Smart Industrial IoT Wireless Vibration Temperature Sensor

Industrial IoT Wireless Vibration Sensor

We are introducing NCD’s Long Range Industrial IoT Wireless Vibration Temperature Sensor and boasting up to a 2-mile range using a wireless mesh networking architecture. Incorporating a 16-bit Vibration and Temperature sensor, this sensor transmits highly accurate vibration data at user-defined intervals. This all-in-one vibration sensor can send computed results thanks to inbuilt FFT and RAW data for further processing on the user end.

The Industrial IoT Wireless Vibration Temperature Sensor V3 is packed with features like Acceleration calculation, Velocity Calculation, and Time Domain Data Analysis For FFT. User configurable Data aggregation intervals range from 1 second to 10 seconds.

The Industrial IoT Wireless Vibration Temperature Sensor V3 samples 2048 of each Axis and then calculates RMS and maximum vibration readings. This sensor combines the information with temperature data in a packet and transmits the result to modems and gateways within wireless range.  Once the transmission is complete, the vibration sensor returns to sleep – thus minimizing power consumption.

Powered by Two AA batteries with a ten-year battery life can be expected depending on environmental conditions and the data transmission interval.

With an open communication protocol, the Industrial IoT Wireless Vibration Temperature Sensor V3 transmits hardware encrypted data that can be integrated with just about any control system or gateway.  Data can be sent simultaneously to a PC, a Raspberry Pi, to Losant IoT cloud, Microsoft® Azure® IoT, and an embedded system. Our free node-red monitoring software can change sensor parameters and wireless transmission settings.

The long-range, price, accuracy, battery life, and security features of the Industrial IoT Wireless Vibration Temperature Sensor V3 make it an affordable choice that exceeds the requirements for most industrial and consumer market applications.

Vibration Sensor Monitoring Applications

• Ideal for Wireless Vibration Measurement of Motors, Pumps, Compressors
• Wireless Industrial Vibration of Robotic Equipment, Conveyors, and Transport Vehicles
• Machine Health Monitoring for a Predicative Maintenance System
• Future Fail Detection for Industrial Machines
• Vibration Monitoring of Conduits, Pipes, and Air Passages
• Vibration and Temperature Monitoring for AWS, Azure, and Losant

Read more about Wireless Vibration Sensor

• Preventive Maintenance of Industrial Conveyor Belt Failure Analysis
• Harnessing The Power of Predictive Maintenance in HVAC Systems
• Vibration Analysis Data in Detail
• Understanding Wireless Vibration Analysis
• Monitoring Pumps Health Using Wireless Vibration Sensors

Download The 3-Axis Vibration Sensor Brochure

NOTE — RMS is calculated using Parseval’s theorem. 

General Vibration Guidelines

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 correctly or if it may require service (note that actual equipment and application may vary):
A. 0.01g or Less & 0.5mm/sec or Less   — Excellent condition, No action required
B. 0.35g or less  & 0.8mm/sec or Less  — Good Condition, No action required unless the machine is noisy or running at an abnormal temperature
C. 0.5g or less & 2.0mm/sec or Less  — Fair Condition, No action required unless the machine is noisy or running at an abnormal temperature
D. 0.75g or More & 5mm/sec or Less — Rough Condition, possible action required if the machine is noisy and also check the bearing temperature
E. 1g or More  & 7.5mm/sec or Less — Very Rough Conditions, further analysis and see if it’s doing this continuously. Also, check for noise and temperature
F. 1.5g or More & 12.0mm/sec or Less  — Danger Level, there is a problem with the machine or installation. Also, check the temperature Log
G. 2.5g or More & 18mm/sec or Less — 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 those listed above.

ISO 20816-1:2016

1X — Normal ( if the peak is at one time of motor running frequency)
1X — if increase over time — unbalance
1X,2X,3X — 2X max — Misalignment
1X,2X,3X,4X,5X — Looseness
3X,6X,9X,12X — Bearing
1X — period will increase — resonance

Change in velocity — unbalance, misalignment or looseness
Change in Acceleration — indicates issues with  bearing

Transmission Interval

This device sends data periodically, based on user-preset timing intervals and on INT.

Industrial IoT Wireless Vibration Temperature Sensor V3 vs. Long Range IoT Vibration Monitor

We realize that the Industrial Wireless version and the Long Range IoT version seem very similar and are. The Industrial Wireless line has a few improvements over its counterpart in the Long Range Wireless line in terms of form and fits but maintains the same function.  Industrial Wireless versions may have a longer battery life, optional off-board sensors, more accurate readings, and other frequency ranges.

Sensor Data Overview

NCD IoT Sensors send a lot more than just sensor data.  For instance, a unique serial number is sent so you can always identify a particular sensor on the network.  A Node ID is also included, which a single byte of data that you can use for anything, such as the floor of a building or to help identify which group a sensor belongs to.  Also included in the data packet is a firmware version, battery level, and sensor type.  This allows your software to positively identify and manage the health of NCD IoT wireless sensors.  While signal strength data is also available, it is handled in a different way, and is not included in the sensor data packet (but rest assured, signal strength data for each sensor is available).  Please see the Resources tab to see detailed information on the data structure of this device.  

Good to know…

NCD wireless sensors transmit data and require a receiver.  There are many options available for receiving data from NCD IoT devices, which will be discussed in much greater detail below. We highly recommend at least one USB Modem for the purposes of sensor configuration (available during checkout). Also, our LabVIEW software is typically used for advanced sensor configuration, which is located in the “Resources” tab above.

