Industrial IOT applications just got better

Broadsens recently released its latest vibration monitoring and analysis software BroadVibra 2.6.6. The major improvement of this software is the advanced capability of industrial IOT (IIOT) applications. Users can remotely trigger the powerful FFT analysis and advanced filtering ability for vibration monitoring with MQTT protocol. The remote FFT analysis allows users to change sampling rate from 50Hz up to 25.6kHz, and from 2,048 sample points to 16,384 sample points. The advanced filtering includes high-pass, low-pass and band-pass filter with arbitrary cutoff frequencies. This makes Broadsens's wireless vibration monitoring system one of the most powerful for IIOT.  Moreover, the MQTT message is in JSON string format, which makes it easy to parse at the MQTT broker. This feature improvement makes Broadsens's wireless vibration and temperature sensor system one of the best for industrial IOT applications.



Broadsens wireless vibration and temperature sensor system for IIOT

Broadsens wireless vibration and temperature sensor system for IIOT applications

The system is very flexible that allows users to obtain key vibration monitoring parameters at different frequency range, including velocity and acceleration.

For example, to get the parameter Velocity (mm/s) RMS from 2Hz-1kHz range, you can do the following:

1. At the gateway MQTT configuration page, enable remote control and set the control password.

2. Send remote "DAQ command" to the wireless vibration and temperature sensors with sampling rate set at 3.2kHz or 6.4kHz, select single DAQ mode, 4,096 sample points (or 8,192 or 16,384 for better line of resolution)

3. Send remote "check DAQ status" command. Wait for the DAQ to finish. Or wait a fixed time

4. Send remote "FFT analysis" command, select "velocity" measurement, use bandpass filter cutoff frequency at 2Hz, 2nd cutoff frequency at 1kHz,

then voila, you get Velocity (mm/s) RMS from 2Hz-1kHz, triaxial velocity raw data and FFT analysis. You even get temperature with the measurement.

The MQTT message is in JSON string format, which can be converted to JSON objects easily. An example of the MQTT message is shown in Figure 2.

The cutoff frequencies can be adjusted continuously to obtain any desired envelope analysis with BroadVibra vibration analysis software's advanced filtering ability.

Figure 2. Remote FFT analysis via MQTT

BroadVibra vibration monitoring & analysis software is pre-installed at Broadsens's wireless gateway. Users can access the software through any web browsers for sensor configuration and system maintenance.

To make the IIOT better, Broadsens's SVT-A series wireless vibration and temperature sensors can be trigger remotely via MQTT protocol too. With the latest software, users can select DAQ mode, DAQ sample rate, sensor group, sample points with the MQTT protocol. The new MQTT feature just make the best wireless vibration and temperature sensors in the industry even better.

Broadsens IIOT sensor systems are deployed worldwide

As of December 2022, Broadsens’s wireless vibration and temperature sensor systems and ultrasonic systems are deployed in more than 30 countries worldwide. Broadsens’s wireless vibration & temperature sensors are ultra-compact, light-weight with one of the best performances (sampling rate, bandwidth, features, line of resolution, battery life, signal to noise ratio et al) in the industry. Due to their long-lasting battery life and the best battery efficiency, the sensors are helping many industrial customers for machine condition monitoring and predictive maintenance.

Broadsens wireless vibration sensors
Broadsens wireless vibration sensors for pump & motor monitoring

Broadsens’s wireless gateway and vibration monitoring software are designed for large-scale IIOT applications, in which case thousands of sensors and hundreds of gateways can be configured easily and quickly. Sensor data are encrypted for enhanced security. The explosive atmosphere certified wireless vibration & temperature sensors are used for condition monitoring of motors, pumps, bearings, gearboxes, wind turbines, heavy machines, trains, UAVs, powerlines, ships, fans, compressors, spindles and so on. Sensor data can be transferred to local servers or clouds via MQTT protocol efficiently.

