intervals. These All-In-One Vibration Sensors can send computed and measured data thanks to Inbuild FFT and also RAW data for further processing on the user end. Using a 3-Axis Sensor as opposed to a 1-Axis (such as Piezo Sensors) users will achieve a much more accurate measurement count, and user friendly process.
Our Vibration and Temperature Sensor includes many features such as acceleration calculation, velocity calculation and time domain data analysis for FFT. As well as, user configurable data aggregation interval l ranging from one-second to 10-seconds. This type of sensor can be used in various applications. One, is for aircraft. This sensor can measure the about of “G-Force” during flight to protect the aircraft and passengers alike. This Sensor may also be used in automobiles to detect rapid deceleration, possible collision, and airbag deployment.
Our Industrial IoT Wireless Vibration Sensor samples 2048 samples each Axis and then calculates RMS and maximum vibration readings. This sensor then combines this data with temperature data into a packet and transmits the results to modems and gateways within wireless range. Once the transmission is complete, the vibration sensor goes back to sleep, thus minimizing power consumption. Our Vibration Sensor can be used for a multitude of applications to gather data AND detect early faults from compressors, pumps, motors, conveyors, etc. All at a safe distance from the factory floor.
Our Thermocouple Sensor Characteristics include: Long Range Industrial IoT Wireless Predictive Maintenance Sensor, which is capable of measuring extreme high and low temperatures. This wireless thermocouple includes one 5SRTC-TT-K-24-36 K-Type thermocouple probe from Omega.com with a 1m, 24 AWG connection cable, rated for temperature measurement applications up to 260°C (500°F) with an accuracy of ±2.2°C. This wireless thermocouple device comes with a K-Type connector, which can be used to connect higher temperature range thermocouple if needed. This sensor has a built-in hot and cold junction to provide highly accurate readings. This wireless IoT sensor is an ideal product for high temperature measurements, industrial boiler temperature measurements, liquid temperature measurement, and temperature monitoring of food storage units.
Our AC Current Sensor Characteristics include: Capabilities of measuring AC RMS current. The Long Range Industrial IoT Wireless Predictive Maintenance Sensor comes with a 100 Amp Split Core AC Current Sensor. Our Current Sensor can be applied to supervision of circuits, protection against over-current on machinery, motors, and various power supplies.
This Predictive Maintenance Sensor is powered by just six AA batteries and a 5-year battery life can be expected. (Depending on environmental conditions and the data transmission interval.)
*PLEASE NOTE — RMS is calculated using Parseval’s theorem.
When obtaining the Predictive Maintenance Sensor, there are Vibration guides to observe. Here are some recommended Vibration standards, you can compare these readings with our Long Range IoT Wireless Vibration Temperature Sensor to determine if your device is operating properly or if it may require service (note that actual equipment and application may vary):
A. 0.01g or Less — Excellent condition, No action required
B. 0.35g or less — Good Condition, No action required unless the machine is noisy or running at abnormal temperature
C. 0.5g or less — Fair Condition, No action required unless the machine is noisy or running at abnormal temperature
D. 0.75g or More— Rough Condition, possible action required if machine is noisy and also check the bearing temperature
E. 1g or More — Very Rough Conditions, further analysis and see if its doing this continuously. Also check for noise and temperature
F. 1.5g or More — Danger Level, there is definitely a problem in the machine or installation. Also check the temperature Log
G. 2.5g or More — Shut-down the Machine immediately and look for possible causes. Call a technician for immediate repair
For Heavy Machinery these readings could be 1.5 times to 2 times more than listed above.
This Predictive Maintenance Sensor sends data periodically, based on user-preset timing intervals.
We realize that the Industrial Wireless version and the Long Range IoT version seem very similar and in fact are. The Industrial Wireless line has a few improvements over its counterpart in the Long Range Wireless line in form and fit, but maintain the same function.  Industrial Wireless versions may have a longer battery life, optional off-board sensors, more accurate readings, and other frequency ranges. Below is a table based on the Vibration Sensor included in the Predictive Maintenance Sensor:
| Feature | Industrial Wireless | Long Range IoT | Industrial Wireless V3 |
|---|---|---|---|
| 900 MHZ | X | X | X |
| 868 MHz Option | X | X | |
| 2-Mile Range | X | X | X |
| Battery Powered | X | X | X |
| Optional External Power | X | X | X |
| Wireless Mesh Capabilities | X | X | X |
| IP65/Outdoor Rated | X | X | |
| Magnetic Mounting Attachments | X | (Optional) | X |
| External Sensor Probe | (Optional) | X | |
| Acceleration Measurement | X | X | X |
| Velocity Measurement | X | ||
| Displacement Measurement | X | ||
| Time Domain | X | X | |
| FFT | X | ||
| Frequency Measurement | X | ||
| OTA | X | ||
| FIIR Filters | X | ||
| Configurable Frequency Range | X | X | |
| Configureable Sample Duration | X | ||
| 1/4 NPT Housing | X | ||
| 1/4-28 UNF Housing | X |