How long Will the Batteries really Last?

Most NCD IoT Sensors are rated for 300,000 to 500,000 transmissions until the batteries become so weak they are unreliable.  You could spread these transmissions out over a 10 year period and send 50,000 transmissions per year.  This would allow up to 136 transmissions per day, or about 5 transmissions per hour (for a 500K sensor, or 3 per hour for 300K sensor).  If you only need the batteries to last 3 years, you could send 166,666 transmissions per year, or about 456 transmissions per day (about 19 transmissions per hour for a 500K sensor).  As you can see, battery life is really up to you.  By altering advanced settings in the NCD IoT sensor, you have control over longevity.  Please note the 500,000 transmission rating is for premium alkaline batteries.  NCD ships all sensors with premium Lithium batteries, which include a ultra-wide temperature range that typically lasts in excess of 600,000 transmissions for some sensor types.  These batteries weigh less than half of alkalines, and they work in the freezer!  A word of caution though, putting a sensor in configuration mode will drain the batteries very quickly.  It’s important to configure your sensors and exit configuration mode as soon as possible or use a external power supply during configuration (if supported by the sensor).  The table below indicates how many Transmissions Per Hour (TPH) your can expect from different sensors over a lifespan of up to 10 years.

Battery Life:	3 Months	6 Months	1 Year	2 Years	3 Years	5 Years	10 Years
300K Sensor	136 TPH	68 TPH	34 TPH	17 TPH	11 TPH	6 TPH	3 TPH
400K Sensor	180 TPH	90 TPH	45 TPH	22 TPH	15 TPH	9 TPH	4 TPH
500K Sensor	228 TPH	114 TPH	57 TPH	28 TPH	19 TPH	11 TPH	5 TPH
600K Sensor	272 TPH	136 TPH	68 TPH	34 TPH	22 TPH	13 TPH	6 TPH

TPH = Transmissions per Hour

The Truth About Battery Life

Under the best of circumstances, the best non-rechargeable batteries commonly available today are limited to a 10 year non-working shelf life in a room temperature environment. Factors such as actual usage, temperature, and humidity will impact the working life. Be wary of any battery claims in excess of 10 years, as this would only apply to the most exotic and expensive batteries that are not commonly available. Also note that most battery chemistries are not rated for use in extreme temperatures. NCD only uses the best Non-Rechargeable Lithium batteries available today, which are also rated for use in extreme temperatures and have been tested by our customers in light radioactive environments. Lithium batteries offer a 10 year maximum expected shelf life due to limitations of battery technology. NCD will never rate sensor life beyond the rated shelf life of the best batteries available today, which is currently 10 years.

How Do I Change Settings and Examine Raw Sensor Data?

Using our long-range USB wireless modem, users can expect easy operation over a virtual COM port at 115.2K baud.  Simply open the virtual COM port of the USB modem and watch data stream in.  Optionally, we offer a Wireless receiver that operates over Ethernet.  Data from NCD sensors will appear over TCP/IP on port 2101.  Simply open a TCP/IP socket, port 2101, to the IP address of the Ethernet modem and see your data stream in to your local area network.  We have developed LabVIEW® software for each sensor to change advance sensor settings using both Ethernet and USB modems.  Alpha Station also allows display of sensor readings as well as limited configuration (this feature is still in development).  Of course gateways are also available for sending data to popular cloud platforms such as Amazon® AWS® IoT, Microsoft® Azure® IoT, and Losant (more information below).  We take software samples seriously, so be sure to to check out the “Resources” tab to see code samples for Raspberry Pi, Visual Studio, LabVIEW®, Arduino, Python, and more.

 

What Frequency Do I Need?

Range and Frequency of NCD Wireless Sensors

During purchase, you will see three frequency options.  Not all options are legal for use in all areas, so it’s important to make the right selection during purchase.  We will build your product and accessories based on the options chosen.  Here, we will explain these options in much greater detail, but please check your local laws BEFORE purchase.

900MHz for North America (U.S., Canada, and Mexico)

If you are located in North America, the 900MHz Option will provide the longest range currently supported with the best penetration through walls, buildings, industrial equipment, and trees.  This option is also the best choice for long range applications.

900MHz Wireless Sensor Range

The official Line of Sight rating for this option is 2 Miles with included antennas or 28 Miles with high-gain antennas.  These distances are characterized for direct line of sight applications with no obstructions.  Real-world range will vary greatly depending on surrounding buildings, trees, and other objects that may cause reflections or interfere with the transmission.  900MHz has excellent RF penetration characteristics, and we have successfully completed installations in excess of of a half mile on a automotive factory floor with active robots in between.  We have also seen excellent penetration in mild radioactive installations making this a possible candidate for use in nuclear energy applications.

We suggest contacting Digi.com for a high-gain antenna recommendation if required.  Please check your local laws before choosing this option.

868MHz for Europe Only

If you are located in Europe, the 868MHz Option is the longest range choice available at this time. This option offers better penetration through walls, buildings, trees, and industrial equipment than 2.4GHz. The official line of site rating for this option is 14.5km using 2.1dBi antennas. Please check your local laws before choosing this option.

2.4Ghz for Worldwide Use

The 2.4GHz option should be chosen if 900MHz and 868MHz are not legal for use in your country.  This option is now certified for use worldwide, including Europe, United States, Japan, Australia, Brazil, and South Korea. Please check your local laws before choosing this option just in case 2.4GHz is not legal in your area.

Not Sure?

If you are unsure of which sensor option to choose, please contact us.  We may be able to help determine which sensors are legal for use in your area.