Broadsens wireless vibration sensors in production line
Broadsens wireless vibration sensors mounted on motor & pump
Broadsens ultrasonic device for train coupler monitoring

Broadsens’ ultrasonic systems include multichannel ultrasonic scanner for composite & metal structure NDT (Non Destructive Testing)/SHM(Structural Health Monitoring), and multichannel thickness gauge for corrosion monitoring and NDT. Broadsens’s ultrasonic systems use high-resolution 14-bit ADC with up to 80MS/s sampling rate, which offers high sensitivity that can  detect sub 1mm crack/defects for the SHM and NDT purpose. The ultrasonic devices can be remotely controlled via TCP/IP protocol, which are ideal for IIOT applications.

Explosive atmosphere certified wireless vibration sensors

Broadsens's ultra-low power wireless vibration and temperature sensors are now explosive atmosphere (Ex) certified! The Ex certificate was issued by an Ilac-MRA certified lab. The Ex rating of Broadsens's SVT-200, SVT-300 and SVT400 (A or V series) is Ex ia IIC T4 Ga. The rating is one of the highest that allows the sensors to be used in dangerous oil and gas fields. Broadsens wireless vibration & temperature sensors use intrinsic safe battery and IP68 case for maximum safety operation in harsh and dangerous environments. The ultra-compact sensors are light weight, and have adjustable sampling rate from 50Hz up to 25.6kHz. Adjustable sampling points range from 1,024, 2,048, 4,096, 8,192, 16,384 (in single DAQ, single FFT modes) to unlimited sample points (in real-time, batch, multi-DAQ and live FFT modes).

IIOT wireless vibration sensors & gateway

Explosive atmospheres certificate

The wireless vibration and temperature sensors should be used with Broadsens's advanced edge-computing gateway. The gateways has BroadVibra vibration monitoring and analysis software pre-installed. BroadVibra software uses Node-RED for the dashboard design, which can be customized for industrial IOT applications quickly.

Multiple Broadsens wireless gateways can be used for large-scale factory condition based monitoring and predictive maintenance. The system is ideal for wireless IIOT applications such as motor and pump monitoring, and structural health monitoring. They are also ideal for high-voltage applications due to the high battery efficiency.

Broadsens & Elipsa Use AI for Predictive Maintenance

Broadsens, a leader in low-power industrial sensors, and Elipsa a leader in plug and play AI solutions for IIOT are combining machine data with machine learning to provide easy to configure predictive maintenance at scale.

Industrial equipment such as pumps, compressors, generators, HVAC, etc. are critical to successful business operation.  Unplanned downtime of such equipment can be catastrophic in terms of economic loss to an organization.  Historically, maintaining such equipment has been reactive, incorporating onsite diagnostic or notifications of failures that have already occurred.

With the growth of the Industrial Internet of Things (“IIOT”) this critical equipment is becoming smart and connected.  With this new stream of data, machine learning has proven capable of detecting patterns indicative of future problems allowing for predictions of downtime and a proactive approach to equipment maintenance. This growing area is known as Predictive Maintenance.

Machine learning algorithms can learn from numerous types of sensors and data points.  Often times, the most effective data points for successfully building predictive maintenance algorithms have proven to be vibration data, learning that certain vibration profiles can predict the future failure of a machine.

Data Acquisition

The Broadsens SVT200-V is the only compact true real-time wireless vibration sensor that can monitor machine condition continuously with more than 3-year battery life in typical usage.

SVT200-V has two sampling modes: continuous low-speed sampling mode and high-speed sampling mode. It acquires x, y and z axis data in 16-bit resolution continuously. When the sensor detects a vibration event, it switches to high-speed 6.4kHz sampling rate, takes a fixed amount of data, calculates velocity RMS and acceleration RMS value, and sends the result plus temperature to the wireless gateway.

The smart algorithm inside SVT200-V adjusts the sampling mode dynamically and optimizes the energy usage. It can capture both high frequency and low frequency defects from the machine and structures.

The Broadsens wireless gateway connects and controls many sensors including the SVT200-V, SV200-A, SVT300-V, SVT300-A, SVT400-V and SVT400-A. The gateway includes 4-core ARM processor for real-time data visualization and processing. The gateway is configurable to transfer real-time sensor data to third-party systems via MQTT such as the Elipsa AI Platform.

