Device Overview
The IoT Wireless Machine Run Time Hour Meter is a device specifically designed to track machine and production run time in industrial settings. It is a flexible device that observes the behavior of the machine it is attached to via its built-in accelerometer and magnetometer,
It has long range wireless capabilities utilizing robust Mesh networking protocols with high level of security and network reliability. It is compact, durable and powered by long lasting batteries.
Features
- Industrial Grade Machine Runtime Monitoring
- Measure Production Runtime
- Measure Number of Cycles
- Acceleration Motion Detection based Runtime calculator
- Magnetic Field Detection based Runtime calculator
- Encrypted Communication with 2 Mile Wireless Range
- Operating Temperature Range -40 to +60 °C
- Humidity Range 0-90%
- Magnet Mounted IP67 Rated Enclosure
- For Indoor and Outdoor Use
- Many Gateway and Modem Options Available
Wireless Technology
The NCD Industrial range of sensors utilizes DigiMesh, a proprietary networking technology designed by Digi® International. It is especially suitable for IIoT applications as it provides a number of benefits over conventional wireless stacks:
- Long range – up to 1000 feet in urban environments and 2 miles+ in open areas with the included antennas
- Mesh networking topology – no single point of failure, self healing network with high redundancy.
- Long battery life due to low power consumption – up to 10 years
- Simplified provisioning – extending the mesh network via repeater at no additional configuration complexity
- Works in the 868MHz, 900MHz and 2.4GHz bands – worldwide region interoperability.
If you want to learn more about DigiMesh and how it compares with another popular IoT stack (LoRaWAN) head to the article below:
IoT Wireless Sensor Networks: Digi®Mesh vs LoRaWAN®
Battery Life
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| Specifications | Minimum | Nominal | Maximum | Notes |
|---|---|---|---|---|
| Batteries size | 16000mAh | This device has a single D-Cell (LR20) battery | ||
| Battery Life 1 TPD | 10 Years | TPD Transmissions per Day | ||
| Battery Life 12 TPD | 8 Years | TPD Transmissions per Day | ||
| Battery Life 24 TPD | 5 Year | TPD Transmissions per Day | ||
| Battery Life 96 TPD | 3 Year | TPD Transmissions per Day |
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.
Applications & Use-cases
This sensor is a versatile device that brings a new level of precision and reliability to runtime monitoring across a wide range of industrial applications. Its combination of both accelerometer and magnetometer runtime sensing, coupled with robust wireless communication and a durable enclosure, makes it an ideal choice for diverse environments and challenging operational conditions.
Machine Runtime Applications
Manufacturing Plants
In manufacturing settings, the ability to monitor machine uptime accurately is crucial for minimizing downtime and maximizing productivity. The sensor’s multi-sensor functionality enables detailed tracking of production uptime and cycle counts. Its dry and wet contact closure inputs, along with current-based, acceleration motion detection, and magnetic field detection-based uptime calculators, provide a comprehensive view of machine performance. This ensures manufacturing plants can swiftly identify and address issues, maintain high operational standards, and optimize production schedules.
Automotive Production Lines
Automotive manufacturing demands high precision and efficiency, where any interruption can lead to significant financial losses. The Machine Uptime sensor’s IP65 rating and ability to operate in extreme temperatures (-40 to +60 °C) and humidity (0-90%) conditions make it suitable for the rigorous demands of automotive production lines. Its real-time monitoring capabilities allow for immediate detection of performance deviations, facilitating rapid response to prevent downtime and ensure continuous production flow.
Food Processing Facilities
In the food processing industry, hygiene and safety are paramount. The sensor’s wall-mounted or magnet-mounted IP65 rated enclosure ensures it can withstand the wet and variable temperature environments typical in food processing plants without compromising performance. Moreover, its versatile connectivity options support adherence to strict quality and safety standards by enabling seamless data integration with existing quality management systems.
Chemical and Pharmaceutical Industries
For chemical and pharmaceutical manufacturing, maintaining consistent operational conditions is critical to product quality and compliance with regulatory standards. The Machine Uptime sensor’s encrypted communication and its ability to monitor machinery in real-time provide an extra layer of security and compliance assurance. The sensor’s accurate detection capabilities, including current-based and magnetic field-based measurements, ensure precise monitoring of sensitive production processes, aiding in the early identification of equipment malfunctions that could affect product quality or worker safety.
Mining and Heavy Machinery Operation
The rugged design of the Machine Uptime sensor, combined with its long-range wireless communication capabilities (up to 2 miles), makes it exceptionally well-suited for the harsh and remote environments of mining and heavy machinery operations. Its battery-powered operation allows for easy installation in locations where power sources are not readily available, ensuring continuous monitoring of equipment uptime. This is critical for identifying potential equipment failures before they occur, reducing costly unplanned downtime and enhancing operational efficiency in these industries.
Machine Runtime Use-cases
Production Benchmarking
In manufacturing, benchmarking machine productivity is essential for continuous improvement. IoT run-time hour meters supply precise data on machine uptime, forming the basis for performance metrics like Overall Equipment Effectiveness (OEE). These benchmarks highlight bottlenecks, enabling organizations to optimize workflows and meet production targets with greater efficiency.
Idle Time Detection
Unplanned idle time reduces efficiency and increases wear on machines. IoT wireless hour meters identify patterns of short, frequent runs or extended idle intervals, signaling operational inefficiencies. Armed with this data, managers can adjust processes, retrain operators, or reallocate equipment to maximize productivity and reduce wasted time.
Operator Accountability
Operator accountability ensures that machines are run responsibly and within scheduled operating times. IoT wireless hour meters provide precise logs of run-time data, creating transparency around equipment use. Managers can identify discrepancies between scheduled and actual operation, promoting better adherence to protocols, reducing misuse, and strengthening accountability across teams.