Broadsens real time wireless vibration & temperature sensor

The AI

Elipsa’s AI-based Predictive Maintenance seamlessly deploys across any workflow on the edge or in the cloud, increasing the availability and output of critical equipment. Elipsa’s self-training AI models and bolt-on approach enable AI deployments that are simple, fast, and flexible.

Through the use of Elipsa’s Rapid Deployment Templates, users can start intelligently monitoring critical equipment in as little as five minutes.  Elipsa’s Broadsens Vibration Analysis template takes in real-time velocity RMS data on the x, y, and z axis.

Once an SVT200-V is connected, data is streamed to Elipsa via MQTT. Elipsa’s Rapid Deployment Template automatically starts to learn the normal vibration profile of the machine that the sensor is attached to.  After a set number of data points (as defined in the template), Elipsa automatically builds a machine learning model and returns predictions back to the Broadsens gateway.

Elipsa’s innovative approach learns normal vibration of a given machine in order to detect abnormalities of any kind reported back to the user via the Broadsens software.

Case Study

In this case study, Broadsens's wireless vibration sensor SVT200-V and wireless gateway GU200S, vibration analysis software BroadVibra are used to monitor an air condenser. SVT200-V inside single screw-hole package is used with magnet mount. The sensor with magnet mount can be installed in several seconds. Data are fed to Elipsa’s AI platform continuously in real time via MQTT protocol. 24-hour data from the sensor is shown as below.

After several days, the sensor was removed to simulate accident to the air condenser. Elipsa AI algorithm detected the change with both velocity RMS and acceleration RMS value. Velocity RMS value showed more significant change, which is consistent with the industrial standard that prefers vibration velocity RMS over acceleration RMS for machine condition monitoring.

Wireless vibration sensor mounted on panel

Vibration velocity RMS AI prediction

24-hour vibration data from the panel

Acceleration RMS AI prediction

Predictive Maintenance at Scale

The combined Broadsens/Elipsa solution can easily be deployed across a range of equipment at scale. Make the promise of predictive maintenance a reality to start proactively managing critical equipment. There’s no need for a data scientist or a large capital ex spend.  This plug-and-play solution will reduce downtime, increase operating efficiency, improve scheduling of key employees, making your machines more sustainable.

IP68 Wireless Vibration and Temperature Sensors

After many testing, Broadsens updated its wireless vibration and temperature sensors' rating from IP67 to IP68. This rating could truly reflect the ability of the sensors working under tough environments. The testing were performed in different environments, including ice water submerge, deep water submerge, and long duration water submerge. The testing proved that Broadsens wireless vibration and temperature sensors are some of the best and toughest in the industry.

Ice water submerge testing

In this testing, Broadsens's wireless vibration and temperature sensors are submerged under iced water for more than 1 hour. There were random-selected one SVT-A series and one SVT-V series wireless vibration sensor. Both sensors took data continuously. Yes Broadsens's innovative design allow the ultra-low power wireless vibration sensors take data continuously.

SVT-A wireless vibration sensors include SVT200-A, SVT300-A and SVT400-A. They take triaxial acceleration raw data, which allows for predictive maintenance and AI-based analysis.

SVT-V wireless vibration sensors include SVT200-V, SVT300-V and SVT400-V. They take data continuously non-stop, which allows for real-time machine condition monitoring and accidents alarm in time.

Both type of sensors should be used for industrial IOT applications.

In the pictures below, the left pictures show long-duration testing. In this test, the sensors were submerge in a water bottle for more than 48 hours. There is no leak detected and the sensors are working normally after 48 hours. In the right picture, the sensors were submerged under a well water with a depth of 1.5m for more than 4 hours. The sensors are also working normally without any water damage. The wireless vibration and temperature sensors are perfect solutions for industrial IOT applications and machine condition monitoring.

Long duration underwater test

1.5m under water test

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